ABB ACS880-604LC Series Hardware Manual
3-phase dynamic brake units as modules
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Summary of Contents for ABB ACS880-604LC Series
- Page 1 — ABB INDUSTRIAL DRIVES ACS880-604LC 3-phase dynamic brake units as modules Hardware manual...
- Page 3 ACS880-604LC 3-phase dynamic brake units as modules Hardware manual Table of contents 4. Cabinet construction 6. Electrical installation 10. Start-up 3AXD50000581641 Rev C Original instructions EFFECTIVE: 2024-06-03...
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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 Liquid pipe connector installation instructions ..........Pipe connector types .
- Page 7 Table of contents 7 Connecting the brake resistor cables and thermal switch ......Connection diagram .
- Page 8 8 Table of contents Power connections ................Retightening the power connections .
- Page 9 Table of contents 9 Cooling system parts ................Coolant distribution manifold kits .
- Page 10 10 Table of contents Coolant connections ................Auxiliary power consumption .
- Page 11 Table of contents 11 16 Example circuit diagrams Contents of this chapter ............... . Component designations used in the diagrams .
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Page 13: Introduction To The Manual
Introduction to the manual 13 Introduction to the manual Contents of this chapter This chapter gives basic information on the manual. Applicability The manual is applicable to ACS880-604LC 3-phase brake chopper modules intended for user-defined cabinet installations. Safety instructions Obey all safety instructions of the drive. •... -
Page 14: Categorization By Frame Size And Option Code
[Q20]). This will help you to identify the components in the circuit diagrams of the drive. 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 modules Terms and abbreviations Term... - Page 15 Introduction to the manual 15 Term Description DC link DC circuit between rectifier and inverter Drive Frequency converter for controlling AC motors Electromagnetic compatibility Frame, frame size Physical size of the drive or power module Intermediate circuit DC circuit between rectifier and inverter Inverter unit Inverter module(s) under control of one control unit, and related components.
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Page 17: Operation Principle And Hardware Description
Operation principle and hardware description 17 Operation principle and hardware description Contents of this chapter This chapter describes the operation principle and construction of a liquid-cooled brake unit that consists of ACS880-604LC modules and related components. Product overview The ACS880-604LC is a liquid-cooled brake unit as modules. The brake unit as modules range contains components for building the brake unit(s) to be used in a common DC bus system drive. -
Page 18: Overview Diagram Of The Drive System
18 Operation principle and hardware description Overview diagram of the drive system The diagram that follows shows an example of a multidrive. The supply unit connects the drive to the AC supply network. It converts the AC voltage into DC. The DC voltage is distributed through the DC bus to all inverter units and optional brake units. -
Page 19: Cooling System
Operation principle and hardware description 19 Cooling system The brake module has an internal air-to-liquid heat exchanger. Another heat exchanger is mounted below the module. A cooling fan forces air through the external heat exchanger and the module, circulating the air inside the cubicle. Internal cooling circuit (page 133). -
Page 20: Frame R8I Hardware
20 Operation principle and hardware description Frame R8i hardware ￭ Module layout DC connection busbars, + (a) and - (b) Lifting eyes, front (a) and back (b) Coolant in (a) and out (b) connectors Handle Fiber optic connectors Quick connector (3-phase power connection) (the counterpart fastened to the cabinet behind the module) Terminal block X50 (auxiliary power input for internal boards) Terminal block X51 and X52 (Safe torque off in inverter modules only) -
Page 21: Connectors X50
Operation principle and hardware description 21 Connectors X50…X59 R8i modules contain a power supply (BDPS) that provides 24 V DC for the circuit boards of the module. The 24 V DC voltage provided by the BDPS is also available on X53, and can be used to power the control unit of a single R8i module. -
Page 22: Fibre Optic Connectors
22 Operation principle and hardware description AC IN Auxiliary voltage inputs for internal power supply (BDPS) 24V OUT 24 V DC output (for eg. control unit) STO IN STO connectors of the module. Must be connected to 24 V DC for the supply module to start. STO OUT Not in use. -
Page 23: Overview Circuit Diagram Of The Brake Unit
The following figure shows a simplified connection example of a brake unit. Item Explanation Available through Brake unit cabinet DC link DC- fuses ABB or third party DC+ fuses ABB or third party Brake resistor fuses ABB or third party Brake chopper module R8i Brake resistor cabinet... -
Page 24: Brake Unit Control Devices
24 Operation principle and hardware description Brake unit control devices Each brake chopper module employs a dedicated control unit that contains the control board with basic I/Os and slots for optional modules. A fiber optic link connects the control unit to the brake chopper module. Overview of the control connections of the UCU control unit ￭... -
Page 25: Overview Of The Control Connections Of The Bcu Control Unit
Operation principle and hardware description 25 Overview of the control connections of the BCU control unit ￭ Analog and digital I/O extension modules and Fiber optic links to power modules (inverter, fieldbus communication modules can be in- supply, brake or converter) serted into slots 1, 2 and 3. -
