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ABB ACS880-207LC Hardware Manual
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ABB ACS880-207LC Hardware Manual

Igbt supply units
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ABB INDUSTRIAL DRIVES
ACS880-207LC IGBT supply units
Hardware manual

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Summary of Contents for ABB ACS880-207LC

  • Page 1 — ABB INDUSTRIAL DRIVES ACS880-207LC IGBT supply units Hardware manual...
  • Page 3 ACS880-207LC IGBT supply units Hardware manual Table of contents 3. Electrical installation 6. Start-up and operation 3AXD50000174782 Rev C Original instructions EFFECTIVE: 2023-06-30...

  • Page 5: Table Of Contents

    Table of contents 5 Table of contents 1 Introduction to the manual Contents of this chapter ............... . Applicability .
  • Page 6 6 Table of contents Emergency stop button [S61] and reset button [S62] ....... . . Control panel [A59] .
  • Page 7 Table of contents 7 4 The control unit Contents of this chapter ............... . General .
  • Page 8 8 Table of contents Supply modules ................. . . Replacing the supply module (frame R7i) .
  • Page 9 Table of contents 9 100 kA input cubicle (option +F274) ............Tightening torques .

  • Page 11: Introduction To The Manual

    This chapter also includes a list of related manuals. Applicability The manual is applicable to liquid-cooled, cabinet-installed ACS880-207LC IGBT supply units that form a part of an ACS880 multidrive system. Safety instructions Obey all safety instructions delivered with the drive.

  • Page 12: Purpose Of The Manual

    The unit size can be identified from the basic code visible on the type designation label, for example, ACS880-207LC-4360A-7 where 4360A is the unit size. The option codes of the unit are listed after the plus sign. Section Type designation key (page 38) explains the type designation code in detail.The frame size is marked on the type...
  • Page 13 Introduction to the manual 13 Term/ Description Abbreviation FDIO-01 Optional digital I/O extension module FDNA-01 Optional DeviceNet™ adapter module FDPI Diagnostics and panel interface board FEA-03 Optional I/O extension adapter FECA-01 Optional EtherCAT® adapter module FEN-01 Optional TTL incremental encoder interface module FENA-11 Optional Ethernet adapter module for EtherNet/IP™, Modbus TCP®...

  • Page 14: Related Documents

    14 Introduction to the manual Related documents You can find manuals on the Internet. See below for the relevant code/link. For more documentation, go to www.abb.com/drives/documents. Manuals for ACS880 multidrives cabinets...

  • Page 15: Operation Principle And Hardware Description

    Contents of this chapter This chapter describes the operation basics and the hardware of the IGBT supply unit (ACS880-207LC). Operation principle IGBT supply unit 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.

  • Page 16: Simplified Main Circuit Diagram

    6E1F Licensing fault. Auxiliary code in the event logger indicates the plus code of missing license, in this case N8053. For further assistance, contact your local ABB representative. Simplified main circuit diagram ￭...

  • Page 17: Overview Diagram Of The Drive

    Operation principle and hardware description 17 Overview diagram of the drive This diagram shows a simplified diagram of a drive with IGBT supply unit (frame R7i) and inverter unit. Auxiliary voltage transformer ([T21], option +G344) Auxiliary voltage switch [Q21] Main switch-disconnector ([Q1], option +F253) (standard, always with +F250) AC fuses [F1] Main contactor ([Q2], option +F250) (standard, always with +F253) Charging circuit...

  • Page 18: Layout Drawings

    18 Operation principle and hardware description Layout drawings This section contains layout drawings of cubicles that are included in a supply unit. The components, layout and size of the cubicles vary depending on the supply unit size and selected options. Supply unit ￭...

  • Page 19: Incoming Cubicle

    Operation principle and hardware description 19 Incoming cubicle ￭ This section shows examples of incoming cubicle layout. The cubicle contains the main switching and disconnecting devices. The input power cables are connected to the incoming cubicle through cabinet bottom. The components, layout and size vary depending on the supply unit size and selected options.
  • Page 20 20 Operation principle and hardware description Grounding switch (option +F259) Main switch-disconnector...

  • Page 21: Incoming Cubicle For Frame R7I (Door Open)

    Operation principle and hardware description 21 Incoming cubicle for frame R7i (door open) DC fuses Diode bridge CIO-01 I/O module DC switch BAMU auxiliary measurement unit Heat exchanger Auxiliary voltage switch Charging switch Grounding switch (option +F259) Charging resistors Main switch-disconnector Input power cable terminals [L1, L2, L3] Current transformers...

  • Page 22: Incoming Cubicle For Frame R8I (Door Closed)

    22 Operation principle and hardware description Inlet manifold with stop and drain valves Outlet manifold with stop and drain valves Incoming cubicle for frame R8i (door closed) Auxiliary voltage switch [Q21] Meters: Voltage meter [P5.x] (option +G334), phase selector switch for voltage meter [S5.x] (option +G334), AC phase current meters [P2.x] (option +G335) Charging switch [Q3] Grounding switch [Q9] (option +F259)

  • Page 23: Incoming Cubicle For Frame R8I (Door Open)

    Operation principle and hardware description 23 Incoming cubicle for frame R8i (door open) Auxiliary voltage disconnector [Q21] Charging circuit disconnector, AC side DC fuses Option +F259: Grounding switch [Q9] Charging circuit disconnector, DC side Option +G442: BAMU measurement unit Option +F255: Main circuit breaker [Q1] Cooling fan and heat exchanger [G115.x] Charging resistors [R4.x] Input power cable terminals [L1, L2, L3]...

