ACS880-307 +A018 supply units hardware manual · ACS880-207 IGBT supply units Hardware manual 3AUA0000130644 ... Categorization by frame size and option code ... Electrical power

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Hardware manualACS880-307 +A018 diode supply units

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You can find manuals and other product documents in PDF format on the Internet. See section Document library on the Internet on the inside of the back cover. For manuals not available in the Document library, contact your local ABB representative.

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Hardware manual

ACS880-307 +A018 diode supply units

3AXD50000011408 Rev A ENEFFECTIVE: 2014-01-02

2014 ABB Oy. All Rights Reserved.

Table of contents

3. Electrical installation

5. Start-up

5

Table of contents

1. Introduction to the manual

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Applicability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Target audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Contents of the manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Related documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Categorization by frame size and option code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Use of item designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Terms and abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2. Operation principle and hardware description

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Operation principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

12-pulse connection (option +A004) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Overview diagram of a drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Overview drawing of a drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Layout drawings of the cubicles in the supply unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Layout drawing of an auxiliary control cubicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18Layout drawings of incoming cubicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Layout drawing of a 400 mm incoming cubicle . . . . . . . . . . . . . . . . . . . . . . . . . . . 20Layout drawing of a 600 mm incoming cubicle . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Layout drawing of a supply module cubicle 2×D7T . . . . . . . . . . . . . . . . . . . . . . . . . . 22Layout drawing of a supply module cubicle 1×D8T . . . . . . . . . . . . . . . . . . . . . . . . . . 23Layout drawing of a supply module cubicle 2×D8T . . . . . . . . . . . . . . . . . . . . . . . . . . 24Layout drawing of a supply module cubicle 3×D8T . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Layout drawings of the supply modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26Layout drawing of D7T supply module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26Layout drawing of D8T supply module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Control of the supply unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28Overview of the supply unit control interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28Door switches and lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Main switch-disconnector (Q1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31Auxiliary voltage switch (Q21) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31earthing/grounding switch (Q9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31Operating switch (S21) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31Emergency stop button (S61) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32E-stop reset button (S62) and indication lamp (P62) . . . . . . . . . . . . . . . . . . . . . . . 32Other door controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32The ACS-AP-I control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33PC connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33Fieldbus control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Type designation labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34Type designation keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Type designation key of the supply unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35Type designation key of the diode supply module . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

6

3. Electrical installation

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39Basic electrical safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40Checking the insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Supply unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40Supply cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Connecting the input power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41Connection diagram – 6-pulse supply unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41Connection diagram – 12-pulse supply unit (option +A004) . . . . . . . . . . . . . . . . . . . 42Connection procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Connecting the external power supply cable for the auxiliary circuit (option +G307) . . 45Wiring the functional safety options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45Connecting the control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Control cable connection procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46Grounding the outer shields of the control cables at the cabinet lead-through . . 46Routing the control cables inside the cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Connecting a PC to the supply unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

4. Installation checklist

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

5. Start-up

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53Start-up procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Basic checks with no voltage connected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54Connecting voltage to input terminals and auxiliary circuit . . . . . . . . . . . . . . . . . . 54Setting the supply unit parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54Switching the supply unit on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55On-load checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Switching off the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56Disconnecting and temporary grounding the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Disconnecting – excluding the input power cable terminals . . . . . . . . . . . . . . . . . . . 56Disconnecting – including the input power cable terminals . . . . . . . . . . . . . . . . . . . . 56

6. Maintenance

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57Maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Cleaning the interior of the cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59Cleaning the air inlet meshes – IP22 and IP42 (option +B054) . . . . . . . . . . . . . . . . 59Replacing the inlet (door) filters – IP54 (option +B055) . . . . . . . . . . . . . . . . . . . . . . 60Replacing the outlet (roof) filters – IP54 (option +B055) . . . . . . . . . . . . . . . . . . . . . . 61

Power connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61Tightening the power connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62Checking and replacing the D7T module DC fuses . . . . . . . . . . . . . . . . . . . . . . . . . 62Checking and replacing the D8T module DC fuses . . . . . . . . . . . . . . . . . . . . . . . . . 63Checking and replacing AC fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

7

Replacing the fan in the auxiliary control cubicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65Replacing a fan in the incoming cubicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66Replacing the fan of the D7T supply module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67Replacing the fan of the D8T supply module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68Replacing the roof fan for IP54 cabinet (option +B055) . . . . . . . . . . . . . . . . . . . . . . . 69

Supply module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70Cleaning the heatsink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70Replacing the D7T supply module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70Replacing the D8T supply module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79Replacing the control panel battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Memory unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80Replacing the memory unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

LEDS and other status indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

7. Technical data

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85Ambient temperature derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85Altitude derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Supply module types and frame sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

Module DC fuses (internal) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87Module-specific AC fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88Fuses on CVAR board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

Dimensions and weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89Free space requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90Losses, air flow, efficiency and noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91Terminal and lead-through data for the input power cable . . . . . . . . . . . . . . . . . . . . . . . 92

400 mm incoming cubicle – main switch (+F253) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92600 mm incoming cubicle – main switch (+F253), 6-pulse . . . . . . . . . . . . . . . . . . . . . 93600 mm incoming cubicle – main switch (+F253), 12-pulse (+A004) . . . . . . . . . . . . . 94600 mm incoming cubicle – main breaker (+F255) . . . . . . . . . . . . . . . . . . . . . . . . . . 951000 mm incoming cubicle – main breaker (+F255) . . . . . . . . . . . . . . . . . . . . . . . . . 96

Electrical power network specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97Control unit connection data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97Protection classes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97Ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99Markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

Cable lugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100Mechanical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100Insulation supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

8

8. Control unit

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101Control unit layout and connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102Default I/O connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

Additional remarks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105Additional DIIL input (XDI:7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105Drive-to-drive link (X2D2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105Safety functions (X12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106SDHC memory card slot (X205) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

Control unit connector data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

Further information

Product and service inquiries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109Product training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109Providing feedback on ABB Drives manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109Document library on the Internet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

Introduction to the manual 9

1

Introduction to the manual

Contents of this chapterThis chapter contains information on the manual.

ApplicabilityThe manual is applicable to the cabinet-installed ACS880-307 +A018 diode supply units that form a part of an ACS880 multidrive system.

Safety instructionsFollow all safety instructions delivered with the drive.• Read the complete safety instructions before you install, commission, use or

service the drive. The complete safety instructions are given in ACS880 multidrive and multidrive modules safety instructions [3AUA0000102301 (English)].

• Read the software-function-specific warnings and notes before changing the default settings of the function. For each function, the warnings and notes are given in the section describing the related user-adjustable parameters.

• Read the task-specific safety instructions before starting the task. See the section describing the task.

Target audienceThis manual is intended for people who plan the use of, install, start-up, use or service multidrives. Read the manual before working on the drive. You are expected to know the fundamentals of electricity, wiring, electrical components and electrical schematic symbols.

10 Introduction to the manual

Contents of the manual

• Introduction to the manual

• Operation principle and hardware description

• Electrical installation

• Installation checklist

• Start-up

• Maintenance

• Technical data

• Control unit

Related documentsThe multidrive user documentation consists of technical drawings and a set of manuals. The technical drawings are tailor-made for each drive. The composition of the manual set depends on the composition of the drive, eg, which supply unit type, options and inverter control program has been ordered by the customer. The manuals have been listed on the back of the front cover.

Categorization by frame size and option codeThe information which concern only certain supply module frame size is marked with the frame size identifier. The frame size identifier is D7T or D8T. If there are several parallel modules, also the number of parallel modules is shown, for example 2×D8T. The Supply module types and frame sizes table on page 86 lists the supply unit types, module types and the frame sizes. The frame size is also shown on the type designation label of the supply unit.

The information which concern only certain option device or feature is marked with the option code in brackets, for example (option +F255). The option codes are indicated by a plus sign and the code. Option codes are listed in section Type designation key of the supply unit on page 35.

Use of item designationsSome device names include the item designations in brackets, for example (Q11) to make it possible to identify the components in the circuit diagrams of the drive.