Page 26: Control By Pc Tools
26 Operation principle and hardware description Control by PC tools ￭ There is a USB connector on the front of the control panel that can be used to connect a PC to the drive. Fieldbus control ￭ The unit can be controlled through a fieldbus interface if it is equipped with an optional fieldbus adapter, and when the control program has been configured for fieldbus control by parameters. -
Page 27: Type Designation Label
Operation principle and hardware description 27 Type designation label Each brake module has a type designation label attached to it. The type designation stated on the label contains information on the specifications and configuration of the unit. The first digits express the basic construction of the unit, for example “ACS880-104LC-0850A-7”. -
Page 28: Type Designation Key
28 Operation principle and hardware description Type designation key Type designation describes the composition of the module in short. Note that in the type designation label of a brake module (ACS880-604LC), the type of the module is ACS880-104LC. The complete designation code is divided in subcodes: •... -
Page 29: Moving And Unpacking The Module
Moving and unpacking the module 29 Moving and unpacking the module Contents of this chapter This chapter gives basic information on unpacking and moving the module. Moving and unpacking the module WARNING! Obey the safety instructions given in ACS880 liquid-cooled multidrive cabinets and modules safety instructions (3AXD50000048633 [English]). -
Page 31: Cabinet Construction
National Fire Protection Association 70 (National Electric Code). Liquid pipe connector installation instructions These instructions are applicable to the liquid pipe connectors that are used in ABB drives. There are three types of pipe connectors: type A, type B and type C. Refer to the illustrations below. -
Page 32: Pipe Connector Types
32 Cabinet construction Pipe connector types ￭ Type A pipe connector Type B pipe connector Thread size: G 3/8" Thread size: G 1/4" or G 3/8" Type C pipe connector Thread size: G 3/4" WARNING! Do the electrical safety precautions steps before you do work on the drive. Refer to the drive safety instructions. - Page 33 Cabinet construction 33 Put the pipe connector base carefully onto the threads and start to turn it in by hand. Tighten the pipe connector base to 30 N·m (22.1 lbf·ft). Push the locking ring onto the pipe. Then push the pipe onto the pipe connector base and pull down the locking ring.
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Page 34: Type B Pipe Connector
34 Cabinet construction Type B pipe connector ￭ This section is applicable to type B pipe connectors. Reserve these materials and tools at hand: • Loctite® 2700 threadlocker. If Loctite 2700 is not available, use an equivalent threadlocker. • torque wrench •... -
Page 35: Type C Pipe Connector
Cabinet construction 35 Start to turn the locking ring by hand. Tighten the locking ring with adjustable pliers. Leave 2…3 mm thread visible. 2…3 mm (0.08 … 0.12″) WARNING! Do not tighten the locking ring of the pipe connector too much. It can cause damage to the pipe. -
Page 36: General
36 Cabinet construction Push the locking ring onto the pipe. Then push the pipe onto the pipe connector base and pull down the locking ring. Make sure that the pipe is perpendicular to the pipe connector base. Start to turn the locking ring by hand. Tighten the locking ring with a wrench. WARNING! Do not tighten the locking ring of the pipe connector too much. -
Page 37: Cabinet Configuration Overview
Cabinet construction 37 Cabinet configuration overview This figure shows the configuration of 1×R8i dynamic brake unit (DBU) installed in 600 mm wide Rittal VX25 or generic enclosure. With DC switch-disconnector Without DC switch-disconnector Installation examples This section contains cabinet construction example(s). Each example presents the cubicle with the power module(s) and related main circuit components. -
Page 38: R8I Module In A 600 Mm Wide Rittal Vx25 Enclosure
Internet. Go to https://sites-apps.abb.com/sites/lvacdrivesengineeringsupport/content. If needed, contact your local ABB representative. The example includes also cabinet assembly drawings that show each stage listed in the table. More detailed steps of each stage are described in the kit-specific assembly drawings. -
Page 39: Layout With Dc Switch-Disconnector
Cabinet construction 39 Layout with DC switch-disconnector Description DC switch-disconnector behind the fuses DC fuses Charging mechanics Brake module Heat exchanger (between module and cooling fan) Outgoing resistor connection busbars (behind cooling fan) Coolant inlet manifold with stop and drain valves Cooling fan Cable entries Charging resistors (obscured) -
Page 40: Pipe Routing Example
40 Cabinet construction Pipe routing example Description Coolant in Inlet manifold with stop and drain valves Heat exchanger Brake chopper module Outlet manifold with stop and drain valves Coolant out... -
Page 41: Installation Stages
Cabinet construction 41 Installation stages Installation stage Instruction code Kit code Kit ordering code Baying parts 3AXD50000336340 A-468-X-001- DC bus support kit 3AXD50000333639 3AXD50000333387 Side plate kit 3AXD50000327591 L-468-8-020-VX 3AXD50000360543 L-468-X-450- Main pipe support kit 3AXD50001155353 3AXD50001155179 PE busbar 3AXD50001155353 Module mounting mechanics 3AXD50000536733 L-6-8-315-VX... -
Page 42: Overview Of Kits
42 Cabinet construction Overview of kits... -
Page 43: Stage 1: Installation Of Common Parts
Cabinet construction 43 Stage 1: Installation of common parts... -
Page 44: Stage 2: Installation Of Side Plates, Module Mounting Mechanics And Quick Connector