  • Page 24: Supply Module Cubicle (Frame R7I)

    24 Operation principle and hardware description Supply module cubicle (frame R7i) ￭ This section shows an example of supply module cubicle layout. The cubicle contains IGBT supply module and LCL filter. Door closed Door open DC switch Charging circuit disconnector DC fuses IGBT supply module of frame size R7i (on its side) BSFC-12C charging controller...

  • Page 25: Supply Module Cubicle (Frame R8I)

    Operation principle and hardware description 25 Supply module cubicle (frame R8i) ￭ This section shows an example of supply module cubicle layout. The cubicle contains IGBT supply modules. Door open DC fuses [F2.x] Common mode filters [R1.x] IGBT supply module of frame size R8i [T01] Coolant connections Air-to-liquid heat exchanger installed below each module (Behind the mounting plate) Fan.

  • Page 26: Filter Cubicle (Frame R8I)

    26 Operation principle and hardware description Filter cubicle (frame R8i) ￭ This section shows an example of LCL filter cubicle layout. The cubicle contains LCL filter(s). There are no switches or devices on the cabinet door. Door open AC fuses Capacitors.

  • Page 27: Auxiliary Control Cubicle (Width 400 Mm, Frame R7I)

    Operation principle and hardware description 27 Auxiliary control cubicle (width 400 mm, frame R7i) ￭ This section shows an example of auxiliary control cubicle layout. The composition and size of the cubicle vary depending on the selected options. There are no switches or devices on the cabinet door. Door open Control unit CIO-01 I/O module [A115]...

  • Page 28: Auxiliary Control Cubicle (Width 600 Mm)

    28 Operation principle and hardware description Auxiliary control cubicle (width 600 mm) ￭ This section shows an example of auxiliary control cubicle layout. The composition and size of the cubicle vary depending on the selected options. The cubicle has a bottom control cable entry. The top cable entry (option +H351) increases the cubicle height.

  • Page 29: Door Open

    Operation principle and hardware description 29 Door open CIO-01 I/O module [A115] BCU control unit [A51] Cooling fan and heat exchanger [G115.x] Transformer. Two transformers can also be behind the assembly plates. Inlet manifold with stop and drain valves Outlet manifold with stop and drain valves...

  • Page 30: Ka Input Cubicle (Option +F274)

    100 kA input cubicle. All other customer cables enter the auxiliary control cubicle or other supply unit cubicles. ABB does not install optional door devices (for example, meters) on the door of the 100 kA cubicle at the factory. No UL version (option +C129) is available.

  • Page 31: Overview Of Power And Control Connections

    Operation principle and hardware description 31 Overview of power and control connections Input power connections of the IGBT supply unit are terminals L1, L2 and L3 located in the lower part of the incoming cubicle. Power cables enter the cabinet via lead-throughs on the floor of the cubicle as standard.

  • Page 32: Overview Of The Control Connections Of The Bcu Control Unit

    32 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. Analog and digital I/O extension modules and Control panel. fieldbus communication modules can be in- serted into slots 1, 2 and 3.

  • Page 33: Supply Unit Control Devices

    Operation principle and hardware description 33 Supply unit control devices Run enable is the main control signal of the supply unit. The control program reads it from digital input DI2. User controls the signal with an operating switch installed on the cabinet door, typically.

  • Page 34: Operating Switch [S21]

    34 Operation principle and hardware description User operates the charging switch with a handle on the cabinet door. The switch must be closed during the drive power up to enable charging. ABB recommends to keep the switch open otherwise. If the supply unit is equipped with the DC switch/disconnector [Q11] (option +F286), ABB adds an additional DC switch/disconnector [Q40] to the supply unit charging circuit automatically.

  • Page 35: Local Charging Control Switch [S4]

    Operation principle and hardware description 35 Make sure that the charging switch [Q10] is open. It isolates the supply module charging circuit from the drive DC link. Open the DC switch/disconnector [Q40] of the charging circuit. It isolates the drive charging circuit from the drive DC link. Handle is on the incoming unit door. Lock out and tag out the switches.

  • Page 36: Control Panel [A59]

    36 Operation principle and hardware description Control panel [A59] ￭ With the control panel, the user can: • start and stop the unit • view and reset the fault and warning messages, and view the fault history • view actual signals •...

  • Page 37: Type Designation Label(S)

    Operation principle and hardware description 37 Type designation label(s) Each IGBT supply unit has a type designation label attached onto the inside of the cubicle door. The type designation label includes the ratings, appropriate markings, a type designation and a serial number of the unit. Example label is shown below. Quote the complete type designation and serial number when contacting technical support.