Introduction to the manual 11

Terms and abbreviations

Term/Abbreviation Description

Auxiliary control cubicle The cubicle with auxiliary devices such as auxiliary voltage circuit breakers, control electronics, measurement boards, etc.

BCON Type of a control board

BCU Type of a control unit (contains BCON)

Control board Circuit board in which the control program runs.

Control unit Control board built in a rail-mountable housing

Cubicle One section of a cabinet-installed drive. A cubicle is typically behind a door of its own.

CVAR Varistor board

D7T Frame size of a diode supply module

D8T Frame size of a diode supply module

DC link DC circuit between Rectifier and Inverter

DI Digital input

Diode supply module Diode (or diode-thyristor) rectifier and related components enclosed inside a metal frame or enclosure. Intended for cabinet installation.

Diode supply unit Diode supply modules under control of one control board, and related components. See Diode supply module.

Drive Frequency converter for controlling AC motors

DSU Diode supply unit

FCAN-01 Optional CANopen adapter module

FCNA-01 Optional ControlNet™ adapter module

FDCO-01 Optional DDCS communication module

FDNA-01 Optional DeviceNet™ adapter module

FEA-03 Optional option module extension adapter

FECA-01 Optional EtherCAT adapter module

FENA-11 Optional high-performance Ethernet/IP™, Modbus/TCP and PROFINET adapter module

FENA-21 Optional high-performance Ethernet/IP™, Modbus/TCP and PROFINET adapter module

FEPL-01 FEPL-01 Ethernet POWERLINK adapter module

FIO-01 Optional digital I/O extension module

FIO-11 Optional analog I/O extension module

FLON-01 Optional LonWorks® adapter module

FPBA-01 Optional PROFIBUS DP adapter module

FSCA-01 Optional Modbus/RTU adapter module

Frame (size) Physical size of the diode supply module, for example, D7T.

Intermediate circuit DC link

12 Introduction to the manual

INU Inverter unit

Inverter Converts direct current and voltage to alternating current and voltage.

Inverter module Inverter bridge, related components and drive DC link capacitors enclosed inside a metal frame or enclosure. Intended for cabinet installation.

Inverter unit Inverter module(s) under control of one control board, and related components. One inverter unit typically controls one motor. See Inverter module.

I/O Input/Output

Multidrive Drive for controlling several motors which are typically coupled to the same machinery. Includes one supply unit, and one or several inverter units.

Parameter In the control program, user-adjustable operation instruction to the drive, or signal measured or calculated by the drive

Rectifier Converts alternating current and voltage to direct current and voltage. See Diode supply module.

Single drive Drive for controlling one motor

ZCON Type of a control board

ZCU Type of a control unit

Term/Abbreviation Description

Operation principle and hardware description 13

2

Operation principle and hardware description

Contents of this chapterThis chapter describes how the diode supply unit operates. It also contains description on the diode supply unit hardware. The information is valid for the ACS880-307 +A018 diode supply units.

Operation principleThe heart of the diode supply unit is a diode-thyristor bridge. It rectifies three-phase AC current to direct current for the intermediate DC link of the drive. The intermediate DC link supplies the inverters that run the motor. There can be one inverter unit only (single drives) or several inverter units (multidrives) connected to the intermediate circuit. The AC choke smoothens the current waveform in the power supply network and voltage in the DC link of the drive.

The main difference between the ordinary diode-diode bridge and the controlled diode-thyristor bridge is the controllability. You cannot control the operation of the diodes but you can control the thyristors. By controlling the thyristors, you can limit the AC current of the drive at the power up without additional charging circuit in the supply unit or in inverter units.

14 Operation principle and hardware description

There are two control modes for the upper leg thyristor firing: the charging mode and the normal mode:• The charging mode is in operation a short period after the power switch on: the supply

control program controls the thyristor firing angle gradually from a large value towards zero while the intermediate circuit capacitors located in the inverter module(s) get charged.

• In the normal mode, the thyristor firing angle is 0 degrees: The thyristors operate as diodes.

The following figure shows a simplified main circuit diagram of the rectifier bridge.

Description

1. Diodes. The diodes connect the AC terminals in cyclic sequence to the lower DC busbar (-).

2. Thyristors. The thyristors connect the AC line terminals in cyclic sequence to the upper DC busbar (+).

3. AC choke

4. DC fuses

+

-

Uc

+

-

Uc

2

1

3

4

4


12-pulse connection (option +A004)

The figure below illustrates the difference between 6-pulse and 12-pulse AC supply connections. 6-pulse connection is standard. If the drive has an even number of supply modules, you can order it as a 12-pulse version (option +A004).

12-pulse supply connection eliminates the fifth and seventh harmonics, which remarkably reduces the harmonic distortion of the line current and the conducted emissions.

12-pulse connection requires a three-winding transformer, or two separate transformers. There is a 30-degree phase shift between the two 6-pulse supply lines, which are connected to different supply modules through electrically separate switching equipment.

No. Description

1. Supply transformer

2. Switching equipment

3. Diode supply modules

1 2

3

1 2

3

6-pulse connection

12-pulse connection


Overview diagram of a driveThe following figure shows an example drive with a 6-pulse diode supply unit and three inverter units.

No. Description

1. Main switch-disconnector ((Q1), option +F253)

2. AC fuses

3. Main contactor (Q2)

4. Supply module (T01) (including choke, rectifier and DC fuses)

5. Inverter DC fuses (with or without DC switch)

6. Inverter module (T11)

7. Motor

8. Auxiliary voltage switch (Q21)

9. Auxiliary voltage transformer ((T21), option +G344)

M3~

M3~

~ 3

M3~

1

2

3

4

5

6

7

8

9

66

5 5


Overview drawing of a driveThis drawing shows an example of a drive with a diode supply unit and an inverter unit. Cables enter the cabinet through the bottom.

Description

A Auxiliary control cubicle (ACU). Contains control electronics and customer I/O connections. See page 18.

B Incoming cubicle (ICU). Contains the power input cable terminals and switchgear. See pages 20 and 21.

C Supply module cubicle. Contains two D8T supply modules. See pages 22, 23 24 and 25

D Inverter module cubicle. Contains two R8i inverter modules. As standard, the motor cables are run from each inverter module. See ACS88-107 inverter units Hardware manual [3AUA0000102519 (English)].

E Inverter control cubicle. Contains inverter control unit.

A B C D E

Supply unit Inverter unit


Layout drawings of the cubicles in the supply unitThis section contains layout drawings of cubicles that are included in a supply unit: auxiliary control cubicle, incoming cubicle and supply module cubicle. The components, layout and size of the cubicles vary depending on the supply unit size and options.

Layout drawing of an auxiliary control cubicle

This is an example of a 600 mm wide auxiliary control cubicle. The control unit of the supply unit, and auxiliary and control devices of the whole drive are located in the auxiliary cubicle, as well as the auxiliary voltage transformer(s) that supply the auxiliary circuits. The composition and size of the cubicle vary depending on the selected options.

Door closed Door open

5

32 4

14

7

8

9

10

11

12

13

16

15

17

18

19

61


No. Desig. Description

1 S21, etc. Control panel and operating switches. See section Door switches and lights on page 30.

2 F111 Fuses, constant speed module cooling fans (option +C188)

3 F101 Fuses, IP54 roof fans (option +B055)

4 F21 Fuses, auxiliary voltage transformer

5 A41 Control unit (BCU) for diode supply unit ACS880-307 +A018

6 T130 24 V DC power supply for cabinet lighting (option +G301)

7 Reserved space for customer-defined equipment

T21 At the backside of the assembly plate: Auxiliary voltage transformer (option +G344). Note: Connections are accessible from front. (Terminal block is at the lower part of cubicle.)

T101 At the backside of the assembly plate: Auxiliary voltage transformer, IP54 roof fans (option +B055). Note: Connections are accessible from front. (Terminal block is at the lower part of cubicle.)