44 Cabinet construction Stage 2: Installation of side plates, module mounting mechanics and quick connector... -
Page 45: Stage 3: Installation Of Output Terminals (For Cabling) And Cable Entries
Cabinet construction 45 Stage 3: Installation of output terminals (for cabling) and cable entries... -
Page 46: Stage 4A: Installation Of Dc Busbars (Without Dc Switch-Disconnector Or Charging)
46 Cabinet construction Stage 4A: Installation of DC busbars (without DC switch-disconnector or charging) -
Page 47: Stage 4B: Installation Of Dc Busbars (With Dc Switch-Disconnector And Charging)
Cabinet construction 47 Stage 4B: Installation of DC busbars (with DC switch-disconnector and charging) -
Page 48: Stage 5: Installation Of Incoming Resistor Connection Busbars
48 Cabinet construction Stage 5: Installation of incoming resistor connection busbars... -
Page 49: Stage 6: Installation Of Cooling Components
Cabinet construction 49 Stage 6: Installation of cooling components... -
Page 50: Stage 7: Installation Of Module
50 Cabinet construction Stage 7: Installation of module... -
Page 51: Stage 8: Installation Of Swing-Out Frame And Shrouds
Cabinet construction 51 Stage 8: Installation of swing-out frame and shrouds... -
Page 52: Generic Enclosures
52 Cabinet construction Generic enclosures ￭... -
Page 53: Guidelines For Planning The Electrical Installation
Limitation of liability The installation must always be designed and made according to applicable local laws and regulations. ABB does not assume any liability whatsoever for any installation which breaches the local laws and/or other regulations. Furthermore, if the recommendations given by ABB are not followed, the drive may experience problems that the warranty does not cover. -
Page 54: Selecting The Brake Resistor
54 Guidelines for planning the electrical installation Selecting the brake resistor WARNING! ABB is not responsible for user resistor selection or protection of the resistor. Select the resistor according to the resistor specification given in the technical data. In addition, consider the following: •... -
Page 55: Selecting The Installation Location For The Brake Resistors
Guidelines for planning the electrical installation 55 Selecting the installation location for the brake resistors Protect the open (IP00) brake resistors against contact. Install the brake resistor in a place where it cools effectively. Arrange the cooling of the resistor so that: •... -
Page 57: Electrical Installation
Safety and liability The installation must always be designed and made according to applicable local laws and regulations. ABB does not assume any liability whatsoever for any installation which breaches the local laws and/or other regulations. Furthermore, if the recommendations given by ABB are not followed, the drive system may experience problems that the warranty does not cover. - Page 58 58 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. Prepare for the work.
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Page 59: General Notes
Electrical installation 59 Important! Repeat the measurement with the DC voltage setting of the voltage tester. Measure between each phase and ground. There is a risk of dangerous DC voltage charging due to leakage capacitances of the motor circuit. This voltage can remain charged for a long time after the drive power-off. - Page 60 60 Electrical installation Stop the drive and do the steps in section Electrical safety precautions (page 57) before you start the work. Make sure that the resistor cable is connected to the resistor and disconnected from the drive output terminals. At the drive end, connect the R+ and R- conductors of the resistor cable together.
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Page 61: Connecting The Brake Resistor Cables And Thermal Switch
Electrical installation 61 Connecting the brake resistor cables and thermal switch Connection diagram ￭ Brake chopper cubicle DC switch-disconnector including charging circuit Control unit Brake chopper module Brake resistor assembly This diagram shows the brake resistor cable connections and an example connection of the thermal switches. -
Page 62: Connection Procedure Of The Components Inside The Brake Chopper Module Cubicle
62 Electrical installation The diagram also shows the internal connections of the brake chopper module cubicle to be done by the system integrator. Connection procedure of the components inside the brake chopper ￭ module cubicle WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. -
Page 63: Connection Procedure Of The Thermal Switch Cable
Open the door of the brake chopper module cubicle and remove any shrouding. Run the thermal switch cable inside the brake unit cubicle. ABB recommends that you ground the cable shield 360° at the cable entry. Run the cable to its connection point using existing trunking wherever possible. - Page 64 64 Electrical installation Run the control cables into the cubicle. If possible, arrange for a 360° grounding of the cable shield at the cable entry. If the outer surface of the shield is non-conductive, turn the shield inside out as shown below and wrap copper foil around the cable to keep the shielding continuous.
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Page 65: Installing Option Modules
Electrical installation 65 Connect the conductors to appropriate terminals. Install any shrouds removed earlier. Installing option modules 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 66 66 Electrical installation Connect the wiring to the module. Obey the instructions given in the documentation of the module. If you must remove the option module after it is installed into the drive, use a suitable tool (for example, small pliers) to carefully pull out the lock.