  • Page 38: Type Designation Key

    38 Operation principle and hardware description Type designation key The type designation contains information on the specifications and configuration of the supply unit. The first digits from left express the basic supply unit type. The optional selections are given thereafter, separated by plus signs, eg, +F255. The main selections are described below.
  • Page 39 Operation principle and hardware description 39 Code Description C241 800 mm wide input cubicle C245 1000 mm wide input cubicle C243 Additional voltage measurement for optimal grid control Filters E205 du/dt filtering by choke E210 2nd environment, C3, grounded (TN) and ungrounded (IT) networks Line options F250 Main (line) contactor...
  • Page 40 40 Operation principle and hardware description Code Description G344 Auxiliary voltage transformer G426 Arc monitoring unit, extension for 2 loops, Rea 105 G432 Frequency monitoring device G442 BAMU auxiliary measurement unit G453 Common mode filter temperature monitoring J400 Bluetooth control panel J410 Control panel connection kit J425...
  • Page 41 Operation principle and hardware description 41 Code Description L526 FDIO-01 digital I/O extension module Control program N8010 IEC 61131-3 application programmability N8053 Optimal grid control mode in ACS880 IGBT supply control program. See Optimal grid control of ACS880 IGBT supply control program supplement (3AXD50000164745 [English]). Specialties P913 Special color...

  • Page 42: Weak Supply Networks

    42 Operation principle and hardware description Weak supply networks In weak supply networks with a short-circuit ratio less than 8, ABB recommends to equip the supply unit with BAMU auxiliary measurement unit (option +G442). If it is not included, there is a risk of nuisance DC overvoltage trippings due to disturbances caused by high-voltage THD in the supply voltage.

  • Page 43: Electrical Installation

    This chapter instructs how to install the input power cables and control cables, and it contains electrical safety precautions. The information is valid for cabinet-installed ACS880-207LC supply units. Required tools The tools required for tightening the connections are listed below: •...
  • Page 44 44 Electrical installation 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. Do these steps before you begin any installation or maintenance work. Clearly identify the work location and equipment.
  • Page 45 Electrical installation 45 voltage can remain charged for a long time after the drive power-off. The measurement discharges the voltage. • Make sure that the voltage between the drive DC terminals (UDC+ and UDC-) and the grounding (PE) terminal is zero. In cabinet-built drives, measure between the drive DC busbars (+ and -) and the grounding (PE) busbar.

  • Page 46: Isolation From Ac Supply Networks

    46 Electrical installation Isolation from AC supply networks Clearly identify the work location. Disconnect all possible voltage sources. • Open the main switch-disconnector [Q1], or rack out the main breaker [Q1] of the drive (whichever is present). Note that some drives have two switch-disconnectors or main breakers [Q1.1 and Q1.2].

  • Page 47: Isolation From Common Dc Bus

    Electrical installation 47 Isolation from common DC bus In case of units with DC voltage remaining: if there are several power sources for the DC bus, the supply unit which shall be isolated must be equipped with a DC switch-disconnector (option +F286). In order to isolate the supply unit from the live DC bus, open the DC switch-disconnector [Q11] and also the charging switch [Q10] in EVERY cubicle containing supply modules.

  • Page 48: Connecting The Input Power Cables

    48 Electrical installation Connecting the input power cables Connection diagram (frame R7i) ￭ Components for the drive main charging circuit. For details, see the delivery-specific circuit dia- grams. Components for the supply module (DC) charging circuit. For details, see the delivery-specific circuit diagrams.

  • Page 49: Removing Shrouds

    Roxtec cable entry plate (option +H394), or cable gland plate (option +H358), refer also to the instruction of the related non-ABB installation accessories. For example, the Roxtec instructions or the instructions by...
  • Page 50 50 Electrical installation IP54 cabinet: Remove the rear horizontal cable support and the cable entry plate. IP54 cabinet: Remove a sealing grommet from the cable entry plate for each cable. Cut hole into the rubber grommet and slide it onto the cable. Lead the cables inside the cabinet through the cable entry plate.

  • Page 51: Installing Shrouds

    Electrical installation 51 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. For each cable, attach the conductive sleeve to the bare cable shield with a cable tie.

  • Page 52: Connection Diagram (Frame R8I And Multiples)

    52 Electrical installation Connection diagram (frame R8i and multiples) ￭ Components for the drive main charging circuit. For details, see the delivery-specific circuit dia- grams. Components for the supply module (DC) charging circuit. For details, see the delivery-specific circuit diagrams. Incoming cubicle LCL filter cubicle IGBT supply module cubicle...

  • Page 53: Removing Shrouds

    Roxtec cable entry plate (option +H394), or cable gland plate (option +H358), refer also to the instruction of the related non-ABB installation accessories. For example, the Roxtec instructions or the instructions by the cable gland manufacturer.
  • Page 54 54 Electrical installation IP54 cabinet: Attach the the sealing grommets to the cable entry plate. Attach also the cable entry plate, and the cable support. For each cable, strip off 3…5 cm (1.2 … 2 inches) of the outer insulation above the cable entry plate.

  • Page 55: Installing Shrouds

    Electrical installation 55 For each cable, attach the conductive sleeve to the bare cable shield with a cable tie. Attach the cable to the support bracket with a clamp. For each cable, connect the PE conductor to the PE busbar, and the phase conductors to the phase terminals.

  • Page 56: Use Of Fasteners In Cable Lug Connections

    56 Electrical installation Use of fasteners in cable lug connections Use the bolts, nuts and washers delivered with the drive. Install all the fasteners in the correct order. See the figure below. Tighten the cable lug to the torque specified for the connection.