8 A61 Main safety relay (optional)

A62 Safety relay (optional)

A63 Safety relay (optional)

9 A611 Safety relay (optional)

A612

A613

A614

A621

A622

A623

A624

10 K61…K66 Relays (optional)

11 X60 Terminal block, emergency stop circuit (optional)

12 T61 Power supply, safety circuit (optional)

T62 Power supply, safety circuit (optional)

F61 Protection switch, safety circuit (optional)

13 T21X1, T101X1

Terminal blocks, auxiliary voltage transformers T21 and T101 connections

14 T111 Auxiliary voltage transformer, constant speed module cooling fans (option +C188))

15 X22 Auxiliary circuit terminal block (on side plate)

16 T22, X21 24 V DC power supply (on side plate)

17 F20, F22 Circuit breakers, auxiliary voltage circuits (on side plate)

18 Q20 Connections and switches for external auxiliary voltage supplies (UPS), (option +G307, on side plate)Q95

Q130

19 X60, X61 Terminal blocks, emergency stop circuits (option, on side plate)


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 supply unit size and options.

Layout drawing of a 400 mm incoming cubicle

These layout drawings show a 400 mm wide incoming cubicle. This cubicle is in supply units with:• a 6-pulse connection, bottom cable entry, main switch-disconnector (option +F253)

• a 12-pulse connection (option +A004), bottom cable entry, main switch-disconnector (option +F253), and a earthing/grounding switch (option +F259). There are two similar cubicles, one for each input.

For the dimensions on the cable connections, see section Terminal and lead-through data for the input power cable on page 92.

1

2

5

6

7

8

9

12

11

10

4

3


No. Description

1. Main switch-disconnector handle

2. earthing/grounding switch handle (Q9, option +F259)

3. Auxiliary voltage switch handle

4. Selector switch for V meter (option +G334)

5. Grounding busbar (PE)

6. Input power cable terminals (1L1…2L3)

7. Main switch-disconnector (Q1)

8. Grounding/earthing switch (Q9, option +F259)

9. Main AC fuses (F1…3)

10. Main contactor (Q2, option +F250)


12. Cubicle cooling fan


Layout drawing of a 600 mm incoming cubicle

These layout drawings show a 600 mm wide incoming cubicle. This cubicle is in supply units with a 12-pulse configuration (option +A004), bottom cable entry, main switch-disconnector (option +F253) and no earthing/grounding switch (no option +F259).

Note: 12-pulse supply units (option +A004), with earthing/grounding switch (option +F259) have two separate incoming cubicles. See section Layout drawing of a 400 mm incoming cubicle on page 20.

1

4

5

6

7

10

9

8

3

2


No. Description

1. Main switch-disconnector handle

2. Auxiliary voltage switch handle

3. Selector switch for V meter (option +G334)

4. Grounding (PE) busbar

5. Input power cable termi-nals (1L1…2L3)

6. Main switch-disconnectors (Q1.1, Q1.2)

7. Main AC fuses (F1.1…F2.3)

8. Main contactors (Q2.1, Q2.2, option +F250)


10. Cubicle cooling fans

10

8

7


Layout drawing of a supply module cubicle 2×D7T

This is a layout drawing of the supply module cubicle with door open and shrouds removed.

No. Description

1. Supply module (See Layout drawing of D7T supply module on page 26).

2. AC busbars (on back)

3. DC busbars

1

2

3

1

3

2




No. Description


2. AC busbars

3. DC busbars

1

2

3




No. Description


2. AC busbars with module-specific AC fuses (no fuses in 12-pulse 2×D8T supply unit)

3. DC busbars

1

2

3

1

3




No. Description


2. AC busbars with module-specific AC fuses

3. DC busbars

1

2

3

1

3 3

2 2

1


Layout drawings of the supply modules

Layout drawing of D7T supply module

No. Description

1. AC input busbars

2. DC output busbars

3. Type designation label

4. Cover of the module’s DC fuses

5. Lifting eyes

6. Fan

7. Unpainted fastening hole. Grounding point (PE) between module frame and cabinet frame.

8. Terminal block X53. 24 V DC power for supply module control unit.

9. Terminal block X50. Auxiliary AC power supply for module. When constant-speed fan is in use: Also AC power supply for cooling fan.

10. Terminal block X54/X55. Power supply for fan.

11. Fibre optic connectors. Communication link to the control unit of the supply unit. When speed-controlled fan is in use: Communication link to fan control unit.

7

Front Back

4

11

8

10

1

6

9

2

3

5


Layout drawing of D8T supply module

No. Description

1. AC quick connector and AC input busbars

2. DC output busbars

3. Type designation label

4. Cover of the module’s DC fuses

5. Lifting eyes

6. Fan

7. Unpainted fastening hole. Grounding point (PE) between module frame and cabinet frame.

8. Terminal block X53. 24 V DC power for supply module control unit.

9. Terminal block X50. Auxiliary AC power supply for module. When constant-speed fan is in use: Also AC power supply for cooling fan.

10. Terminal block X54/X55. Power supply for fan.

11. Fibre optic connectors. Communication link to the control unit of the supply unit. When speed-controlled fan is in use: Communication link to fan control unit.

12. Wheels

4

Front

12

83

10

1

6

97

2

11

Back

5


Control of the supply unitA cabinet-installed supply unit is typically controlled using the local control devices installed on the cabinet door. No additional control connections are needed. However, it is possible to:• control the supply unit through the control panel and the fieldbus

• read the status information of the supply unit through the control panel, fieldbus and relay output

• halt the supply unit with an externally wired emergency stop button (if the unit is equipped with an emergency stop option).

The supply unit I/O control interface is in internal use. See section Default I/O connections on page 104.

Overview of the supply unit control interfaces

This figure shows the control interfaces of the BCU control unit of the supply unit.

1

2

3

4

56

7

FXX

FXX

FXXX

8

CLO

SE

9

10


No. Description No. Description

1.2.3.

Analog and digital I/O extension modules and fieldbus communication modules can be inserted into slots 1, 2 and 3.

7. Control panel.

4. Memory unit 8. Fiber optic links to supply modules

5. Slot 4 for RDCO-0x 9. Ethernet interface

6. Terminal blocks. See chapter Control unit on page 101.

10. Safety option interface (FSO-xx)


Door switches and lights

This figure shows an example of the door control devices. The devices and their exact locations varies depending on the options selected.

No. Desig. Description / See section …

1. Q1 Main switch-disconnector (Q1) on page 31.

2. Q21 Auxiliary voltage switch (Q21) on page 31.

3. S21 Operating switch (S21) on page 31.

4. A59 The ACS-AP-I control panel on page 33.

5. S61 Emergency stop button (S61) on page 32.

6. S62 E-stop reset button (S62) and indication lamp (P62) on page 32.

7. S23 Electrical disconnect push button. See section Other door controls on page 32.

8. S90 Ground/Earth fault indicator light (option +Q954)

9. S22 Tripping button for the breaker of the supply transformer. See section Other door controls on page 32.

Auxiliary control cubicle Incoming cubicle

1

2

3

4

8

10

6

5

9

7

11 12

12


Main switch-disconnector (Q1)

When the supply unit is equipped with a main contactor (option +F250), the unit is automatically also equipped with a main switch-disconnector ((Q1), option +F253). With this switch, you can isolate the main circuit of the drive from the power line. The switch has an operating handle on the cabinet door. For the 12-pulse supply unit there are two main switch-disconnector (Q1.1 and Q1.2).

WARNING! The switch does not isolate the input power terminals, AC voltage meters ((P5), option +G334) or the auxiliary circuit from the power line. To isolate auxiliary voltage, use the auxiliary voltage switch (Q21). To isolate the input power

terminals and AC voltage meters, open the main breaker of the supply transformer.

Note: The earthing/grounding switch ((Q9), option +F259) and the main switch-disconnector are electrically interlocked: The earthing/grounding switch can be closed only when the main switch-disconnector is open. The main switch-disconnector can be closed only when the earthing/grounding switch is open. That is, only one of the switches can be closed at a time. To close the switches, you must also have the auxiliary control voltage on.