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Page 67: Connecting A Pc
Electrical installation 67 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 69: Control Unit (Ucu) 69
The data is stored on the microSDHC memory card inserted into the microSD card slot in the UMU-01 memory unit and can be analyzed by ABB service personnel. Layout... - Page 70 70 Control unit (UCU) 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. Data logger microSDHC memory card for inverter module communication is inside the memory unit.
- Page 71 Control unit (UCU) 71 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 72 72 Control unit (UCU) Description XFSO Not in use Humidity and temperature measurements XFSO...
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Page 73: Default I/O Diagram Of The Brake Control Unit
Control unit (UCU) 73 Default I/O diagram of the brake control unit The table below describes the use of the connections in the brake 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. - Page 74 74 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.
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Page 75: Additional Information On The Connections
Control unit (UCU) 75 Terminal Description Analog outputs Zero (no signal indicated) 0…20 mA, R < 500 ohm (not in use by default) AGND 0…20 mA, R Zero (not signal indicated) < 500 ohm (not in use by default) AGND XPOW External power input +24VI... -
Page 76: Digital Interlock (Diil)
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 memory unit and can be analyzed by ABB service personnel. -
Page 77: Connector Data
Control unit (UCU) 77 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 78 78 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)
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Page 79: Ground Isolation Diagram
Control unit (UCU) 79 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 81: Control Unit (Bcu) 81
BCU-12 has seven, and BCU-22 has 12 power module connections. The BCU control units have integrated branching unit functionality for collecting and storing real-time data from the converters to help fault tracing and analysis. The data is stored on a memory card which can be analyzed by ABB service personnel. -
Page 82: Layout
82 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 83 Control unit (BCU) 83 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...
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Page 84: Default I/O Diagram Of The Brake Control Unit
84 Control unit (BCU) Default I/O diagram of the brake control unit The table below describes the use of the connections in the brake unit. Terminal Description XD2D Drive-to-drive link Not supported. BGND Shield X485 RS485 connection Not in use by default. Can be used for CIO-01 module connection. BGND Shield XRO1, XRO2, XRO3... -
Page 85: Additional Information On The Connections
Control unit (BCU) 85 Terminal Description DIO1 Not in use by default DIO2 Not in use by default DIOGND Digital input/output ground DIOGND Digital input/output ground XD24 Auxiliary voltage output +24VD +24 V DC 200 mA DICOM Digital input ground +24VD +24 V DC 200 mA DIOGND... -
Page 86: Digital Interlock (Diil)
The BCU 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 87: Connector Data
Control unit (BCU) 87 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 88 88 Control unit (BCU) 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)
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Page 89: Bcu Ground Isolation Diagram
Control unit (BCU) 89 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 91: Installation Checklist
Installation checklist 91 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 92 92 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. The enclosures of the equipment in the cabinet have proper galvanic connection to the cabinet protective earth (ground) busbar;...
- Page 93 Installation checklist 93 Make sure that … The coolant connections between cubicles (if any) and to the cooling circuit are tight. If the drive is equipped with a cooling unit: Make sure that the mechanical and electrical installation of the cooling unit is completed. Refer to the cooling unit documentation.
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Page 95: Start-Up
The symbols in brackets, for example [Q1], refer to the item designations used in the circuit diagrams. ABB recommends that you connect a commissioning PC tool (DriveComposer) to the brake unit for the start up. By using the tool, you can set up parameters and monitor the drive during the test. -
Page 96: Start-Up Procedure
96 Start-up Start-up procedure Tasks Safety WARNING! Obey the safety instructions during the start-up procedure. See ACS880 liquid-cooled multidrives cabinets and modules safety instructions (3AXD50000048633 [English]). If you ignore the safety instructions, injury or death, or damage to the equipment can occur. If you are not a qualified electrical professional, do not do installation or maintenance work. - Page 97 Start-up 97 Tasks Setting up the parameters in the brake control program Check the brake control program parameter settings. If the brake unit has the UCU control unit (option +V998): ACS880 brake control program firmware manual (3AXD50001150723 [English]). If the brake unit has the BCU control unit: ACS880 brake control program firmware manual (3AXD50000020967 [English]).
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Page 99: Maintenance
Maintenance 99 Maintenance Contents of this chapter This chapter instructs how to maintain the brake module and how to interpret its fault conditions. The information is valid for ACS880-604LC modules and the cabinet construction examples presented in this manual. -
Page 100: Maintenance Intervals
100 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 101: Cooling System
• 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 102: Cooling Fans
Reset the running time signal after fan replacement. See also CIO-01 I/O module and distributed I/O bus user's manual (3AXD50000126880 [English]). Replacement fans are available from ABB. Do not use other than ABB-specified spare parts. Fan replacement ￭ WARNING! Obey the safety instructions of the drive. -
Page 103: Brake Module
The module is heavy. Reserve two persons, hoist and a suitable platform for the replacement procedure. Keep the module fastened to the hoist to prevent the module from falling. For information on a lifting device available from ABB, refer to... - Page 104 104 Maintenance Remove the L-shaped DC busbars at the top of the module. Make note of the orientation of the screws as well as the order of the washers. Close the inlet valve (a) and outlet valve (located on the right-hand side of the cubicle).