  • Page 57: Connecting Input Power Cables - Cable Entry In 100 Ka Input Cubicle (Option +F274)

    Electrical installation 57 Connecting input power cables - cable entry in 100 kA input cubicle (option +F274) Connection diagram ￭ 100 kA input cubicle Incoming cubicle Note: This diagram shows the installation with shielded single core cables. The shields are grounded at both ends and they operate as the PE conductors of the drive.

  • Page 58: Connecting The Cables

    Roxtec cable entry plate (option +H394), or cable gland plate (option +H358), refer also to the instruction of the related non-ABB installation accessories. For example, the Roxtec instructions or the instructions by the cable gland manufacturer.
  • Page 59 Electrical installation 59 conductors. Twist the shield to form a PE conductor, and mark it with yellow-green tape or heat-shrink tubing. For each cable, attach cable lugs at the end of the PE conductor (twisted shield) and phase conductors. WARNING! Apply grease to stripped aluminum conductors before attaching them to non-coated aluminum cable lugs.

  • Page 60: Replacing Shrouds And Beams In Front Of Input Power Cable Terminals

    60 Electrical installation Replacing shrouds and beams in front of input power cable terminals Install the beams. Reinstall the shrouding and assembly plates. Close the cubicle door.

  • Page 61: Connecting The External Power Supply Cable For The Auxiliary Circuit

    Electrical installation 61 Connecting the external power supply cable for the auxiliary circuit The customer/installer must provide the auxiliary voltage from an external supply to the drive. For details, see the delivery-specific circuit diagrams. Connection diagram ￭ External control voltage supply External fan voltage supply Q115...

  • Page 62: Checking The Settings Of The Auxiliary Voltage Transformer ([T21], Option +G344)

    62 Electrical installation Checking the settings of the auxiliary voltage transformer ([T21], option +G344) Check the tap settings of all auxiliary voltage transformers. Transformer T21 is optional equipment. The voltage settings of transformer T21 are made at terminal blocks T21_X1/X2 and T115_X1/X2 respectively.

  • Page 63: Checking The Settings Of The Cooling Fan Transformer

    Electrical installation 63 Checking the settings of the cooling fan transformer Check the tap settings of all cooling fan transformers. Cooling fan transformers T115 and T125 are present depending on drive configuration. If the delivery contains an incoming unit, the cooling fan transformer connections are made at the factory. The connection of the primary winding of the fan transformer depends on the actual system voltage.

  • Page 64: Connecting The Control Cables

    64 Electrical installation Connecting the control cables The control interface of the supply unit is mainly reserved for internal use. It is possible that there is no, or only a few user-specific control connections. See the delivery-specific circuit diagrams. See the control unit chapter for the default I/O connections of the supply unit.
  • Page 65 Electrical installation 65 If the outer surface of the shield is non-conductive: • Cut the shield at the midpoint of the peeled part. Be careful not to cut the conductors or the grounding wire. • Turn the conductive side of the shield inside out over the insulation. •...
  • Page 66 66 Electrical installation Routing the control cables inside the cabinet Use the existing trunking in the cabinet where 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.
  • Page 67 Electrical installation 67 Connecting control cabling Connect the conductors to the appropriate terminals. Refer to the wiring diagrams delivered with the drive. Obey these instructions: • Connect the inner twisted pair shields and all separate grounding wires to the grounding clamps near the terminals. •...

  • Page 68: Powering The Heating And Lighting Equipment (Options +G300 And +G301)

    68 Electrical installation Powering the heating and lighting equipment (options +G300 and +G301) See the circuit diagrams delivered with the supply unit. Cabinet heaters and/or lighting (230 or 115 V AC, options +G300/+G301) are to be supplied from external power sources. Connection diagram ￭...

  • Page 69: Connecting A Pc

    Electrical installation 69 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, for example, the Drive composer PC tool) can be connected as follows: To connect a control panel to the unit, either •...

  • Page 70: Installing Optional Modules

    70 Electrical installation Installing optional modules WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. Pay attention to the free space required by the cabling or terminals coming to the option modules.

  • Page 71: The Control Unit

    The control unit 71 The control unit Contents of this chapter This chapter • describes the connections of the control unit • contains the specifications of the inputs and outputs of the control unit. General The BCU-x2 control unit is used with both frame sizes (R7i and R8i) and multiples. The BCU-x2 consists of a BCON-12 control board (and a BIOC-01 I/O connector board and power supply board) built in a metal housing.

  • Page 72: Bcu-X2 Layout

    72 The control unit BCU-x2 layout Description 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 I/O extension, encoder interface or fieldbus adapter module connection SLOT 3 I/O extension, encoder interface, field-...
  • Page 73 The control unit 73 Description Analog inputs Analog outputs Digital inputs, Digital input interlock (DIIL) XRO3 XD24 XPOW XDIO Digital input/outputs XD2D Drive-to-drive link XRO2 XD24 +24 V output (for digital inputs) XDIO XETH Ethernet port – Not in use XPOW External power input XRO1...

  • Page 74: Default I/O Diagram Of The Supply Control Unit (Bcu-X2)

    74 The control unit Default I/O diagram of the supply control unit (BCU-x2) 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.
  • Page 75 The control unit 75 Terminal Description Temp fault (0 = overtemperature) Run / enable (1 = run / enable) MCB feedback (0 = main contactor/breaker open) Not in use by default. Can be used for eg, auxiliary circuit breaker fault. Not in use by default.