Auxiliary voltage switch (Q21)

The supply unit is equipped with an auxiliary voltage switch (Q21) as standard. Using the switch, you can disconnect the auxiliary circuit from the power line. The switch has an operating handle on the cabinet door.

earthing/grounding switch (Q9)

The supply unit can be equipped with an earthing/grounding switch ((Q9), option +F259)). Using the switch, you can temporarily ground the main AC busbars of the supply unit during the maintenance work. The switch has an operating handle on the cabinet door.

WARNING! The earthing/grounding switch (Q9) does not ground the input power terminals or auxiliary circuits.

Note: The earthing/grounding switch and the main switch-disconnector ((Q1), option +F253) are electrically interlocked: The earthing/grounding switch can be closed only when the main switch-disconnector is open. The main switch-disconnector can be closed only when the earthing/grounding switch is open. That is, only one of the switches can be closed at a time. To close the switches, you must also have the auxiliary control voltage on.

Operating switch (S21)

The operating switch (S21) is a standard device.

10. P5.x Voltage meters (optional). One meter in 6-pulse supply unit and two in 12-pulse. Size of the meters vary. See section Other door controls on page 32.

11. S5.x Selector switches for voltage meters (optional). There is one switch in 6-pulse supply unit and two in 12-pulse. See section Other door controls on page 32.

12 P2.x AC phase current meters (optional). Number of meters depends on option selection. There are max. 6 meters in 12-pulse unit. See section Other door controls on page 32.

No. Desig. Description / See section …


By default, the operating switch controls the unit as follows:• ON position energizes digital input DI2 of the control unit: Control program receives

Run enable command and it closes main contactor (Q2) or main breaker. Supply module starts to rectify: it first charges DC link capacitors and then feeds inverter units and motors.

• OFF position de-energizes digital input DI2 of the control unit: Control program does not receive Run enable command and it opens the main contactor (Q2) or main breaker. Supply module stops rectifying.

Emergency stop button (S61)

The emergency stop button (S61) is an optional device (option +G331). Pressing the button activates an emergency stop function of the supply unit. The button locks to open position automatically. You must release the button before you can return to the normal operation. Before the restart, you also need to reset the emergency stop circuit with a separate reset button (S62). See section E-stop reset button (S62) and indication lamp (P62) below.

E-stop reset button (S62) and indication lamp (P62)

The emergency stop reset button (S62) is automatically installed on the door when the supply unit is equipped with an emergency stop function (eg, options +Q951,+Q952, etc). The button is illuminated, ie it includes an indication lamp (P62). You can reset the emergency stop circuit with the button.

Note: The functional safety options, for example the options +Q951, +Q952, etc. are described in separate option manuals. See section List of related manuals on page 2.

Other door controls

• A voltage meter is an optional device ((P5), option +G334). There is a meter on the door and a switch (S5) with which you can select which phase voltage value to display.

• An AC phase current meter is an optional device ((P2), option +G335). It is also possible to have three meters on the door - one for each phase currents.

• Tripping button for the supply breaker ((S22), option +Q959) is a push button on the cabinet door for the user-defined use, for example, for tripping the breaker of the supply transformer of the drive. The button is wired to a terminal block at the factory. The user connects the external circuit to be controlled on site.

• An electrical on/off push button ((S23), option +G332) on the cabinet door for tripping the supply unit. The button is connected in series with the operating switch. The button trips the Run enable signal and further the main contactor of the drive.


The ACS-AP-I control panel

With the control panel, you can:• start and stop the supply unit

• view and reset the fault and warning messages, and view the fault history

• view actual signals

• change parameter settings

• change between local and external control.

The Run enable command at digital input DI2 must be on (1) so that the DSU can be started and stopped with the control panel. That is the case when the operating switch (S21) is switched to the on (1) position.

To change between local and remote control mode, press the Loc/Rem key of the control panel. For the instructions on the use of the panel, see ACS-AP-x Assistant control panels user's manual [3AUA0000085685 (English)]. For the parameter settings, see ACS880 diode supply control program firmware manual [3AUA0000103295 (English)].

PC connection

There is a USB connector on the front of the panel that can be used to connect a PC to the drive. When a PC is connected to the control panel, the control panel keypad is disabled. See also section Connecting a PC to the supply unit on page 49.

Fieldbus control

You can control the supply unit through a fieldbus interface if the unit is equipped with an optional fieldbus adapter (for example, option +K454), and when you have configured the control program for the fieldbus control with the parameters. For information on the parameters, see ACS880 diode supply control program firmware manual [3AUA0000103295 (English)].

Note: To be able to switch the main contactor (Q2) (or breaker) and the supply unit on and off (Run enable signal) through the fieldbus, the Run enable command at digital input DI2 must be on (1). That is the case when the operating switch (S21) is switched to the on (1) position.


Type designation labelsExample labels are shown below.

The type designation label of the supply unit is attached to the cabinet on the inside of the door. The type designation label of the module is attached to the module.

No. Description

1. Supply module frame size

2. Degree of protection

3. Type designation, see section Type designation keys on page 35.

4. Ratings. See also section Ratings on page 83.

5. Valid markings

6. Serial number. The first digit of the serial number refers to the manufacturing plant. The next four digits refer to the unit’s manufacturing year and week, respectively. The remaining digits complete the serial number so that there are no two units with the same number.

1

2

3 4 5

6

1

2

3 4 5

6


Type designation keys

Type designation key of the supply unit

Type designation describes the composition of the unit in short. The type designation is visible on the label (sticker) which is attached to the cabinet. The complete designation code is divided in subcodes:• The first 1…18 digits form the basic code. It describes the basic construction of the

unit. The fields in the basic code are separated by hyphens.

• The option codes follow the basic code. Each option code starts with an identifying letter (common for the whole product series), followed by descriptive digits. The option codes are separated by plus signs.

This table describes the fields of basic code. Type ACS880-307-1820A-3 is used as an example.

This is a list of options codes. It includes also the standard features. The standard features are marked with *.

Code Description

ACS880 Product series identifier

307 Construction identifier. 307 = cabinet-installed diode unit supply unit

1820A Size. For all sizes, see section Ratings on page 83.

3 Nominal voltage. 3 = 400 V AC, 5 = 500 VAC, 7 = 690 VAC

Code Description

Standard Supply Frequency Supply Frequency 50 Hz *

+A013 Supply Frequency Supply Frequency 60 Hz

+A018 Diode-thyristor bridge *

Standard Control Voltage for Relays and Fans 230 VAC *

+G304 Control Voltage for Relays and Fans 115 VAC

+G307 Terminals for External Control Voltage Terminals for External Control Voltage (for UPS)

+G344 Auxiliary Transformer Auxiliary transformer (standard)

Standard Cabinet Construction Industrial Version IEC *

+C121 Cabinet Construction Marine Construction

+C180 Cabinet Construction Seismic design

Standard Standards EN/IEC *

+C134 Standards CSA-approved

+C129 Standards UL-approved

Standard Degree of Protection IP22, UL type 1 *

+B054 Degree of Protection IP42, UL type 1

+B055 Degree of Protection IP54, UL type 12

+C130 Channeled Air Channeled Air Outlet

+C128 Channeled Air Cooling air through bottom

Standard Control Cabling Control cable Bottom *

+H368 Control Cabling Control cable Top

Standard Power Cabling Entry Bottom Entry *

+H351 Power Cabling Entry Top Entry

Standard Motor Cabling Cable lead through (European) *

+H365 Motor Cabling Cable gland plates (Brass 6mm, undrilled)


+H364 Motor Cabling Cable gland plates (Aluminium 3mm, undrilled)

+H358 Motor Cabling Cable gland plates (Steel 3mm, undrilled)

+G314 DC Bus Material Aluminium (standard up to 3200A) *

+G315 DC Bus Material Tin plated copper (option up to 3200ADC, standard above)

*

Standard Supply Conductor Type Cable Supply Conductors *

+G317 Supply Conductor Type Busbar Supply Conductors

standard Wiring materials standard wire material *

+G330 Wiring materials Halogen free wiring

+E202 EMC 1st environment, restricted (max 1000A)

+E210 EMC 2nd Environment

+G301 Cabinet Options Cabinet Lighting

+G300 Cabinet Options Cabinet Heater

+C164 Cabinet options Plinth height 1 (100 mm)