- Page 105 Maintenance 105 After the module has drained, disconnect the piping from the module. Remove the module retaining screws at the top and the bottom of the module.
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Page 106: Installing The Module
106 Maintenance Pull the module carefully out onto a suitable 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 [English]). -
Page 107: Control Unit
Maintenance 107 Fill up the cooling system. For instructions, see section Filling up and bleeding the internal cooling circuit. Close the swing-out frame (if present). Install all shrouds removed earlier. Control unit UCU control unit ￭ Replacing the memory unit of the UCU control unit If you replace the control unit, move the memory unit from the old control unit to the new control unit to keep the existing parameter settings. -
Page 108: Replacing The Ucu Control Unit Battery
108 Maintenance Replacing the UCU control unit battery 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. Replace the real-time clock battery if the BAT LED is off when the control unit is powered. -
Page 109: Replacing The Bcu Control Unit Battery
Maintenance 109 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 57) before you start the work. Make sure that the control unit is not powered. Remove the fastening screw and pull the memory unit out. -
Page 110: Capacitors
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 111: Led Indications
Maintenance 111 LED indications Warnings and faults reported by the control program are displayed on the control panel or in the Drive composer PC tool. For further information, see the firmware manual of the inverter control program. Control panel and panel platform/holder LEDs ￭... - Page 112 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.
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Page 113: Ordering Information
Note: • This chapter only lists the installation accessories available from ABB. All other parts must be sourced from a third party (such as Rittal) by the system integrator. For a listing, refer to the kit-specific installation instructions available at https://sites-apps.abb.com/sites/lvacdrivesengineeringsupport/content. - Page 114 114 Ordering information • A = air-cooled (some of these kits are also used with liquid-cooled drives) • L = liquid-cooled • w = cabinet width • 4 = 400 mm • 6 = 600 mm • 8 = 800 mm •...
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Page 115: Brake Chopper Modules
Ordering information 115 Brake chopper modules The frame size of the brake chopper modules is R8i. The delivery of a brake chopper module includes these items: Brake units consisting of frame R8i brake chopper modules are to be ordered as separate modules. -
Page 116: Control Panel
116 Ordering information Control panel The control panel is not included with the module but must be ordered separately. One control panel is required for the commissioning of an ACS880 drive system, even if the Drive Composer PC tool is used. The control panel can be flush mounted on the cabinet door with the help of a door mounting kit. -
Page 117: Control Electronics
You must connect the control unit to each brake chopper module with a pair of fiber optic cables. You can order them from ABB. You can supply 24 V DC for the control unit from the brake module. Alternatively, you can take the power supply from another suitable power source. -
Page 118: Control Unit (Bcu)
Connect the control unit to the brake chopper module with a pair of fiber optic cables (available from ABB). You can supply 24 V DC for the control unit from the brake module. Alternatively, you can take the power supply from another suitable power source. -
Page 119: Fiber Optic Cables
Ordering information 119 Fiber optic cables ￭ The following kits, each contain a pair of plastic fibre optic cables. They are needed in communication between the control unit and the power (inverter/supply/brake/converter) module. Length Kit type designation Ordering code 2 m (6.6 ft) NLWC-02 58988821 3 m (9.8 ft) -
Page 120: Module Top/Bottom Guides
120 Ordering information Module top/bottom guides ￭ This kit contains the frames that support the module at the top and the bottom. Used with… Ordering code Kit code Illustration 600 mm 3AXD50000536634 L-6-8-315-VX VX25 enclosure Instruction code: 3AXD50000536733 Swing-out frame ￭... -
Page 121: Shrouds
Ordering information 121 Shrouds ￭ This kit contains the shrouds, as well as the necessary brackets and screws, to cover the top and bottom parts of the cubicle. Frame size Ordering code Kit code Illustration 600 mm 3AXD50000361267 L-6-8-023-VX VX25 enclosure Instruction code: 3AXD50000353521... -
Page 122: Lifting Device
122 Ordering information Lifting device ￭ Use the lifting device when replacing a module in the Rittal VX25 enclosure. Frame Enclosure Ordering code Illustration R7i, R8i Rittal VX25 3AXD50000439997 Instruction code: 3AXD50000210268, 3AXD50000439409 DC-side components Frame R8i modules are connected to the DC bus through fuses. A DC switch-disconnector can be installed if quick isolation of the module from the DC bus is required. -
Page 123: Dc Connection Flanges And Busbars
Ordering information 123 DC connection flanges and busbars ￭ These DC busbars provide connection from the common DC bus to the module DC input. Used with… Ordering code Kit code Illustration 600 mm 3AXD50000545858 L-6-8-266-VX VX25 enclosure Instruction code: 3AXD50000562671 3AXD50000545810 L-6-8-262-VX Instruction code:... - Page 124 124 Ordering information Used with… Ordering code Kit code Illustration 3AXD50000545834 L-6-8-264-VX Instruction code: 3AXD50000543205 600 mm VX25 enclosure with switch-disconnector 3AXD50000360567 L-46-8-207-VX Instruction code: 3AXD50000343614 Incoming resistor con- 3AXD50000545841 L-6-8-265-VX nection busbars kit Instruction code: 3AXD50000545087...