  • Page 76: Connecting Motor Temperature Sensors To The Drive

    76 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. 2) Use of the signal in the control program. When parameter 120.30 External charge enable has value Yes (default setting), the control program reserves this I/O terminal for external charging circuit control and monitoring, and parameters 110.24 RO1 source and 110.30 RO3 source are write-protected.

  • Page 77: Safe Torque Off (Xsto, Xsto Out)

    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.

  • Page 78: Connector Data

    78 The control unit Connector data Power supply (XPOW) Connector pitch 5 mm, wire size 0.5 … 2.5 mm (22…12 AWG) Maximum tightening torque 0.45 N·m (4 lbf·in) 24 V (±10%) DC, 2 A External power input. Two supplies can be connected to the BCU-x2 for redundancy. Relay outputs RO1…RO3 Connector pitch 5 mm, wire size 0.5 …...
  • Page 79 The control unit 79 Analog inputs AI1 and AI2 Connector pitch 5 mm, wire size 0.5 … 2.5 mm (22…12 AWG) (XAI:4 … XAI:7). Maximum tightening torque 0.45 N·m (4 lbf·in) Current/voltage input mode selection Current input: -20…20 mA, R = 100 ohm by switches Voltage input: -10…10 V, R...
  • Page 80 80 The control unit SDHC memory card slot (SD CARD) Memory card type: SDHC Maximum memory size: 4 GB Battery Real-time clock battery type: BR2032 The terminals of the control unit fulfill the Protective Extra Low Voltage (PELV) requirements. The PELV requirements of a relay output are not fulfilled if a voltage higher than 48 V is connected to the relay output.

  • Page 81: Bcu-X2 Ground Isolation Diagram

    The control unit 81 BCU-x2 ground isolation diagram ￭ XPOW +24VI +24VI +VREF -VREF AGND AI1+ AI1- AI2+ AI2- AGND AGND XD2D BGND SHIELD XRO1, XRO2, XRO3 XD24 +24VD DICOM +24VD DIOGND XDIO DIO1 DIO2 DIOGND DIOGND DIIL XSTO SGND XSTO OUT SGND SGND...

  • Page 83: Installation Checklist

    Installation checklist 83 Installation checklist Contents of this chapter This chapter contains a checklist for 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.
  • Page 84 84 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.

  • Page 85: Start-Up And Operation

    Contents of this chapter This chapter describes the start-up procedure of the IGBT supply unit. The information is valid for cabinet-installed ACS880-207LC IGBT supply units. Note: These instructions do not cover all possible start-up tasks of a customized drive. Always refer to the delivery-specific circuit diagrams when proceeding with the start-up.

  • Page 86: Start-Up Procedure

    86 Start-up and operation Start-up procedure Action Safety WARNING! Only qualified electricians are allowed to do the work described in this chapter. Obey all safety instructions in ACS880 liquid-cooled multidrives cabinets and modules safety in- structions (3AXD50000048633 [English]) and section Electrical safety precautions (page 43).
  • Page 87 Start-up and operation 87 Action Close the cabinet doors. Close the main breaker of the supply transformer. Close the auxiliary voltage switch [Q21]. Also switch on the voltage to any other externally-supplied options (such as the cooling fan supply, lighting, heating). Setting up the supply unit parameters Check the voltage range setting in parameter 195.01 Supply voltage.

  • Page 88: Additional Instructions For Closing The Dc Switch-Disconnector Of The Supply Module Cubicle ([Q11], Option +F286)

    88 Start-up and operation Action Drives with an emergency stop circuit (options +Q951, +Q952, +Q963, +Q964, +Q978, +Q979): Test and validate the operation of the emergency-stop circuit. See the delivery specific circuit diagrams and wiring, start-up and operating instructions of the option. Additional instructions for closing the DC switch-disconnector of the ￭...

  • Page 89: Maintenance

    Maintenance Contents of this chapter This chapter instructs how to maintain the IGBT supply unit and how to interpret its fault indications. The information is valid for cabinet-installed ACS880-207LC IGBT supply units. Maintenance intervals The tables below show the maintenance tasks which can be done by the end user. The complete maintenance schedule is available on the Internet (https://new.abb.com/drives/services/maintenance/preventive-maintenance).
  • Page 90 Tightening if needed. Checking ambient conditions (dustiness, corrosion, temperature) Checking coolant pipe connections Other ABB SACE main circuit breaker maintenance ABB contactors maintenance Functional safety Safety function test See the maintenance information of the safety function. Safety component expiry (Mission time, T...

  • Page 91: Maintenance Timers And Counters

    • 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. • Long term operation near the specified maximum ratings or ambient conditions may require shorter maintenance intervals for certain components.

  • Page 92: Cabinet

    92 Maintenance Cabinet Cleaning the interior of the cabinet ￭ 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, commissioning or maintenance work.

  • Page 93: Fuses

    Maintenance 93 Fuses Replacing the supply unit AC fuses (frame R8i) ￭ WARNING! Use the required personal protective equipment. Wear protective gloves and long sleeves. Some parts have sharp edges. Repeat the steps described in section Electrical safety precautions (page 43) before you start the work.

  • Page 94: Replacing Ac Fuses - 100 Ka Input Cubicle (Option +F274)

    94 Maintenance Replacing AC fuses - 100 kA input cubicle (option +F274) ￭ 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.
  • Page 95 Maintenance 95...