+C176 Cabinet options Door hinges on left side

+C179 Cabinet options Plinth height 2 (200 mm)

+P913 Cabinet options Special color

+Z0010 ACU ACU width 400

+Z0015 ACU ACU width 600

+Z2005 Drive composer pro Drive composer pro (replaces DriveWindow and DriveDebug)

+K480 Ethernet switch Ethernet switch for PC tool and control network

+K483 Ethernet switch Ethernet switch with optical link for PC tool or control network

+Z2010 DDCS NDBU-95 (for max. 7 units) including fibre optic link. Star network

+Z2011 DDCS Fibre optic link (without NDBU-95) Ring network

+F250 Line Options Line Contactor, standard in small power, (always with disconnector F253)

*

+Standard Line Options Disconnector switch (door interlocked), standard in small power, (always with line contactor F250)

*

+F255 Breaker Option Circuit Breaker, standard in high power *

+F285 Earthing Switch Earthing terminals

+F259 Ear hi ng Switch Earthing Switch

+G331 Emergency Stop Emergency Stop Push button on the door (red)

+Q951 Emergency Stop Emergency stop, cat 0 with opening main contactor with safety relay

+Q952 Emergency Stop Emergency stop, cat 1 with opening main contactor with safety relay

+Q963 Emergency stop Emergency stop, stop cat 0, with STO with safety relay

+Q964 Emergency stop Emergency stop, cat 1 with STO with safety relay

+Q979 Emergency stop Emergency Stop, configurable stop cat 0 or 1 with FSO with STO

+Z150 Emergency Stop Acknowledgment Via control board

+Z160 Emergency Stop Acknowledgment Via AC800M

+Z2025 Emergency Stop Location Standard

+Z2026 Emergency Stop Location Master

Code Description


+Z2027 Emergency Stop Location Follower

+J410 Panels Drive control panel connection kit

+J412 Panels Common control panel for a line up

+K450 Panels Panel Bus, built with ethernet cable, needs FDPI option board in each unit, max. 32

+J400 CDP-panel Control Panel AP-I (max. 4 panels on the door)

+J401 LMD-panel Drive Monitoring Display

+G332 Electrical Disconnect Button Electrical disconnect push button on the door (black, opens main contactor / ACB)

+Q959 Electrical Disconnect Button Supply transformer breaker disconnect push button (red, wired to terminals) on the door

+Q953 Earth Fault Monitoring Earth Fault Monitoring, Earthed Mains TN

+Q954 Earth Fault Monitoring Earth Fault Monitoring, Unearthed Mains IT

+G336 Arc Monitoring, 1 loop Arc monitoring unit, 1 loop, Rea 101, including cable

+G337 Arc Monitoring Arc monitoring unit, extension for 2 loops, Rea 103, including cable

+G334 Meters V-meter with selector switch

+G335 Meters A-meter in one phase

+3G335 Meters A-meter in three phases

+G333 Meters kWh-meter

+J411 ON/OFF Control Type Remote Supply Control (from upper controller)

+G343 Special Options Corrosion Classification Coupon in ACU (Purafil 3AUA64044052)

+P913 Special Options Special color

+L501 I/O-Options 1 FIO-01, Digital I/O extension

+L500 I/O-Options 2 FIO-11, Analogue I/O extension

+L515 I/O-Options 4 FEA-03 option module extension adaptor

+L503 I/O-Options 4 FDCO-01, DDCS communication for ZCU-xx (2xTransmitter/Receiver)

+L509 DDCS RDCO-04 DDCS communication for BCU-xx (4xTransmitter/Receiver)

+L504 I/O-Options 5 Additional control unit Terminal Block

+K451 FieldBus1 FDNA-01 (DeviceNet)

+K452 FieldBus1 FLON-01 (LonWorks)

+K454 FieldBus1 FPBA-01 (Profibus)

+K458 FieldBus1 FSCA-01 (Modbus RTU)

+K462 FieldBus1 FCNA-01 (Control Net)

+K473 FieldBus1 FENA-01 (Ethernet (EtherNet/IP, Modbus/TCP, PROFINET)

+K475 FieldBus1 FENA-21 (High performance Ethernet (EtherNet/IP, Modbus/TCP, PROFINET) Daisy chain

+K457 FieldBus1 FCAN-01 (CANOpen)

+K470 FieldBus1 FEPL-01 (Ether POWERLINK)

+K469 FieldBus1 FECA-01 (EtherCAT)

Standard Speed Controlled fan speed controlled fan *

+C188 DOL cooling fan DOL cooling fan

Standard Documentation Complete documentation, user manuals in memory stick

*

Code Description


Type designation key of the diode supply module

Type designation describes the composition of the supply module in short. The type designation is visible on the label (sticker) which is attached to the module. The complete designation is divided in subcodes:• The first 1…18 digits form the basic code. It describes the basic construction of the

unit. The fields in the basic code are separated with hyphens.

• The option codes follow the basic code. Each option code starts with an identifying letter (common for the whole product series), followed by descriptive digits. The option codes are separated by plus signs.

This table describes the fields of the basic code. Type ACS880-304-1820A-3 is used as an example.

This is a list of options codes. It includes also the standard features. The standard features are marked with *.

+R716 Documentation Paper copy A4, Complete documentation and user manuals / Drive Unit

+R717 Documentation Paper copy, circuit diagrams and dimension drawings A3, other A4, complete documentation 2 and user manuals / Drive Unit

Standard Language English *

+R701 Language German manuals

+R702 Language Italian manuals

+R705 Language Swedish manuals

+R706 Language Finnish manuals

+R707 Language French manuals

+R708 Language Spanish manuals

+R711 Language Russian manuals

Code Description

ACS880 Product series identifier

304 Construction identifier. 304 = diode supply module

1820A Size. For all sizes, see section Supply module types and frame sizes on page 86.

3 Nominal voltage. 3 = 400 V AC, 5 = 500 VAC, 7 = 690 VAC

Option codes (plus codes)

+A018 Diode-thyristor bridge *

Code Description

Electrical installation 39

3

Electrical installation

Contents of this chapterThis chapter instructs how to check the insulation of the assembly and how to install the input power cables and control cables. The information is valid for ACS880-307 +A018 diode supply units.

For more information on cable selection, protections, etc, see Electrical planning instructions for ACS880 multidrive cabinets and modules [3AUA0000102324 (English)].

WARNING! Only qualified electricians are allowed to carry out the work described in this chapter. Read the safety instructions given in Safety instructions for ACS880 multidrive cabinets and modules [3AUA0000102301(English)] before you install, commission, use or service the drive.

40 Electrical installation

Basic electrical safety precautions

WARNING! Do the electrical safety precautions before starting any work on the installation. If you ignore the precautions, physical injury or death, or damage to the equipment can occur. Only a qualified electrician is allowed to work on the installation.

1. Clearly identify the work location.

2. Disconnect the circuit to be worked on completely. After disconnection, always wait for 5 minutes to let the capacitors to discharge. See section Disconnecting and temporary grounding the drive on page 56.

Note: Identify all possible power sources. Note that the input power busbars are under voltage even though the main switch-disconnector (Q1) is open.

Note: In some 12-pulse supply units, there are two separate main switch-disconnectors (Q1.1 and Q1.2), one for each input power connection point. You must open both disconnectors to disconnect the supply unit completely from the power line. See the circuit diagrams of the drive.

3. Secure against re-connection. Lock the disconnectors and attach warning notices.

4. Provide protection against adjacent live parts.

5. Verify by measuring that there is no voltage present.

6. Carry out grounding and short-circuiting when necessary. Refer to local regulations and EN 50110-1: 2004.

7. Ask for a work permit. Only the nominated person in control of the electrical installation work is allowed to issue the work permit.

Checking the insulation

Supply unit

Do not make any voltage tolerance or insulation resistance tests on the supply unit as this may cause damage. Every drive system has been insulation tested between the main circuit and the chassis at the factory. Also, there may be voltage-limiting circuits inside the drive system which cut down the testing voltage automatically.

