ABB ACS880-907 Series Hardware Manual
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ABB ACS880-907 Series Hardware Manual

Regenerative rectifier unit
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ABB INDUSTRIAL DRIVES
ACS880-907 regenerative rectifier units
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Summary of Contents for ABB ACS880-907 Series

  • Page 1 — ABB INDUSTRIAL DRIVES ACS880-907 regenerative rectifier units Hardware manual...
  • Page 3 ACS880-907 regenerative rectifier units Hardware manual Table of contents 3. Electrical installation 7. Start-up 3AXD50000020546 Rev C Original instructions EFFECTIVE: 2024-06-19...

  • 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 Type designation label of the L-filter module ......... . . Type designation keys .
  • Page 7 Table of contents 7 Layout ....................Default I/O diagram of the regenerative rectifier unit .
  • Page 8 8 Table of contents Capacitors ..................Reforming the capacitors .
  • Page 9 Table of contents 9 Control unit connection data ..............Energy efficiency data (ecodesign) .

  • Page 11: Introduction To The Manual

    Introduction to the manual 11 Introduction to the manual Contents of this chapter This chapter gives basic information on the manual. Applicability The manual is applicable to the cabinet-installed ACS880-907 regenerative rectifier units that form a part of an ACS880 multidrive system. Safety instructions Obey all safety instructions of the drive.

  • Page 12: Categorization By Frame Size And Option Code

    12 Introduction to the manual Categorization by frame size and option code The instructions and technical data which concern only certain unit or frame sizes are marked with the size identifier. The unit size can be identified from the basic code visible on the type designation label, for example, ACS880-907-0600A-5 where 0600A is the unit size.

  • Page 13: Related Documents

    Type of control unit. USCA-02 Adapter for installing F-series option modules onto the UCU control unit. 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

    Operation principle and hardware description 15 Operation principle and hardware description Contents of this chapter This chapter describes the operation basics and the hardware of the ACS880-907 regenerative rectifier unit.

  • Page 16: Operation Principle

    18 Operation principle and hardware description 16 Operation principle and hardware description Operation principle The regenerative rectifier unit (RRU) consists of one or more rectifier modules (n×R8i) and Operation principle an L-filter. Each R8i module consists of six IGBT components and six diodes connected in The regenerative rectifier unit (RRU) consists of one rectifier module or anti-parallel.

  • Page 17: Overview Diagram Of The Drive System

    Operation principle and hardware description 17 The control program has a function for controlling the charging circuit. For further information, refer to the firmware manual. Overview diagram of the drive system The following figure shows a single-line diagram of a drive with a regenerative rectifier unit.

  • Page 18: Overview Drawing Of A Drive

    18 Operation principle and hardware description Overview drawing of a drive This drawing shows an example of a drive with a supply unit and an inverter unit. Cables enter the cabinet through the bottom. Auxiliary control cubicle (ACU). Contains control electronics and customer I/O connections. Incoming cubicle (ICU).
  • Page 19 Operation principle and hardware description 19 Door open Door closed S21, etc. Control panel and operating switches. F111.1…F111.3 Fuses, direct-on-line module cooling fans (option +C188) F101 Fuses, IP54 roof fans (option +B055) Fuses, auxiliary voltage transformer Control unit T130 24 V DC power supply for cabinet lighting (option +G301) Reserved space for customer-defined equipment At the backside of the assembly plate: Auxiliary voltage transformer (option +G344).
  • Page 20 20 Operation principle and hardware description A611 Safety relay (optional) A612 A613 A614 A621 A622 A623 A624 K61…K66 Relays (optional) Terminal block, emergency stop circuit (optional) Power supply, safety circuit (optional) Power supply, safety circuit (optional) Protection switch, safety circuit (optional) T21X1, Terminal blocks, auxiliary voltage transformers T21 and T101 connections T101X1...

  • Page 21: Layout Drawings Of Incoming Cubicles

    Operation principle and hardware description 21 Layout drawings of incoming cubicles ￭ This section shows examples of the incoming cubicle layouts. The input power cables are connected to the incoming cubicle and it contains the main switching and disconnecting devices. The components, layout and size vary depending on the rectifier unit size and options.
  • Page 22 22 Operation principle and hardware description Auxiliary voltage switch [Q21] Phase selector switch for voltage meter [S5.x] (option +G334) Grounding busbar [PE] Input power cable terminals [L1…L3] Main switch-disconnector [Q1] (option +Q253) Grounding switch [Q9] (option +F259) Main AC fuses [F1…3] Main contactor [Q2] (option +F250) Auxiliary voltage switch [Q21] Cubicle cooling fan...