  • Page 96: Replacing The Supply Unit Dc Fuses (Frame R7I)

    96 Maintenance Replacing the supply unit DC fuses (frame R7i) ￭ WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. WARNING! Use the required personal protective equipment. Wear protective gloves and long sleeves.
  • Page 97 Maintenance 97...

  • Page 98: Replacing The Supply Unit Dc Fuses (Frame R8I)

    98 Maintenance Replacing the supply unit DC fuses (frame R8i) ￭ WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. WARNING! Use the required personal protective equipment. Wear protective gloves and long sleeves.

  • Page 99: Fans

    Reset the running time signal after fan replacement. See also CIO-01 I/O module for distributed I/O bus control user's manual (3AXD50000126880 [English]). Replacement fans are available from ABB. Do not use other than ABB-specified spare parts.

  • Page 100: Frame R7I - Internal Module Fan Replacement

    100 Maintenance Frame R7i – internal module fan replacement ￭ 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, commissioning or maintenance work.

  • Page 101: Frame R8I Fan Replacement

    Maintenance 101 Frame R8i fan replacement ￭ 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, commissioning or maintenance work.

  • Page 102: Replacing The Cabinet Fan In The Module Cubicle (Frame R7I)

    102 Maintenance Replacing the cabinet fan in the module cubicle (frame R7i) ￭ 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, commissioning or maintenance work.

  • Page 103: Replacing The Heat Exchanger Fan In The Filter Cubicle (Frame R8I)

    Maintenance 103 Replacing the heat exchanger fan in the filter cubicle (frame R8i) ￭ WARNING! Read the safety instructions given in ACS880 liquid-cooled multidrives cabinets and modules safety instructions (3AXD50000048633 [English]). If you ignore them, injury or death, or damage to the equipment can occur.

  • Page 104: Replacing The Fan In The Incoming Cubicle (Frame R7I)

    104 Maintenance Replacing the fan in the incoming cubicle (frame R7i) ￭ 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.

  • Page 105: Replacing The Fan In The Incoming Cubicle (Frame R8I)

    Maintenance 105 Replacing the fan in the incoming cubicle (frame R8i) ￭ 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.
  • Page 106 106 Maintenance...

  • Page 107: Replacing The Fan In The 400 Mm Wide Auxiliary Control Cubicle (Frame R7I)

    Maintenance 107 Replacing the fan in the 400 mm wide auxiliary control cubicle ￭ (frame R7i) Auxiliary control cubicle has a fan in the lower part of the cubicle. WARNING! Read the safety instructions given in ACS880 liquid-cooled multidrives cabinets and modules safety instructions (3AXD50000048633 [English]).

  • Page 108: Replacing The Fan In The 600 Mm Wide Auxiliary Control Cubicle

    108 Maintenance Replacing the fan in the 600 mm wide auxiliary control cubicle ￭ Auxiliary control cubicle has a fan in the lower part of the cubicle. WARNING! Read the safety instructions given in ACS880 liquid-cooled multidrives cabinets and modules safety instructions (3AXD50000048633 [English]).

  • Page 109: Replacing The Cooling Fan In The 100 Ka Input Cubicle

    Maintenance 109 Replacing the cooling fan in the 100 kA input cubicle ￭ WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. WARNING! Use the required personal protective equipment. Wear protective gloves and long sleeves.
  • Page 110 110 Maintenance Remove the 4 screws that attach the fan assembly to the frame. Pull the fan assembly out.
  • Page 111 Maintenance 111 Disassemble the fan assembly as follows: • Remove the 3 screws and 6 nuts that attach the front casing to the rear casing. • Remove the 4 screws that attach the fan to the front casing. Replace the fan. Assemble and install the fan assembly in reverse order.

  • Page 112: Supply Modules

    112 Maintenance Supply modules Replacing the supply module (frame R7i) ￭ 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.
  • Page 113 Maintenance 113 Locking screw Install the module lifting device. Pull the module out enough to attach a lifting chain to chain holes of the module. Lift the module carefully out. WARNING! Move the module with another person as it is heavy. Keep the module secured to a hoist or equivalent to prevent the module from falling.

  • Page 114: Reinstalling The Module

    114 Maintenance Reinstalling the module Push the module carefully into its bay. Tighten the locking screw (6 mm hex key) at the top of the module to 5 N·m [3.6 lbf·ft] maximum. Fasten the module retaining screws at the top and the bottom of the module (two screws each).

  • Page 115: Removing The Module

    Maintenance 115 WARNING! Make sure that the replacement module has exactly the same type code as the old module. WARNING! Beware of hot coolant. Do not work on the liquid cooling system until the pressure is lowered down by stopping the pumps and draining the coolant. High-pressure warm coolant (6 bar, max.
  • Page 116 116 Maintenance Close the inlet valve (a) and outlet valve (located on the right-hand side of the cubicle). Lead the drain hoses (b, on both sides of the cubicle) into a suitable container. Open the drain valves (c, on both sides of the cubicle). This will drain all modules in the cubicle.

  • Page 117: Reinstalling The Module

    Maintenance 117 Remove the module retaining screws at the top and the bottom of the module. 10. Pull the module carefully out onto the service platform. Keep the module secured to a hoist or equivalent to prevent the module from falling. For information on using the lifting device, see Converter module lifting device for drive cabinets hardware manual (3AXD50000210268...