Supply cable

Check the insulation of the supply (input) cable according to local regulations before you connect it to the drive.


Connecting the input power cables

Connection diagram – 6-pulse supply unit

This is a connection diagram for the 6-pulse supply unit. See also the delivery specific circuit diagrams.

1) Fuses or other protection means.

2) Ground the cable shield 360 degrees at the cable lead-through. See section Connection procedure on page 43.

Notes:

See section Terminal and lead-through data for the input power cable, page 92 for the dimensions and tightening torque guidelines.

Use a separate PE conductor in addition if the conductivity of the shields does not meet the requirement for the PE conductor. See Electrical planning instructions for ACS880 multidrive cabinets and modules [3AUA0000102324 (English)].

For the cable selection instructions, see Electrical planning instructions for ACS880 multidrive cabinets and modules [3AUA0000102324 (English)].

L1

L2

L3

PE2)

1)

ACS880-307


Connection diagram – 12-pulse supply unit (option +A004)

This is a connection diagram for the 12-pulse supply unit (option +A004). See also the delivery specific circuit diagrams.

1) Fuses or other protection means.

2) Ground the cable shield 360 degrees at the cable lead-through. See section Connection procedure on page 43.

Notes:

See section Terminal and lead-through data for the input power cable, page 92 for the dimensions and tightening torque guidelines.

Use a separate PE conductor in addition if the conductivity of the shields does not meet the requirement for the PE conductor. See Electrical planning instructions for ACS880 multidrive cabinets and modules [3AUA0000102324 (English)].

For the cable selection instructions, see Electrical planning instructions for ACS880 multidrive cabinets and modules [3AUA0000102324 (English)].

1L1

1L2

1L3

PE

1) ACS880-307 +A004

2L1

2L2

2L3

PE

2)


Connection procedure

The cable lead-through details, and cable connection details are shown in chapter Terminal and lead-through data for the input power cable, page 92.

WARNING! Only qualified electricians are allowed to do this work. Read the complete safety instructions of the drive. Ignoring the instructions can cause physical injury or death, or damage to the equipment.

1. Disconnect the drive from the AC power line and make sure it is safe to start the work. See section Basic electrical safety precautions on page 40.

2. Open the door of the incoming cubicle.

3. Remove the shrouding covering the input terminals.

4. Peel off 3 to 5 cm of the outer insulation of the cables above the lead-through plate for 360° high-frequency grounding.

5. Prepare the ends of the cables.

6. If fire insulation is used, make an opening in the mineral wool sheet according to the diameter of the cable.

7. For IP22, IP42 drives: Slide the cables through the lead-throughs with the conductive sleeves.

8. For IP54 drives: Remove the rubber grommets from the lead-through plate for the cables to be connected. Cut adequate holes into the rubber grommets. Slide the grommets onto the cables. Slide the cables through the lead-throughs with the conductive sleeves and attach the grommets to the holes.

9. Fasten the conductive sleeves to the cable shields with cable ties.

10. 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).

11. Tie up the unused conductive sleeves with cable ties.

12. Connect the twisted shields of the cables to the PE busbar of the cabinet. Tighten the screws to the torque given under Tightening torques (page 100).

13. Connect the phase conductors of the input cable to the L1, L2 and L3 terminals. Tighten the screws to the torque given under Tightening torques (page 100).

14. Reinstall the shrouding removed earlier.

15. Close the door.


PE5

PE

PE

8

11

9


Connecting the external power supply cable for the auxiliary circuit (option +G307)


For the connection diagram, see the delivery-specific circuit diagrams. For the auxiliary circuit current consumption, see the delivery-specific technical documentation.

Wiring the functional safety optionsThe wiring instructions for the functional safety options such as +Q951, +Q952, etc are in separate option manuals. See section List of related manuals on page 2.


Connecting the control cablesSee the circuit diagrams delivered with the drive for the actual wiring. Most of the supply unit I/O terminals are reserved for internal use. Do not change the connections done at the factory. See chapter Control unit (page 101) for the default I/O connections.

Control cable connection procedure



2. Run the control cables into the auxiliary control cubicle as described in section Grounding the outer shields of the control cables at the cabinet lead-through below.

3. Route the control cables as described in section Routing the control cables inside the cabinet (page 48).

4. Connect the control cables. See the circuit diagrams delivered with the drive.

Grounding the outer shields of the control cables at the cabinet lead-through

Ground the outer shields of all control cables 360 degrees at the EMI conductive cushions as follows:

1. Loosen the tightening screws of the EMI conductive cushions and pull the cushions apart.

2. Cut adequate holes to the rubber grommets in the lead-through plate and lead the cables through the grommets and the cushions into the cabinet.

3. Strip off the cable plastic sheath above the lead-through plate just enough to ensure proper connection of the bare shield and the EMI conductive cushions.

4. Tighten the two tightening screws (a) so that the EMI conductive cushions (b) press tightly round the bare shield.

5. Secure the cables mechanically at the lead-through strain relief.

6. Keep the shields continuous as close to the connection terminals as possible.


Note: If the outer surface of the shield is non-conductive:• Cut the shield at the midpoint of the bare part. Be careful not to cut the conductors or

the grounding wire (if present).

• Turn the shield inside out to expose its conductive surface.

• Cover the turned shield and the stripped cable with copper foil to keep the shielding continuous.

View from above

1 Tightening screw

2 EMI conductive cushion

3 Strain relief

4 Grommet

5 Lead-through plate

2

3

4

5

1 1

A Stripped cable

B Conductive surface of the shield exposed

C Stripped part covered with copper foil

1 Cable shield

2 Copper foil

3 Shielded twisted pair

4 Grounding wire

1

A B C

2 2

3

4


Note for top entry of cables: When each cable has its own rubber grommet, sufficient IP and EMC protection can be achieved. However, if very many control cables come to one cabinet, plan the installation beforehand as follows:

1. Make a list of the cables coming to the cabinet.

2. Sort the cables going to the left into one group and the cables going to the right into another group to avoid unnecessary crossing of cables inside the cabinet.

3. Sort the cables in each group according to size.

4. Group the cables for each grommet as follows ensuring that each cable has a proper contact to the cushions on both sides.

5. Arrange the bunches according to size from thickest to the thinnest between the EMI conductive cushions.

6. If more than one cable go through a grommet, seal the grommet by applying Loctite 5221 (catalogue number 25551) inside the grommet.

Routing the control cables inside the cabinet

Use the existing trunking in the cabinet wherever possible. Use sleeving if cables are laid against sharp edges.

Cable diameter in mm Max. number of cables per grommet

< 13 4

< 17 3

< 25 2

> 25 1


Connecting a PC to the supply unitConnect a PC with an USB data cable (USB Type A <-> USB Type Mini-B) as follows:

1. Lift the USB connector cover on the control panel from bottom upwards.

2. Insert the USB cable Mini-B plug in the control panel USB connector (a). -> The panel displays: USB connected (b).

3. Insert the USB cable A-plug in the USB connector of the PC.

?

StartStop Loc/Rem

USB connected?

StartStop Loc/Rem

2a

1

2b

3

1


Installation checklist 51

4

Installation checklist

Contents of this chapterThis chapter contains a list for checking the installation of the ACS880-307 +A018 diode supply unit.

ChecklistCheck the mechanical and electrical installation of the drive before start-up. Go through the checklist together with another person.

Disconnect the drive from the AC power line and make sure it is safe to start the work. See section Basic electrical safety precautions on page 40.

WARNING! Only qualified electricians are allowed to carry out the work described below. Read the complete safety instructions in Safety instructions for ACS880 multidrive cabinets and modules [3AUA0000102301(English)] before you install, commission, use or service the drive. Ignoring the instructions can cause physical injury or death, or damage to the equipment.

52 Installation checklist

Check that…

The ambient operating conditions meet the specifications given in chapter Technical data.

The cabinet is properly fastened to the floor. See section Free space requirements on page 90.

The cooling air flows freely.

There is sufficient free space around the unit. See Mechanical installation instructions for ACS880 multidrive cabinets [3AUA0000101764 (English)].