  • Page 23: Layout Drawing Of A 600 Mm Incoming Cubicle

    Operation principle and hardware description 23 Layout drawing of a 600 mm incoming cubicle These layout drawings show a 600 mm wide incoming cubicle. Options used with this cubicle are bottom cable entry (options +H350 and +H367) and main switch-disconnector (option +F253). Door closed Door open Main switch-disconnector handle...
  • Page 24 24 Operation principle and hardware description Input power cable terminals [L1…L3] Main switch-disconnectors [Q1.1, Q1.2] (option +Q253) Main AC fuses [F1.1…F2.3] Charging contactor [Q4] Auxiliary voltage switch [Q21] Cubicle cooling fans Charging switch handle Charging switch [Q3] Main contactor [Q2] (option +F250) Charging resistors...

  • Page 25: Layout Drawing Of A 1000 Mm Incoming Cubicle

    Operation principle and hardware description 25 Layout drawing of a 1000 mm incoming cubicle These layout drawings show a 1000 mm wide incoming cubicle with cabling through the bottom (option +H350). Door closed Door open Auxiliary voltage switch [Q21] Grounding switch [Q9] (option +F259) Charging switch [Q3] Auxiliary voltage switch [Q21] Grounding busbar [PE]...

  • Page 26: Layout Drawing Of Rectifier Module Cubicles

    26 Operation principle and hardware description Layout drawing of rectifier module cubicles Layout drawing of a rectifier module cubicle 1×R8i ￭ These layout drawings show the regenerative rectifier module cubicle. The cubicle contains regenerative rectifier module(s) and L-filter module(s). Door closed Door open Regenerative rectifier module L-filter module...

  • Page 27: Layout Drawing Of A Rectifier Module Cubicle 2×R8I

    Operation principle and hardware description 27 Layout drawing of a rectifier module cubicle 2×R8i ￭ These layout drawings show the regenerative rectifier module cubicle. The cubicle contains regenerative rectifier module(s) and L-filter module(s). Door closed Door open Regenerative rectifier module L-filter module DC fuses AC fuses...

  • Page 28: Layout Drawings Of Rectifier And L-Filter Modules

    28 Operation principle and hardware description Layout drawings of rectifier and L-filter modules Regenerative rectifier module ￭ This figure shows the layout of the R8i module. R8i module, front R8i module, back DC busbars Handle LEDs and fiber optic connectors Fan (standard speed-controlled fan shown;...

  • Page 29: L-Filter Module (Bl-1X-X)

    Operation principle and hardware description 29 L-filter module (BL-1x-x) ￭ L-filter module, front L-filter module, back Input (AC) connection Output (AC) connection Terminal block [X55] (power supply for module heating element, option +C183; DOL fan supply, option +C188) (ready-connected) Handle Wheels Terminal block [X30] (power supply for module DOL fan, option +C188 and heating element, option +C183;...

  • Page 30: L-Filter Module (Bl-2X-X)

    30 Operation principle and hardware description L-filter module (BL-2x-x) ￭ L-filter module, front L-filter module, back Input (AC) connection Output (AC) connection Terminal block [X55] (power supply for module heating element, option +C183; DOL fan supply, option +C188) (ready-connected) Handle Wheels Terminal block [X30] (power supply for module DOL fan, option +C188 and heating element, option +C183;...

  • 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 regenerative rectifier 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 ￭ Analog and digital I/O extension modules and Control panel fieldbus communication modules can be in- serted into slots 1, 2 and 3. Memory unit Fiber optic links to power modules (inverter, supply, brake or converter) Slot 4 for RDCO module...

  • Page 33: Control Devices

    Operation principle and hardware description 33 Control devices For examples of the door control devices of the regenerative rectifier unit, see Layout drawing of an auxiliary control cubicle (page 18) Layout drawings of incoming cubicles (page 21). The selection and exact location of control devices varies in different deliveries. This section and the layout drawings sections contain brief descriptions of the control devices.

  • Page 34: Operating Switch [S21]

    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. Operating switch [S21] ￭...

  • Page 35: Control Panel [A59]

    Operation principle and hardware description 35 Control panel [A59] ￭ The control panel is the user interface of the unit. An example control panel is shown below. With the control panel, the user can: • start and stop the unit •...

  • Page 36: Type Designation Labels

    36 Operation principle and hardware description Type designation labels Type designation label of the regenerative rectifier unit ￭ Each regenerative rectifier 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.

  • Page 37: Type Designation Labels Of The Regenerative Rectifier Module

    Operation principle and hardware description 37 Type designation labels of the regenerative rectifier module ￭ Each regenerative rectifier module has type designation labels attached to it. The type designation stated on the labels contains information on the specifications and configuration of the unit. Quote the complete type designation and serial number when contacting technical support on the subject of individual regenerative rectifier modules.

  • Page 38: Type Designation Label Of The L-Filter Module

    38 Operation principle and hardware description Type designation label of the L-filter module ￭ Each L-filter module has a type designation label attached to it. Quote the complete type designation and serial number when contacting technical support on the subject of individual L-filter modules. An example label is shown below.