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Page 125: Dc Fuses
Ordering information 125 DC fuses ￭ DC fuses protect the module and drive DC bus against short circuits. DC fuses (IEC) Fuse Unit type ACS880- Ordering code (per (total) Type Data Size 604LC-... module) 0870-7 63919462 170M6500 1250 A, 1250 V 3 (BKN/90) 1300-7 2×2... -
Page 126: Dc Charging Kits (For Units With Dc Switch-Disconnector)
126 Ordering information DC charging kits (for units with DC switch-disconnector) ￭ Used with… Ordering code Instruction code Frame R8i with DC switch-disconnector Frame 2×R8i with DC switch-disconnector 3AXD50000226801 (IEC) 3AXD50000450978 3AXD50000227013 (UL) Frame 3×R8i with DC switch-disconnector Frame 4×R8i with DC switch-disconnector The kit contains the following components: •... -
Page 127: Outgoing Brake Resistor Connection Busbars
Ordering information 127 Used with Ordering code Kit code Illustration 1 per All enclosure types mod- 3AUA0000119227 A-468-8-100 Instruction code: 3AUA0000118667 Outgoing brake resistor connection busbars ￭ This kit contains busbars that attach to the quick connector, and the terminals for the brake resistor cables. -
Page 128: Cable Entry Kit
128 Ordering information Note: All fuses listed are UL Recognized. Cable entry kit ￭ Cable entry kit, to be installed on the bottom plate of the enclosure, contains four 60 mm diameter inlets for cables with grommets, wire meshing for 360° grounding, and a strain relief bracket. - Page 129 Ordering information 129 Inlet and outlet valves Drain valves Nipples for connecting the valves to manifolds Connectors for PA piping Plugs for unused piping connectors Chokes for flow limitation – not used with the ACS880-604LC. You must order the following parts separately as they are not included in the manifold kits: •...
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Page 130: Piping
130 Ordering information Piping ￭ PA (polyamide) pipe is available in various diameters on reels. Refer to the figure for application. Item Data Ordering code PA12P40, 22/18 mm, 50 m 3AXD50000441419 PA12P40, 16/13 mm, 50 m 3AXD50000047488 PA12P40, 6/4 mm, 100 m 3AXD50001075316 PA11P40, 8/6 mm, 50 m 3AXD50000419302... -
Page 131: Main Pipe Support Kit
Ordering information 131 Main pipe support kit ￭ Used with … Ordering code Kit code Illustration Rittal VX25 en- L-468-X-450- 3AXD50001155179 closure Instruction code: 3AXD50001155353 Cooling fan ￭ The fan blows air through the heat exchanger, circulating the air inside the cabinet. The kit contains the fan installed into its cowling which mounts to the module bottom guide. -
Page 133: 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 134 134 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...
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Page 135: Connection To A Cooling Unit
Internal cooling circuit 135 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 tank to damp pressure rise due to volume changes when the temperature varies. -
Page 136: Filling Up And Bleeding The Internal Cooling Circuit
136 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 137: Draining The Internal Cooling Circuit
Internal cooling circuit 137 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 138: 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. 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 139 Internal cooling circuit 139 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).
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Page 140: Pressure Limits
140 Internal cooling circuit Pressure limits ￭ Note: The pressure limits for ACS880-1007 cooling units manufactured before week 24 of 2020 are given in ACS880-1007LC user's manual, revision C. 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. -
Page 141: Technical Data
Technical data 141 Technical data Contents of this chapter This chapter contains the technical specifications of the brake modules and related components. Ratings Ratings with R Brake resistor values No overload use Cyclic load (1 min / 5 min) cont- ACS880- Frame 604LC-…... -
Page 142: Definitions
142 Technical data Ratings with R Resistor values No overload use Cyclic load (1 min / 5 min) cont- ACS880- Frame 604LC-… size A DC A DC A DC A DC A DC (kVA) = 690 V 0870-7 1300-7 1171 1300 1249 1390... -
Page 143: Derating