If the drive has been stored over one year: The electrolytic DC capacitors in the DC link of the drive have been reformed. See the separate reforming instructions (available in the Internet or from your local ABB representative).

There is an adequately sized protective earth (ground) conductor between the drive and the factory main PE, and the conductor has been connected to the appropriate terminal. Proper grounding has also been measured according to the regulations.

The supply voltage matches the nominal input voltage of the unit. Check the type designation label.

The input power cable has been connected to the appropriate terminals, the phase order is right, and the terminals have been tightened. (Pull the conductors to check.)

Appropriate AC fuses and main disconnector have been installed.

The control cables (if any) have been connected to the appropriate terminals, and the terminals have been tightened. (Pull the conductors to check.)

There are no tools, foreign objects or dust from drilling inside the cabinet.

All shrouds and covers are in place. Cabinet doors have been closed.

Start-up 53

5

Start-up

Contents of this chapterThis chapter instructs how to start-up the diode supply unit. The information is valid for ACS880-307 +A018 diode supply units. The symbols in brackets, for example (Q1), refer to the item designations used in the circuit diagrams. If a task is valid only for a certain option device or feature, the option code is given in brackets, for example, (option +F259).

These instructions do not cover all start-up tasks of all possible variants of the supply unit. Always refer to the delivery-specific circuit diagrams when proceeding with the start-up.

WARNING! Only qualified electricians are allowed to carry out the work described in this chapter. Read the complete safety instructions in Safety instructions for ACS880 multidrive cabinets and modules [3AUA0000102301 (English)]. Ignoring the instructions can cause physical injury or death, or damage to the equipment.

54 Start-up

Start-up procedure

Action

Basic checks with no voltage connected

Make sure that the disconnector of the supply transformer is locked to the off (0) position, that means no voltage is, or cannot be connected to drive inadvertently.

Make sure that the main switch-disconnector (Q1) is open.

Drive with the earthing/grounding switch ((Q9), option +F259): Make sure that the earthing/grounding switch is closed.

Note: You cannot close the earthing/grounding switch before the auxiliary circuits are energized and the main switch disconnector (Q1) is open.

Make sure that the installation has been checked. See chapter Installation checklist on page 51.

Check the settings of breakers/switches in the auxiliary circuits. See delivery-specific circuit diagrams.

If time relays, or relays with delayed make contact or break contact are used, for example, in emergency stop circuits, check the relay time settings. See delivery-specific circuit diagrams and safety function specific documentation (if applicable).

Make sure that the voltage settings of the auxiliary voltage transformers are according to the actual line voltage and desired output voltage. See the delivery-specific circuit diagrams.

Transformer T21 is selected by option +G344; T101 and T111 are present if required by the options specified by the customer.

Disconnect the unfinished or unchecked 230 VAC cables that lead from the terminal blocks to the outside of the equipment.

Check that both circuits of STO terminals on the control boards are closed as shown in Default I/O connections on page 104 (IN1 and IN2 must be connected to OUT). Otherwise the supply unit cannot start.

Connecting voltage to input terminals and auxiliary circuit

Make sure that it is safe to connect voltage:

• nobody is working on the unit or circuits that are wired from outside into the cabinets

• covers of the motor terminal boxes are on

• the main switch-disconnector (Q1) is open.

Drives with voltage meters ((P5), option +G334): Close the circuit breaker for the voltage meters (F5).

Close the circuit breakers supplying the auxiliary circuits (F22, etc.).

Drive with an external control voltage supply (option +G307): Close the circuit breaker of the external control voltage supply.

Close the cabinet doors.

Drive with the earthing/grounding switch ((Q9), option +F259): Open the earthing/grounding switch.

Close the main breaker of the supply transformer.

Close the auxiliary voltage switch (Q21).

Setting the supply unit parameters

Check the correct voltage range, parameter 95.01 Supply voltage.

Make sure that the supply unit is in the remote control mode to enable control of the supply unit with the operating switch (S21). Use Loc/Rem key of the control panel to change the mode.

Start-up 55

Switching the supply unit on

WARNING! If the drive is equipped with a brake unit (option +D150 or +D151), make sure there are inverters connected to the intermediate circuit before closing the main contactor. A rule of thumb: The sum capacitance of the inverters connected must be at least 50% of the

sum capacitance of all inverters.

If there is not enough capacitive load at start, the DC voltage may overshoot the overvoltage limit, causing immediate start of the brake unit and continuous supply for it by the supply unit. Constant braking will overload brake choppers and resistors and cause overheating.

Close the main switch-disconnector (Q1).

WARNING! Do not use excessive force. If the unit is equipped with a earthing/grounding switch (Q9), electromagnetic interlocking is used. You cannot close the main switch-disconnector (Q1) before its locking solenoid (K1) is energized, ie. before the

earthing/grounding switch is open and auxiliary circuit is energized.

Turn the operating switch (S21) to on (1) position to activate the Run enable signal and to switch the main contactor (Q2) on.

On-load checks

Check that the supply module cooling fan rotates freely in the right direction.

Validate the operation of safety functions (for example, emergency stop).

WARNING! The safety functions are not safe before they are validated according to the instructions.

Safety functions are optional. See the function-specific manual for the validation tasks.

Action

56 Start-up

Switching off the drive1. Stop the motors connected to inverter units. See the Inverter unit hardware and

firmware manuals.

2. Turn the operating switch (S21) to the off (0) position to deactivate the Run enable signal of the supply unit and to open the main contactor (Q2).

Disconnecting and temporary grounding the drive

Disconnecting – excluding the input power cable terminals

1. Switch off the drive. See section Switching off the drive above.

2. Open the main switch-disconnector (Q1).

3. Temporary ground the supply unit when necessary. Refer to local regulations and EN 50110-1: 2004.

Supply unit with the earthing/grounding switch ((Q9), option +F259:• Close the earthing/grounding switch ((Q9), option +F259).

WARNING! Do not use excessive force. There is electromagnetic interlocking in use. You cannot close the earthing/grounding switch (Q9) before the main switch-disconnector (Q1) is open.

Supply unit without the earthing/grounding switch (no option +F259):

Connect a temporary grounding set to the main AC busbars after the main switch-disconnector and to the grounding (PE) busbar of the drive.

WARNING! Despite of the temporary grounding of the AC busbars after the main switch-disconnector (Q1), the input power cable terminals are under voltage. Disconnect and ground them separately when necessary. Do not remove the

shroud in front of the busbars.

Disconnecting – including the input power cable terminals

1. Do the tasks listed in section Disconnecting and temporary grounding the drive on page 56.

2. Switch off and disconnect the breaker of the supply transformer.

3. Secure against reconnection: Lock the disconnectors and attach warning signs.

4. Open the door of the incoming cubicle and make sure by measuring that the input busbars are not under voltage.

5. If temporary grounding of the input power terminals is needed, connect a temporary grounding set to the input power terminals and to the grounding (PE) busbar of the drive. See the local regulations and EN 50110-1: 2004.

Maintenance 57

6

Maintenance

Contents of this chapterThis chapter instructs how to maintain the diode supply unit and how to interpret its fault indications. The information is valid for ACS880-307 +A018 diode supply units.

WARNING! Only qualified electricians are allowed to do the work described in this chapter. Read the complete safety instructions before you install, commission, use or service the drive. The complete safety

instructions are given in Safety instructions for ACS880 multidrive cabinets and modules [3AUA0000102301 (English)].

58 Maintenance

Maintenance intervalsThe recommended maintenance intervals and component replacements are based on specified operational and environmental conditions. Maintain the drive according to the recommended maintenance intervals.

Consult your local ABB Service representative for more details on the maintenance. On the Internet, go to: http://www.abb.com/drivesservices.