  • Page 118: Assembling The Service Platform

    118 Maintenance Fill up the cooling system. For instructions, see section Filling up and bleeding the internal cooling circuit. Close the swing-out frame (if present). Reinstall all shrouds removed earlier. Assembling the service platform The service platform is included in the cabinet delivery. It can be used when installing or servicing liquid-cooled R8i modules.

  • Page 119: Lcl Filters

    Maintenance 119 LCL filters Replacing the capacitors of the LCL filter (frame R7i) ￭ WARNING! Read the safety instructions given in ACS880 liquid-cooled multidrives cabinets and modules safety instructions (3AXD50000048633 [English]). If you ignore them, injury or death, or damage to the equipment can occur.

  • Page 120: Replacing The Capacitors Of The Lcl Filter (Frame R8I)

    120 Maintenance Replacing the capacitors of the LCL filter (frame R8i) ￭ WARNING! Read the safety instructions given in ACS880 liquid-cooled multidrives cabinets and modules safety instructions (3AXD50000048633 [English]). If you ignore them, injury or death, or damage to the equipment can occur.

  • Page 121: Lifting The Inductor Of The Lcl Filter

    Maintenance 121 Lifting the inductor of the LCL filter ￭ 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.

  • Page 122: Charging Resistors

    122 Maintenance Charging resistors Replacing the charging resistors (frame R8i) ￭ Charging resistors are located next to the cooling fan of the incoming cubicle. WARNING! Read the safety instructions given in ACS880 liquid-cooled multidrives cabinets and modules safety instructions (3AXD50000048633 [English]).

  • Page 123: Capacitors Of The Dc Circuit

    For information on reforming the capacitors, refer to Capacitor reforming instructions (3BFE64059629 [English]). Replacing the capacitors ￭ See separate service manual by ABB Service. Control panel Refer to ACS-AP-I, -S, -W and ACH-AP-H, -W Assistant control panels user’s manual (3AUA0000085685 [English]).

  • Page 124: Memory Unit

    124 Maintenance Memory 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. Stop the drive and do the steps in section Electrical safety precautions (page 43) before you start the work.

  • Page 125: Leds

    Maintenance 125 LEDs Control unit LEDs ￭ 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 •...

  • Page 126: Reduced Run

    If the control unit is powered from the faulty module, connect the control unit to another 24 V DC power supply. ABB strongly recommends using an external power supply with supply/rectifier units consisting of parallel-connected modules.

  • Page 127: Resuming Normal Operation

    Note that some of the components may already have been renewed earlier, restarting their mission time. The remaining mission time of the whole circuit is however determined by its oldest component. Contact your local ABB service representative for more information.

  • Page 129: Technical Data

    Technical data 129 Technical data Contents of this chapter This chapter contains the technical data valid for the cabinet-installed ACS880-207LC IGBT supply units.

  • Page 130: Ratings

    130 Technical data Ratings Light-over- Heavy-duty Basic No-overload use load use module ACS880- Frame type 207LC- size ACS880- A (AC) A (DC) A (AC) A (DC) A (DC) A (DC) 104LC- (DC) (DC) (DC) = 690 V 0260A-7 0290A-7 1×R7i 0310A-7 0340A-7 1×R7i...

  • Page 131: Derating

    Note 1: The ratings apply at an ambient air temperature of 45 °C (113 °F) and a coolant temperature of 40 °C (104 °F). Note 2: To achieve the rated power given in the table, the rated current must be higher than or equal to the rated current. For dimensioning, use DriveSize dimensioning tool available from ABB. Derating ￭...

  • Page 132: Type Equivalence Table

    132 Technical data Type equivalence table Modules used LCL filter ACS880-207LC-… ACS880- DC capacitance LCL filter type 104LC-… (mF) = 690 V 0260A-7 0290A-7 BLCL-13LC-7 0310A-7 0340A-7 BLCL-13LC-7 0350A-7 0389A-7 BLCL-13LC-7 0360A-7 0390A-7 BLCL-15LC-7 0400A-7 0430A-7 BLCL-15LC-7 0450A-7 0480A-7 BLCL-15LC-7...

  • Page 133: Fuses

    Technical data 133 Fuses Main circuit AC fuses ￭ AC fuses ACS880-207LC-… Manufacturer Type = 690 V 0260A-7 Bussmann 170M4413 0310A-7 Bussmann 170M4414 0350A-7 Bussmann 170M4416 0360A-7 Bussmann 170M6410 0400A-7 Bussmann 170M6411 0450A-7 Bussmann 170M6412 0480A-7 Bussmann 170M6412 0560A-7 Bussmann...

  • Page 134: Main Circuit Ac Fuses - 100 Ka Input Cubicle (Option +F274)

    134 Technical data Main circuit AC fuses - 100 kA input cubicle (option +F274) ￭ AC fuses - 100 kA input cubicle (option +F274) ACS880-207LC-… Manufacturer Type = 690 V 0360A-7 1250 Bussmann 170M7059 0400A-7 1250 Bussmann 170M7059 0450A-7 1250...

  • Page 135: Main Circuit Dc Fuses

    Fuses from other manufacturers can be used if they meet the ratings and the melting curve of the fuse does not exceed the melting curve of the fuse mentioned in the table. DC fuses ACS880-207LC-… Manufacturer Type = 690 V...