  • Page 39: Option Codes

    Operation principle and hardware description 39 380…415 V. This is indicated in the type designation label as typical input voltage level 3 ~ 400 V AC. 380…500 V. This is indicated in the type designation label as typical input voltage levels 3 ~ 400/480/500 V AC.
  • Page 40 40 Operation principle and hardware description Code Description G335 A-meter in one phase 3G335 A-meter in three phases G336 Arc monitoring G343 Corrosion indicator G344 Auxiliary voltage transformer G426 Arc monitoring extension unit G453 Common mode filter temperature monitoring H350 Power cabling entry from bottom H351 Power cabling entry from top...
  • Page 41 Operation principle and hardware description 41 Code Description Q951 Emergency stop (category 0) with safety relays, by opening the main breaker/contactor Q952 Emergency stop (category 1) with safety relays, by opening the main breaker/contactor Q954 Earth fault monitoring for IT (ungrounded) systems Q959 Supply transformer breaker disconnect push button (red, wired to terminals) on the door Q963...

  • Page 42: Type Designation Of The Module

    42 Operation principle and hardware description Type designation of the module ￭ Type designation describes the composition of the module in short. The complete designation code is divided in subcodes: • The first digits form the basic code. It describes the basic construction of the module.

  • Page 43: Type Designation Key Of The L-Filter Module

    Operation principle and hardware description 43 Type designation key of the L-filter module ￭ The designation code of the L-filter is divided in subcodes: • The first 2 letters give the type of the L-filter, for example, BL-15-7. The numbers after the letters describe the rectifier modules with which the filter is used.

  • Page 45: Electrical Installation

    Electrical installation 45 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 cabinet-installed ACS880-907 rectifier units. For more information on cable selection, protections, etc, see ACS880 multidrives cabinets and modules electrical planning instructions (3AUA0000102324...

  • Page 46: Electrical Safety Precautions

    46 Electrical installation Electrical safety precautions These electrical safety precautions are for all persons who do work on the drive, motor cable or motor. This procedure gives information on how to de-energize the drive and make it safe to do work on it. The procedure does not include all possible drive configurations. Each drive is made to order.

  • Page 47: Checking The Insulation Of The Assembly

    Electrical installation 47 structures, obey the local laws and regulations applicable to live electrical work. This includes, but is not limited to, electric shock and arc protection. • Before and after you measure the installation, verify the operation of the voltage tester on a known voltage source.

  • Page 48: T21 And T101 Tap Settings (400

    48 Electrical installation T21 and T101 tap settings (400…500 V units) ￭ T21_X1 or T101_X1 T21_X2 or T101_X2 without +G304 with +G304 T21 and T101 tap settings (690 V units) ￭ T21_X1 or T101_X1 T21_X2 or T101_X2 without +G304 with +G304...

  • Page 49: T111 Tap Settings

    Electrical installation 49 T111 tap settings ￭ 3~ input 3~ output 3~ input 3~ output Tap settings Terminals Supply Terminals 400 V 320/340 V voltage A1– B1– C1– (50 Hz) (60 Hz) 690 V A1, B1, C1 a1, b1, c1 a2, b2, c2 660 V A1, B1, C1...

  • Page 50: Connecting The Input Power Cables

    50 Electrical installation Connecting the input power cables Connection diagram of frame R8i and multiples ￭ Description Incoming cubicle Rectifier cubicle Note: a) Fuses or other protection means. b) Use a separate PE conductor in addition if the conductivity of the shield does not meet the requirement for the PE conductor.
  • Page 51 Fasten the conductive sleeves to the cable shields with cable ties. Seal the slot between the cable and mineral wool sheet (if used) with sealing compound (eg, CSD-F, ABB brand name DXXT-11, code 35080082). Tie up the unused conductive sleeves with cable ties.
  • Page 52 52 Electrical installation...
  • Page 53 Electrical installation 53...

  • Page 54: Use Of Fasteners In Cable Lug Connections

    54 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 55: Connecting The Control Cables

    Electrical installation 55 Connecting the control cables Default I/O connection diagram ￭ See chapters Control unit (UCU) Control unit (BCU). Connecting the control cables ￭ See the control unit chapter for the default I/O connections. Note that the default I/O connections can be affected by some options.
  • Page 56 56 Electrical installation 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 57 Electrical installation 57 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. Connecting control cabling Connect the conductors to the appropriate terminals.

  • Page 58: Wiring The Functional Safety Options

    58 Electrical installation 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. Wiring the functional safety options The wiring instructions for the functional safety options such as +Q951, +Q952, etc are in separate option manuals.

  • Page 59: Installing Optional Modules

    Electrical installation 59 Installing optional modules Installing option modules (UCU) ￭ A slot adapter is necessary if you install F-series option modules onto the control unit. You can install a maximum of 3 slot adapters per control unit. WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur.