Technical data 143 Example: Brake unit with two parallel connected modules Derating Surrounding air temperature derating ￭ In the temperature range +45…55 °C (+113…131 °F), the rated output current is derated by 0.5 percentage points for every added 1 °C (1.8 °F). The output current can be calculated by multiplying the current given in the rating table by the derating factor (k) : 1.00... -
Page 144: Altitude Derating
3900-7 0850A-7 27000 5200-7 0850A-7 36000 *Measured in a typical ABB (ACS880-607LC) cabinet installation. Fuses DC fuses (page 125) Brake resistor fuses (page 127). Dimensions and weights The weights of the modules are shown below. For the dimensions, see chapter Dimension drawings. -
Page 145: Free Space Requirements
Technical data 145 Free space requirements • Left and right sides, front and back: None • Below: Space needed by heat exchanger and cooling fan. • Above: The cooling air flow through the module should not be restricted. Installation orientations The modules must be installed upright or on left-hand side (viewed from the front). -
Page 146: Typical Power Cable Sizes
146 Technical data 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 147: Input Power (Dc) Connection
Technical data 147 Input power (DC) connection Voltage ( U ACS880-104LC-xxxx-7 modules: 709…976 V DC. This is indicated in the type designation label as typical input voltage levels 742 / 849 / 976 (849 UL, CSA) V DC. Input terminals M12, maximum intrusion into module 20 mm (0.8”). -
Page 148: Cooling Fans
Altitude above sea level 0 … 2000 m (0 … 6561.7 ft) no derat- ing. For altitudes over 2000 m (6561.7 ft), contact ABB. Air temperature 0 … +55 °C -40 … +70 °C -40 … +70 °C (+32 … +131 °F), no con- (-40 …... -
Page 149: Materials
Technical data 149 Operation installed for Storage in protective Transportation in pro- stationary use package tective package Contamination IEC/EN 60721-3-3:2002: IEC 60721-3-1:1997 IEC 60721-3-2:1997 Classification of environ- mental conditions - Part 3-3: Classification of groups of environmental parameters and their severities - Stationary use of weather protected locations... -
Page 150: Disposal
Substances of Concern In articles as such or in complex objects (Products) established under the Waste Framework Directive (2008/98/EC). For further information, contact your local ABB distributor or consult European Chemicals Agency's SCIP database to find out which SVHCs are used in the drive, and to find out where those components are located. -
Page 151: Tightening Torques
Technical data 151 Tightening torques For Rittal components, use the torques given in the Rittal assembly documentation. 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... -
Page 152: Cyber Security Disclaimer
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 153: Dimension Drawings
Dimension drawings 153 Dimension drawings Contents of this chapter This chapter contains dimension drawings of the brake chopper module and related components. Dimensional drawings of most installation accessories are available from ABB on request. -
Page 154: Brake Chopper Module
154 Dimension drawings Brake chopper module Dimensions in mm 1 mm = 0.0394 in... -
Page 155: Quick Connector
Dimension drawings 155 Quick connector ￭ Dimensions in mm 1 mm = 0.0394 in... -
Page 156: Control Electronics
156 Dimension drawings Control electronics UCU control unit ￭... -
Page 157: Bcu Control Unit
Dimension drawings 157 BCU control unit ￭... -
Page 158: Dpmp-01 Control Panel Mounting Platform
ACX-AP-x_dimensions control panel with door mount kit.pdf Dimension drawings 155 158 Dimension drawings ACX-AP-x control panel with door mounting kit DPMP-01 control panel mounting platform ￭ 81.0 [3.19] 86.5 [3.41] 123.1 [4.85] 125.0 [4.92]... -
Page 159: Dpmp-02 Control Panel Mounting Platform
Dimension drawings 159 DPMP-02 control panel mounting platform ￭... -
Page 160: Dc Fuse Blocks (Bussmann)
160 Dimension drawings DC fuse blocks (Bussmann) Size 3 ￭ Size mm (inch) mm (inch) mm (inch) mm (inch) mm (inch) mm (inch) 3 (BKN/80) 81 (3.19) 83 (3.27) 92 (3.62) 76 (2.99) 10 (0.39) 30 (1.18) 3 (BKN/90) 81 (3.19) 91 (3.58) 92 (3.62) 76 (2.99) -
Page 161: Switchgear And Charging Components
Dimension drawings 161 Switchgear and charging components DC switch-disconnector ￭ OT1200U11, OT1600E11 OT1000-1250E_ OT1600E_ 4,21 OT1000-1250X_ OT1600X_ 4,80 3,23 OT800U_ 13,5 OT1200U_ 0,53 1,97 9,13 5/16 3,27 4,57 4,80 14,65 223,2 12,05 8,11 8,79 5,31 0,43 1,57 0,24 22,5 0,89 6,93 7,44 0,79... -
Page 162: Charging Switch