  • Page 136: Dimensions And Weights

    Note: The widths of the large UL Listed supply unit variants (option +C129) are bigger due to different main circuit breaker selections and incoming cubicle widths. For dimensions, contact your local ABB representative. Note: The top power cable entry (option +H351) increases height (+50 mm) and width (+200 mm).

  • Page 137: Free Space Requirements

    (if present). Also obey the general mechanical installation instructions. Front Sides Above 1000 9.85 Losses, cooling data and noise Coolant Coolant flow Heat dissipation quantity Noise (total) ACS880-207LC-… into coolant l/min US gal/min into air (kW) dB(A) (kW) = 690 V 0260A-7 0310A-7 0350A-7 10.6 0360A-7 13.7...

  • Page 138: Internal Cooling Circuit Data

    138 Technical data Internal cooling circuit data See chapter Internal cooling circuit. Terminal and lead-through data for the input power cable These drawings (from front, side and above) show the terminal and lead-through dimensions for incoming and input cubicles. The dimensions are given in millimeters. Tightening torque for the cable lug connection depends on the bolt size and type.

  • Page 139: 400 Mm Wide Input Cubicle

    Technical data 139 400 mm wide input cubicle ￭...

  • Page 140: 600 Mm Wide Incoming Cubicle Or Input Cubicle

    140 Technical data 600 mm wide incoming cubicle or input cubicle ￭...

  • Page 141: 1000 Mm Wide Input Cubicle

    Technical data 141 1000 mm wide input cubicle ￭...

  • Page 142: Ka Input Cubicle (Option +F274)

    142 Technical data 100 kA input cubicle (option +F274) ￭...

  • Page 143: Tightening Torques

    Technical data 143 Tightening torques Unless a tightening torque is specified in the text, the following torques can be used. Electrical connections ￭ Size Torque Strength class 0.5 N·m (4.4 lbf·in) 4.6...8.8 1 N·m (9 lbf·in) 4.6...8.8 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)

  • Page 144: Typical Power Cable Sizes

    144 Technical data Typical power cable sizes The tables below give current carrying capacity ( I ) for aluminum and copper Lmax 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.
  • Page 145 Technical data 145 Copper cable PVC insulation XLPE insulation Conductor temperature 70 °C Conductor temperature 90 °C Size Ø [mm] Time const. [s] Time const. [s] Lmax Lmax 3 × 1.5 + 1.5 3 × 2.5 + 2.5 (3 × 4 + 4) 3 ×...

  • Page 146: Electrical Power Network Specification

    Imbalance Max. ± 3% of nominal phase-to-phase input voltage Short-circuit withstand Supply units with ABB-defined main breaker and fuses: strength (IEC/EN 61439- Frame R7i module(s): Rated conditional short-circuit current of LCL+ISU ( I is 50 kA with module's AC fuses given in this manual.

  • Page 147: Control Unit Connection Data (Bcu)

    Technical data 147 Note: When the supply unit includes an earthing switch (option +F259), the short-circuit withstand current is 50 kA. Control unit connection data (BCU) See chapter The control unit. Efficiency Efficiency 98.2…98.8% at nominal power level depending on drive type. The efficiency is not calculated according to the ecodesign standard IEC 61800- 9-2.

  • Page 148: Ambient Conditions

    Installation site altitude 0…2000 m (0…6562 ft) above sea level. For alti- tudes over 2000 m, con- tact ABB. Output derated above 1000 m (3281 ft). Air temperature 0 … +45 °C -40 … +70 °C -40 …...

  • Page 149: Materials

    Technical data 149 Materials Cabinet ￭ Enclosure Zinc coated steel sheet Finish Polyester thermosetting powder coating on visible surfaces, color RAL Classic 7035 and RAL Classic 9017 Busbars for user power Tin-plated copper connections Fire safety of materials Insulating materials and non-metallic items: mostly self-extinctive (IEC 60332-1) Package Standard package...

  • Page 150: Applicable Standards

    Notwithstanding any other provision to the contrary and regardless of whether the contract is terminated or not, ABB and its affiliates are under no circumstances liable for damages and/or losses related to such security breaches, any unauthorized access,...

  • Page 151: Internal Cooling Circuit

    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 •...
  • Page 152 152 Internal cooling circuit Supply modules. The drawing shows the configuration of a diode supply unit with two modules, 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. Inverter modules To/From cooling unit Air-to-liquid heat exchanger...

  • Page 153: Connection To A Cooling Unit

    Internal cooling circuit 153 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.

  • Page 154: Filling Up And Bleeding The Internal Cooling Circuit

    154 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.

  • Page 155: Draining The Internal Cooling Circuit

    Internal cooling circuit 155 Close the bleed valve at the cooling unit. 10. Continue to fill in coolant until a base pressure of approximately 250 kPa is achieved. 11. Open the bleed valve of the pump to let out any air. 12.

  • Page 156: Technical Data

    Coolant type Antifrogen® L (by Clariant International Ltd, www.clariant.com) 25% or 50% mixture, available 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).
  • Page 157 Internal cooling circuit 157 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).

  • Page 158: Pressure Limits

    158 Internal cooling circuit 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®...

  • Page 159: 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 contacts can be found by navigating to www.abb.com/searchchannels.
  • Page 160 3AXD50000174782C © Copyright 2023 ABB. All rights reserved. Specifications subject to change without notice.

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