  • Page 60: Installation Of I/O Extension And Fieldbus Adapter Modules On Bcu

    60 Electrical installation Installation of I/O extension and fieldbus adapter modules on BCU ￭ 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 61: Installation Of An Fso Safety Functions Module To Bcu

    Electrical installation 61 Installation of an FSO safety functions module to BCU ￭ Installation of an FSO safety functions module onto BCU control unit WARNING! Obey the safety instructions given in ACS880 multidrives cabinets and modules safety instructions (3AUA0000102301 [English]). If you ignore the safety instructions, injury or death, or damage to the equipment can occur.

  • Page 62: Mounting Kit For Fso Safety Functions Module

    62 Electrical installation Connect the FSO module data cable between FSO connector X110 and BCU connector X12. To complete the installation, refer to the instructions in the applicable FSO module user's manual. Mounting kit for FSO safety functions module To reserve the slots of the control unit for other modules, you can install the FSO module separately from the control unit using mounting kit 3AXD50000025495.

  • Page 63: Connecting A Pc

    Electrical installation 63 The illustration below shows the FSO module installed onto a DIN rail. Connecting a PC WARNING! Do not connect the PC directly to the control panel connector of the control unit. It 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 64 64 Electrical installation USB connected Stop Start Loc/Rem Start Stop Loc/Rem...

  • Page 65: Control Unit (Ucu)

    14 power module connections. The UCU control units have integrated branching unit functionality for collecting and storing real-time data from the power modules to help fault tracing and analysis. The data is stored on a memory card which can be analyzed by ABB service personnel.

  • Page 66: Layout

    66 Control unit (UCU) Layout The figures below show an example UCU-24 control unit. Description I/O terminals SLOT 1 I/O extension, encoder interface or fieldbus SLOT 2 adapter module connection. For F-type modules with USCA-02 adapter. SLOT 3 SLOT 4 RDCO-0x DDCS communication option module connection UMU-01 memory unit connection.
  • Page 67 Control unit (UCU) 67 Description Analog input Analog output XCAN Not in use XCAN TERM CAN bus termination switch Digital input XDIO Digital input/output XD2D Drive-to-drive link XD24 +24 V output (for digital input) XETH1 Ethernet ports for fieldbus, internal switch XETH2 XETH3 Ethernet ports for tool communication, internal...
  • Page 68 68 Control unit (UCU) Description XFSO Not in use Humidity and temperature measurements XFSO...

  • Page 69: Default I/O Diagram Of The Regenerative Rectifier Unit

    Control unit (UCU) 69 Default I/O diagram of the regenerative rectifier unit This table describes the use of the connections in the regenerative rectifier unit. Terminal Description XD2D Drive-to-drive link Not supported BGND SHIELD XD2D.TERM Drive-to-drive link termination switch X485 RS485 connection Not in use by default BGND...
  • Page 70 70 Control unit (UCU) Terminal Description Norm. closed XRO4: Not supported COM4 Common 250 V AC / 30 V DC, 2 A Norm. open XSTO Safe torque off input connection SGND XSTO: STO1 and STO2 are connected to OUT at the factory. To enable start and operation, STO1 and STO2 must be connected to OUT.
  • Page 71 Control unit (UCU) 71 Terminal Description Analog outputs Zero (no signal indicated) 0…20 mA, R < 500 ohm AGND 0…20 mA, R Zero (no signal indicated) < 500 ohm AGND XPOW External power input +24VI 19…32 V DC, 1.5…2.9 A (depends on the load and supply voltage) External power input +24VI Two supplies can be connected to the control unit for redundancy.

  • Page 72: Additional Information On The Connections

    The control unit 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 microSDHC memory card inserted into the UMU-01 memory unit and can be analyzed by ABB service personnel.

  • Page 73: Connector Data

    Control unit (UCU) 73 Connector data The wire size accepted by all screw terminals (for both stranded and solid wire) is 0.5 … 2.5 mm (22…12 AWG). Connector pitch is 5 mm. Maximum tightening torque of the screw terminals is 0.45 N·m (4 lbf·in). Power supply (XPOW) 19…32 V DC, 2.9 A External power input.
  • Page 74 74 Control unit (UCU) XD2D connector 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)

  • Page 75: Ground Isolation Diagram

    Control unit (UCU) 75 Ground isolation diagram ￭ XPOW XD2D X485 XCAN XETH1 XETH2 XETH3 XETH4 XPAN XRO1-XRO4 COM1 … COM4 XD24 +24VD DICOM +24VD DIOGND XDIO DIO1 DIO2 DIOGND DIOGND DIIL XSTO XSTO OUT Power supply ground *The maximum common mode voltage between each AI input and AGND is ±30 V. **Ground selector (DICOM=DIOGND) settings DICOM=DIOGND: ON All digital inputs share a common ground (DICOM connected to DIOGND).

  • Page 77: Control Unit (Bcu)

    12 power module connections. The BCU control units have integrated branching unit functionality for collecting and storing real-time data from the power modules to help fault tracing and analysis. The data is stored on a memory card which can be analyzed by ABB service personnel.