162 Dimension drawings Charging switch ￭ OS100GJ04FP 138...205 (OXP 6x161) 53,3 33,4 5.35...8.07 1.77 2.10 1.31 20 17,5 0.69 3.19 0.79 0.33 2.72 0.10 95,5 3.76 0.43 1.81 2.36 0.24 125,5 8.66 4.94 1.42 138,5 6.77 5.45 2.56 1.50 min 14 0.55 1.81 1.38... -
Page 163: Os160Gd04F
Dimension drawings 163 OS160GD04F 138...205 (OXP 6x161) 33.4 53.3 95.5 8.5 7.2 17.5 114.5 Back connection types: Ø9 >14 17.5 Switch handles ￭ OHB65J6 L = 65 mm B = 6 × 6 mm... -
Page 164: Ohb150J12P
164 Dimension drawings OHB150J12P Ø 5 Ø 31 ø 69,4 45° L = 300 mm Shaft: 12 × 12 mm Auxiliary contacts ￭ OA1G10 OA3G01... -
Page 165: Charging Resistor
Dimension drawings 165 Charging resistor ￭ f×i D MAX f×i Dimensions in mm 1 mm = 0.0394 in... -
Page 166: Bsfc-12C Charging Controller
STAT 1 24V 2 AUX2 3 GND 4 GND STAT TO BE US ED WITH ABB DRIV ES ONLY. MAXIMUM RA TE D SYS TE M VOL TA GE INV1 UL: 600 V AC IEC: 690 V AC STAT INV2... -
Page 167: Cio-01 I/O Module
Dimension drawings 167 CIO-01 I/O module Dimensions in mm 1 mm = 0.0394 in... -
Page 169: Example Circuit Diagrams
Example circuit diagrams 169 Example circuit diagrams Contents of this chapter This chapter contains connection diagram examples for brake units. Note: The Safe torque off (STO) function is not in use, and has been bridged at the factory. Note: These diagrams do not necessarily match the installation-specific circuit diagrams of a tailor-made cabinet-installed unit. -
Page 170: Frame 2×R8I - Main Circuit (Sheet 001A)
170 Example circuit diagrams Frame 2×R8i - Main circuit (sheet 001a) -
Page 171: Frame 2×R8I - Main Circuit (Sheet 001B)
Example circuit diagrams 171 Frame 2×R8i - Main circuit (sheet 001b) -
Page 172: Frame 2×R8I - Charging Circuit (Sheet 002A)
172 Example circuit diagrams Frame 2×R8i - Charging circuit (sheet 002a) -
Page 173: Frame 2×R8I - Charging Circuit (Sheet 002B)
Example circuit diagrams 173 Frame 2×R8i - Charging circuit (sheet 002b) -
Page 174: Frame 2×R8I - Module Control Circuit (Sheet 005A)
174 Example circuit diagrams Frame 2×R8i - Module control circuit (sheet 005a) -
Page 175: Frame 2×R8I - Auxiliary Voltage Supply (Sheet 020A)
Example circuit diagrams 175 Frame 2×R8i - Auxiliary voltage supply (sheet 020a) -
Page 176: Frame 2×R8I - Auxiliary Voltage Supply (Sheet 020B)
176 Example circuit diagrams Frame 2×R8i - Auxiliary voltage supply (sheet 020b) -
Page 177: Frame 2×R8I - 230/115 V Distribution (Sheet 021A)
Example circuit diagrams 177 Frame 2×R8i - 230/115 V distribution (sheet 021a) -
Page 178: Frame 2×R8I - (230/115 V Distribution (Sheet 021B)
178 Example circuit diagrams Frame 2×R8i - (230/115 V distribution (sheet 021b) -
Page 179: Frame 2×R8I - 24 V Distribution (Sheet 022A)
Example circuit diagrams 179 Frame 2×R8i - 24 V distribution (sheet 022a) -
Page 180: Frame 2×R8I - 24 V Distribution (Sheet 022B)
180 Example circuit diagrams Frame 2×R8i - 24 V distribution (sheet 022b) -
Page 181: Frame 2×R8I - Fan Control (Sheet 026A)
Example circuit diagrams 181 Frame 2×R8i - Fan control (sheet 026a) -
Page 182: Frame 2×R8I - Control Unit 1 / Ro (Sheet 040A)
182 Example circuit diagrams Frame 2×R8i - Control unit 1 / RO (sheet 040a) -
Page 183: Frame 2×R8I - Control Unit 1 / Di (Sheet 040B)
Example circuit diagrams 183 Frame 2×R8i - Control unit 1 / DI (sheet 040b) -
Page 184: Frame 2×R8I - Control Unit 1 / Ai, Ao, Dio (Sheet 040C)
184 Example circuit diagrams Frame 2×R8i - Control unit 1 / AI, AO, DIO (sheet 040c) -
Page 185: Frame 2×R8I - Control Unit 1 (Sheet 040D)
Example circuit diagrams 185 Frame 2×R8i - Control unit 1 (sheet 040d) -
Page 186: Frame 2×R8I - Control Panel (Sheet 041A)
186 Example circuit diagrams Frame 2×R8i - Control panel (sheet 041a) -
Page 187: Frame 2×R8I - Control Unit 2 / Ro (Sheet 042A)
Example circuit diagrams 187 Frame 2×R8i - Control unit 2 / RO (sheet 042a) -
Page 188: Frame 2×R8I - Control Unit 2 / Di (Sheet 042B)
188 Example circuit diagrams Frame 2×R8i - Control unit 2 / DI (sheet 042b) -
Page 189: Frame 2×R8I - Control Unit 2 / Ai, Ao, Dio (Sheet 042C)
Example circuit diagrams 189 Frame 2×R8i - Control unit 2 / AI, AO, DIO (sheet 042c) -
Page 190: Frame 2×R8I - Control Unit 2 (Sheet 042D)
190 Example circuit diagrams Frame 2×R8i - Control unit 2 (sheet 042d) -
Page 191: Frame 2×R8I - Option Modules (Sheet 043A)
Example circuit diagrams 191 Frame 2×R8i - Option modules (sheet 043a) -
Page 193: 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/contact-centers. - Page 194 3AXD50000581641C © Copyright 2024 ABB. All rights reserved. Specifications subject to change without notice.
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