  • Page 78: Layout

    78 Control unit (BCU) 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 79 Control unit (BCU) 79 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 80: Default I/O Diagram Of The Regenerative Rectifier Unit

    80 Control unit (BCU) Default I/O diagram of the regenerative rectifier unit This table describes the use of the default connections in the regenerative rectifier unit. Terminal Description XD2D Drive-to-drive link Not supported BGND Shield D2D.TERM Drive-to-drive link termination switch X485 RS485 connection Not in use by default...
  • Page 81 Control unit (BCU) 81 Terminal Description Temp fault (0 = overtemperature) 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 ->...
  • Page 82 82 Control unit (BCU) Terminal Description Control panel connection X205 Memory unit connection 1) Use of the signal in the control program (fixed). This I/O terminal is reserved in the control program, and parameters 110.24 RO1 source and 110.30 RO3 source are write-protected. 2) Default use of the signal in the control program.

  • Page 83: Additional Information On The Connections

    The control unit 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 84: Connector Data

    84 Control unit (BCU) Connector data The wire size accepted by all screw terminals (for both stranded and solid wire) is 0.5 … 2.5 mm (22…12 AWG). Connector pitch is 5 mm. The maximum tightening torque for screw terminals is 0.45 N·m (4 lbf·in). Power supply (XPOW) 24 V DC (±10%), 2 A External power input.
  • Page 85 Control unit (BCU) 85 XD2D connector 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)

  • Page 86: Bcu Ground Isolation Diagram

    86 Control unit (BCU) BCU 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 87: Installation Checklist

    Installation checklist 87 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 88 88 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. 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.

  • Page 89: Start-Up

    Start-up 89 Start-up Contents of this chapter This chapter describes the start-up procedure of the regenerative rectifier unit. The information is valid for cabinet-installed ACS880-907 rectifier units. The underlined tasks are needed for certain cases only. The option codes (if any) are given in brackets.

  • Page 90: Start-Up Procedure

    90 Start-up Start-up procedure Tasks Safety WARNING! Follow the safety instructions during the start-up procedure. See ACS880 multidrives cabinets and modules safety instructions (3AUA0000102301 [English]). Only qualified electricians are allowed to start-up the drive. Checks/Settings with no voltage connected Make sure that it is safe to start the work. Obey the work instructions for switching off and disconnecting in ACS880 multidrives cabinets and modules safety instructions (3AUA0000102301 [English]).
  • Page 91 Start-up 91 Tasks Powering up the auxiliary circuit of the drive Make sure that it is safe to connect voltage. Ensure that: • nobody is working on the unit or circuits that are wired from outside into the cabinets. • covers of the motor terminal boxes are on. Rectifier unit with voltage meters [P5] on door (option +G344): Close the circuit breaker [F5] for the meters.

  • Page 92: Switching The Unit Off

    92 Start-up Tasks Turn the operating switch [S21] to on (1) position to activate the Run enable signal of the rectifier unit. Now, the rectifier unit starts and the control program steps through the power-up sequence: 1. charging contactor [Q4] closing, 2. charging (until the DC link voltage rises high enough), 3. main contactor [Q2] closing, 4.

  • Page 93: Disconnecting - Including The Input Power Terminals

    Start-up 93 Disconnecting – including the input power terminals ￭ Do the tasks listed in section Disconnecting and temporary grounding the drive (page 92). Switch off and disconnect the breaker of the supply transformer. Secure against reconnection: Lock the disconnectors and attach warning signs. Open the door of the incoming cubicle and make sure by measuring that the input busbars are not under voltage.

  • Page 95: Maintenance

    Maintenance 95 Maintenance Contents of this chapter This chapter instructs how to maintain the regenerative rectifier unit and how to interpret its fault indications. The information is valid for cabinet-installed ACS880-907 regenerative rectifier units. WARNING! Obey the safety instructions given in ACS880 multidrives cabinets and modules safety instructions (3AUA0000102301 [English]).

  • Page 96: Maintenance Intervals

    96 Maintenance Maintenance intervals The tables show the maintenance tasks that can be done by the end user. For the ABB Service offering, contact your local ABB Service representative (new.abb.com/contact-centers). Description of symbols ￭ Action Description Inspection (visual inspection and maintenance action if needed)

  • Page 97: Maintenance Timers And Counters

    • The maintenance and component replacement intervals are based on the assumption that the equipment operates 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 98: Cabinet

    98 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. WARNING! Use a vacuum cleaner with antistatic hose and nozzle, and wear a grounding wristband.

  • Page 99: Cleaning The Door Air Inlets (Ip22 And Ip42)

    Maintenance 99 Cleaning the door air inlets (IP22 and IP42) ￭ Check the dustiness of the air inlet meshes. If the dust cannot be removed by vacuum cleaning from outside through the grating holes with a small nozzle, proceed as follows: Stop the drive and do the steps in section Electrical safety precautions (page 46) before you start the work.

  • Page 100: Replacing The Inlet Door Filters (Ip54)

    100 Maintenance Replacing the inlet door filters (IP54) ￭ Stop the drive and do the steps in section Electrical safety precautions (page 46) before you start the work. Remove the fasteners at the top of the grating. Lift the grating and pull it away from the door. Remove the air filter mat.

  • Page 101: Cleaning The Heatsink

    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 auxiliary control cubicle ￭...

  • Page 102: Replacing The Cooling Fan In The Incoming Cubicle

    102 Maintenance Remove the fastening screws (a) and finger guard (b) of the fan. Install the new fan in reverse order. Make sure that the arrow indicating the air flow direction points up. Replacing the cooling fan in the incoming cubicle ￭...

  • Page 103: Replacing R8I Module Cooling Fan (Speed-Controlled Version)

    If the connectors are not compatible, replace the connector at the end of the fan kit cable. Use the connector in the old fan kit, or order a suitable connector from ABB. Stop the drive and do the steps in section Electrical safety precautions (page 46) before you start the work.

  • Page 104: Replacing R8I Module Cooling Fan (Direct-On-Line Version)

    If the connectors are not compatible, replace the connector at the end of the fan kit cable. Use the connector in the old fan kit, or order a suitable connector from ABB. Refer to Connector replacement guide for ACS880-x04 R8i/D8T, BLCL-2X, BL-2X and BLHF DOL fan (3AXD50001059903 [English]).
  • Page 105 Maintenance 105 Remove the screws holding the front cover plate. Lift the cover plate somewhat to release it. Remove the bracket. Disconnect the wiring of the fan unit. Remove the screws of the fan unit. Pull out the fan unit. Disconnect the fan wire from the fan unit.

  • Page 106: Replacing The Circuit Board Compartment Fan

    106 Maintenance Replacing the circuit board compartment fan ￭ Frame R8i modules are equipped with a fan blowing air through the circuit board compartment. The fan is accessible from the front of the module. WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur.
  • Page 107 Maintenance 107 Install and tighten the four nuts removed earlier. 10. Connect the fan cable. 11. Align and push the fan holder into the module. 12. Install and tighten the two M4×12 (T20) screws.

  • Page 108: Replacing The Fan Of The L-Filter (Bl-1X-X)

    If the connectors are not compatible, replace the connector at the end of the fan kit cable. Use the connector in the old fan kit, or order suitable connector from ABB. Refer to +V112 connector replacement guide for ACS880 BLCL-1X and BL-1X fan kit change, connector X55 (3AXD50001065140 [English]).

  • Page 109: Replacing The Fan Of The L-Filter (Bl-2X-X)

    If the connectors are not compatible, replace the connector at the end of the fan kit cable. Use the connector in the old fan kit, or order suitable connector from ABB. Refer to +V112 connector replacement guide for ACS880-x04 R8i/D8T, BLCL-2X, BL-2X and BLHF DOL fan (3AXD50001059903 [English]).
  • Page 110 110 Maintenance...

  • Page 111: Replacing The Roof Fan For Ip54 Cabinet (Option +B055)

    Maintenance 111 Replacing the roof fan for IP54 cabinet (option +B055) ￭ 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 112: Regenerative Rectifier Module

    112 Maintenance Different fan models Regenerative rectifier module Replacing the rectifier module ￭ WARNING! Obey the safety instructions given in ACS880 multidrives cabinets and modules safety instructions (3AUA0000102301 [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.
  • Page 113 Maintenance 113 WARNING! If you ignore the following instructions, injury or death, or damage to the equipment can occur. • Do not use the module extraction/installation ramp with plinth heights which exceeds the maximum allowed height. • Secure the module extraction/installation ramp carefully. •...
  • Page 114 Wear protective gloves and long sleeves! Some parts have sharp edges. Note: As an alternative to using the extraction/installation ramp, a lifter is available from ABB Service. For more information, contact ABB Service, or see Lifter for air-cooled drive modules user's guide (3AXD50000332588 [English]).
  • Page 115 Maintenance 115 Note: Reinstall the converter and filter module screws before removing the modules from the cubicle. Remove the two screws that fasten the bottom of the module to the base of the cabinet. Install the module pull-put ramp: lift the module pull-out ramp against the cabinet base so that the hooks of the base go into the ramp’s holes.
  • Page 116 116 Maintenance...
  • Page 117 Maintenance 117...

  • Page 118: L-Filter

    Do not use the module extraction/installation ramp with plinth heights which exceeds the maximum allowed height. Note: As an alternative to using the extraction/installation ramp, a lifter is available from ABB Service. For more information, contact ABB Service, or see Lifter for air-cooled drive modules user's guide (3AXD50000332588 [English]).
  • Page 119 Maintenance 119 Unplug the terminal block [X30] cable on top of the module. Remove the screws in the busbars on top of the L-filter module. Be careful not to drop the screws inside the module! Option +C121, marine construction: If a marine support plate is installed in front of the converter and filter modules, undo the screws that fasten the marine support to the modules.
  • Page 120 120 Maintenance...
  • Page 121 Maintenance 121...

  • Page 122: Replacing The L-Filter (Bl-2X-X)

    Do not use the module extraction/installation ramp with plinth heights which exceeds the maximum allowed height. Note: As an alternative to using the extraction/installation ramp, a lifter is available from ABB Service. For more information, contact ABB Service, or see Lifter for air-cooled drive modules user's guide (3AXD50000332588 [English]).
  • Page 123 Maintenance 123 Remove the screws that connect the busbars to the top of the filter module. Be careful not to drop the screws into the module. Remove the fan of the filter module. Unplug the signal connector cable and remove the screws in front of the fan.
  • Page 124 124 Maintenance...
  • Page 125 Maintenance 125...
  • Page 126 Capacitor failure is usually followed by damage to the unit and an input cable fuse failure, or a fault trip. If you think that any capacitors in the drive have failed, contact ABB. Reforming the capacitors ￭ The capacitors must be reformed if the drive has not been powered (either in storage or unused) for a year or more.
  • Page 127 Maintenance 127 Checking and replacing the AC fuses ￭ 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. Disconnect the drive from the AC power line and make sure it is safe to start the work.
  • Page 128 128 Maintenance Bussmann fuses Mersen (Ferraz Shawmut) fuses 50 N·m 46 N·m Attach the shroud and close the door. For the figure, see Checking and replacing the DC fuses (page 126).
  • Page 129 Maintenance 129 Control unit (UCU) UCU control unit types ￭ There are three variants of the UCU control unit used in ACS880: UCU-22, UCU-23 and UCU-24. These have a different number of converter module connections but are otherwise identical. The UCU types are interchangeable if the number of connections is sufficient and the control program is the same.
  • Page 130 130 Maintenance 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. Stop the drive and do the steps in section Electrical safety precautions (page 46) before you start the work.
  • Page 131 Maintenance 131 Push the card to remove it. Install a new card in reverse order.
  • Page 132 132 Maintenance Control unit (BCU) BCU control unit types ￭ There are three variants of the BCU control unit used in ACS880: BCU-02, BCU-12 and BCU-22. These have a different number of converter module connections but are otherwise identical. The BCU types are interchangeable if the number of connections is sufficient and the control program is the same.
  • Page 133 Maintenance 133 Stop the drive and do the steps in section Electrical safety precautions (page 46) before you start the work. Remove the fastening screw. Replace the battery with a new BR2032 battery. If necessary, set the real-time clock. Discard the old battery according to local disposal rules or applicable laws. Control panel Refer to ACS-AP-I, -S, -W Assistant control panels user’s manual (3AUA0000085685...
  • Page 134 134 Maintenance LEDs and other status indicators This section instructs how to interpret the status indications of the ACS880-907 regenerative rectifier 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 delivered with the regenerative rectifier unit.
  • Page 135 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 136 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 137 Technical data 137 Technical data Contents of this chapter This chapter contains the technical data valid for the cabinet-installed ACS880-907 regenerative rectifier units.
  • Page 138 138 Technical data Ratings Light-over- Heavy-duty No-overload use load use Unit type Consists of module type Frame ACS880- ACS880-104-… 907-… (AC) (DC) (AC) (DC) (DC) (DC) (DC) = 400 V 0600A-3 0640A-3 1×R8i 0900A-3 0900A-3 1×R8i 1091 1170 1433 1048 1180A-3 0640A-3 2×R8i...
  • Page 139 Technical data 139 continuous rms current. 10% overload is allowed for one minute every 5 minutes. output power in light-overload use Heavy-duty use (50% overload capability) ratings continuous rms current. 50% overload is allowed for one minute every 5 minutes. output power in heavy-duty use For input frequency f1, see Electrical power network specification (page...
  • Page 140 140 Technical data 4000 m 13123 ft 0.80 3500 m 11429 ft 0.85 3000 m 0.90 9842 ft 0.95 2500 m 8202 ft 1.00 2000 m 6562 ft 1500 m 4921 ft 1000 m 3300 ft +20 °C +25 °C +30 °C +35 °C +40 °C...
  • Page 141 Technical data 141 Fuses Main circuit AC fuses ￭ Unit type Rating Type Example (Bussman) ACS880-907-… = 400 V 0600A-3 1100 A, 690 V, size 3 Flush end type 170M6415 0900A-3 1400 A, 690 V, size 3 Flush end type 170M6417 1180A-3 2000 A, 690 V, size 4...
  • Page 142 142 Technical data Main circuit DC fuses ￭ Unit type Rating Type Example (Bussman) ACS880-907-… = 400 V 0600A-3 1250 A, 690 V, size 3 Flush end contact 170M6416 0900A-3 1800 A, 690 V, size 3 Flush end contact 170M6420 1180A-3 1250 A, 690 V, size 3 Flush end contact...
  • Page 143 Technical data 143 L-filters L-filter type Unit type Frame ACS880-907-… 230 V auxiliary voltage 115 V auxiliary voltage = 400 V 0600A-3 1×R8i BL-15-5+C183+C188+V112 BL-15-5+C183+C188+G304+V112 0900A-3 1×R8i BL-15-5+C183+C188+V112 BL-15-5+C183+C188+G304+V112 1180A-3 2×R8i BL-25-5+C183+C188+V112 1770A-3 2×R8i BL-25-5+C183+C188+V112 2310A-3 4×R8i 2×BL-25-5+C183+C188+V112 3460A-3 4×R8i 2×BL-25-5+C183+C188+V112 5130A-3 6×R8i...
  • Page 144 144 Technical data Dimensions Unit type Height 1 Height 2 Width 1 Width 2 Depth 1 Depth 2 Weight ACS880- 907-… = 400 V 0600A-3 2145 84.4 2315 91.1 1600 63.0 1600 63.3 29.8 1275 2810.9 0900A-3 2145 84.4 2315 91.1 1600 63.0...
  • Page 145 Technical data 145 Free space requirements Leave 400.0 mm (15.75 in) free space above the basic roof level of the cabinet for cooling. For the rest of the free space requirements, see ACS880 multidrive cabinets mechanical installation instructions (3AUA0000101764 [English]).
  • Page 146 146 Technical data Losses, cooling data and noise Unit type Air flow Noise Efficiency lossRRU lossL ACS880-907-… /min = 400 V 0600A-3 2200 1294.9 97.9 0900A-3 2200 1294.9 97.9 1180A-3 10.7 4100 2413.2 98.0 1770A-3 17.7 4100 2413.2 97.9 2310A-3 21.5 10.0 8200...
  • Page 147 Technical data 147 Terminal and cable entry data for the input power cable 400 mm incoming cubicle – main switch-disconnector (+F253) ￭ The dimensions are given in millimeters. Tightening torque for the cable lug connection depends on the bolt size and type. See the technical data. Front Side Above...
  • Page 148 148 Technical data 600 mm incoming cubicle – main switch-disconnector (+F253), bottom ￭ cable entry The dimensions are given in millimeters. Tightening torque for the cable lug connection depends on the bolt size and type. See the technical data. Front Side Above...
  • Page 149 Technical data 149 600 mm incoming cubicle – main circuit breaker (+F255), bottom cable ￭ entry The dimensions are given in millimeters. Tightening torque for the cable lug connection depends on the bolt size and type. See the technical data. Front Side Above...
  • Page 150 150 Technical data 600 mm incoming cubicle – main circuit breaker (+F255), top cable ￭ entry The dimensions are given in millimeters. Tightening torque for the cable lug connection depends on the bolt size and type. See the technical data. Front Side...
  • Page 151 Technical data 151 1000 mm incoming cubicle – main circuit breaker (+F255), bottom ￭ cable entry The dimensions are given in millimeters. Tightening torque for the cable lug connection depends on the bolt size and type. See the technical data. Side Front Above...
  • Page 152 152 Technical data 1000 mm incoming cubicle – main circuit breaker (+F255), top cable ￭ entry The dimensions are given in millimeters. Tightening torque for the cable lug connection depends on the bolt size and type. See the technical data. Side Front...
  • Page 153 Technical data 153 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 154 50/60 Hz, variation ± 5% of nominal frequency Imbalance Max. ± 3% of nominal phase-to-phase input voltage Short-circuit withstand Rectifier units with the ABB-defined main switch-disconnector and fuses: strength (IEC/EN 61439- Rated peak withstand current ( I ): 105 kA...
  • Page 155 Technical data 155 Typical power cable sizes The tables below give the current carrying capacity ( I ) and typical size for copper Lmax and aluminum cables with PVC or XLPE insulation. A correction factor K = 0.70 is used. Time const.
  • Page 156 156 Technical data Terminal and cable entry data for the power cables The locations and sizes of the cable entries are shown in the dimension drawings delivered with the unit. Busbar terminal material: Tin-plated copper. Protection classes Degrees of protection IP22 (standard), IP42 (option +B054), IP54 (option +B055) (IEC/EN 60529) Enclosure types (UL50)
  • Page 157 Technical data 157 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 pack- in the protective pack- Installation site altitude 0…4000 m (0…13123 ft)* Output derated above 1000 m (3281 ft).
  • Page 158 158 Technical data Colors RAL Classic 7035, RAL Classic 9017. Materials Drive ￭ Refer to Recycling instructions and environmental information for ACS880 cabinet-installed drives and multidrive modules (3AXD50000153909 [English]). Packaging of drive ￭ • Plywood • Wood • PET (strapping) •...
  • Page 159 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...
  • Page 161 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/contact-centers.
  • Page 162 3AXD50000020546C © Copyright 2024 ABB. All rights reserved. Specifications subject to change without notice.

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