Component Years from start-up

1 2 3 4 5 6 7 8 9 10 11 12 …

Cooling

Internal cabinet cooling fans (if present)

(R) R(R)

(R) R(R)

Supply module cooling fans R R

Aging

Control panel battery, BCU control unit batteries

R

BCU control unit, BINT, BDPS, BGDR, BTDR and BFPS

boards

R

Flat ribbon cables R

Connections and environment

IP22 and IP42 air inlet (door) meshes

(I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I)

Tightness of terminals (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I)

Dustiness, corrosion and temperature

(I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I)

Supply module heat sink cleaning

(I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I)

I Visual inspection(I) Visual inspection if needed in demanding operation conditions: ambient temperature is constantly over

40 ˚C, especially dusty or humid environment, cyclic heavy load, or continuously high load.R Replacement of component in normal operation conditions: ambient temperature is below 40 °C

(104 °F), clean and non-humid environment, no cyclic heavy load or no continuously high load.(R) Replacement of component in demanding operation conditions: ambient temperature is constantly over

40 ˚C, especially dusty or humid environment, cyclic heavy load, or continuously high load.

Maintenance 59

Cabinet

Cleaning the interior of the cabinet


WARNING! Use a vacuum cleaner with an antistatic hose and nozzle, and wear a grounding wristband. Otherwise an electrostatic charge might build up and damage the circuit boards.


2. Clean the interior of the cabinet. Use a vacuum cleaner and a soft brush.

3. Clean the air inlets and outlets of the fans.

4. Clean the air inlet grating of the door.

5. Close the door.

Cleaning the air inlet meshes – IP22 and IP42 (option +B054)

WARNING! Use a vacuum cleaner with an antistatic hose and nozzle. Using a normal vacuum cleaner creates static discharges which can damage circuit boards.

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:

1. Recommendation: De-energize the fans by switching off the supply unit.

2. Remove the fasteners at the top of the grating.

3. Lift the grating and pull it away from the door.

4. Remove the mesh by turning the clips gently a little.

5. Vacuum clean the mesh.

6. Reinstall the mesh and grating in reverse order.

2 3 4 6

60 Maintenance

Replacing the inlet (door) filters – IP54 (option +B055)

See section Materials on page 98 for the correct filter types.

1. Recommendation: De-energize the fans by switching off the supply unit.

2. Remove the fasteners at the top of the grating.

3. Lift the grating and pull it away from the door.

4. Remove the air filter mat.

5. Place the new filter mat in the grating the metal wire side facing the door.

6. Reinstall the grating in reverse order.

2 3

3

4

5 6

Maintenance 61

Replacing the outlet (roof) filters – IP54 (option +B055)

WARNING! De-energize the fans by switching off the supply unit. Make sure that no restart is possible during the maintenance work. Rotating fan blades can cause serious hand injury.

1. Remove the front and back gratings of the fan cubicle by lifting them upwards

2. Remove the air filter mat.

3. Place the new filter mat in the grating.

4. Reinstall the grating in reverse order.

Power connections

Tightening the power connections



2. Check the tightness of the cable connections. Use the tightening torques given in chapter Tightening torques on page 100.

62 Maintenance

Fuses

Checking and replacing the D7T module DC fuses



2. Undo the screws of the cover panel of the module’s DC fuses (a) and lift and remove the panel.

3. Check the condition of the fuses and replace if necessary.

4. Attach the cover.

2a

2

Maintenance 63

Checking and replacing the D8T module DC fuses



2. Undo the screws of the cover panel of the module’s DC fuses (a) and lift and remove the panel.

3. Check the condition of the fuses and replace if necessary.

4. Attach the cover

2a

2

64 Maintenance

Checking and replacing AC fuses



2. Open the door of the supply module (or incoming) cubicle. (Depending on the delivery, there might be AC fuses in either or both cubicles).

3. Remove the shrouding (a) from in front of the fuses.

4. Slacken the nuts of the headless screws of the fuses so that you can slide out the fuse blocks. Make note of the order of the washers on the screws.

5. Remove the screws, nuts and washers from the old fuses and attach them to the new fuses. Make sure to keep the washers in the original order.

6. Insert the new fuses into their slots in the cubicle.Tighten the nuts to torque as follows:• Cooper-Bussmann fuses: 50 N•m (37 lbf·ft)

• Mersen (Ferraz-Shawmut): 46 N•m (34 lbf·ft)

• Other: Refer to the fuse manufacturer’s instructions.

7. Reinstall the shrouding removed earlier and close the cubicle door.

3a

3

Maintenance 65

FansThe lifespan of the cooling fan depends on the running time of the fan, ambient temperature and dust concentration.

Replacing the fan in the auxiliary control cubicle



2. Remove the shrouding from in front of the fan.

3. Unplug the power supply cable of the fan.

4. Remove the fastening screws of the fan.

5. Install the new fan in reverse order.

66 Maintenance

Replacing a fan in the incoming cubicle

One or two cooling fans are installed in the incoming cubicle.



2. Remove the shrouding in front of the fan (if any).

3. Disconnect the fan wiring (a).

4. Remove the fastening screws (a) and the finger guard (b) of the fan.

5. Install the new fan in reverse order.

4a

3 4

3a

4b

Maintenance 67

Replacing the fan of the D7T supply module



2. Open the cubicle door.

3. Remove the lower support bracket of the module (a).

4. Disconnect the fan wiring from the module: power supply plug (a) and the fibre optic cables (b).

5. Remove the front cover of the fan holder (a).

6. Support the fan holder (a) from below and pull it to release it from the module.

7. Pull out the fan holder.

8. If you have spare fan without the holder: Remove the fan from the fan holder.

9. Install new fan and the fan holder in reverse order to the above.

3

4a

4b

4

3a

5

6a

6

5a

68 Maintenance

Replacing the fan of the D8T supply module



2. Remove the screws holding the front cover plate. Lift the cover plate somewhat to release it.

3. Disconnect the fan wiring from the module: power supply plug (a) and the fibre optic cables (b).

4. Remove the front cover (a) of the fan holder.

5. Pull out the fan holder a).

6. If you have spare fan without the holder: Remove the fan from the fan holder.

7. Install new fan and the fan holder in reverse order to the above

5

3b

3a

4a5a

3 4

Maintenance 69

Replacing the roof fan for IP54 cabinet (option +B055)



2. Open the door of the cubicle.

3. Remove the shroud in front of the fan.

4. Remove all ventilation covers (lift and pull) and filters, and finally remove the roof plate on top of the outlet. Unscrew all necessary screws securing the fan and remove the fan.

5. Pull the fan unit out.

6. Install a new fan in reverse order.

Different roof fan models

70 Maintenance

Supply module

Cleaning the heatsink

The module heatsink fins pick up dust from the cooling air. Clean the heatsink when necessary. Overtemperature warnings and faults indicate that the heatsink is not clean.



2. Remove the cooling fan of the supply module as described in section Fans elsewhere in this chapter.

3. Prevent the dust from entering adjoining equipment. If necessary, remove the module from the cabinet before proceeding.

4. Blow clean and dry compressed air through the module from bottom to top, simultaneously using a vacuum cleaner at the air outlet to trap the dust.

5. Refit the cooling fan.

Replacing the D7T supply module


WARNING! Use extreme caution when maneuvering the supply module. It is heavy and have a high center of gravity. Ignoring the following instructions can cause physical injury, or damage to the equipment.

• Wear appropriate safety equipment.

• Be careful when removing bolts and washers on top of the module. Do not drop anything inside the module.

• Use a lifting device:

• Attach the lifting device to the module lifting eyes before removing the module fastening bolts. Keep the lifting device attached to the module until you have lifted the module onto a pallet and made sure that the module is supported and cannot topple over.

• Lift a replacement module only with a lifting device. Keep the lifting device attached to the module during the work until you are tighten the module fastening bolts.

• Do not tilt the module. Do not leave the module unattended on a floor.

• When you push the replacement module into the cabinet, keep your fingers away from the edge of the module edges to avoid pinching them between the module and the cabinet.

Maintenance 71


2. Open the cubicle door.

3. Remove the shroud.

4. Unplug the plug connector on top of the module (a), and the plug connector and fibre optic connector in front of the module (b).

5. Remove the lower support bracket of the module.

6. Be careful not to drop anything inside the module while you work on top of the module. Remove the fastening bolts of the DC busbars (a) and the DC busbars. Remove the fastening bolts of the AC busbars (b).

7. Remove the cooling fan plug connector (a), fibre optic connectors (b) and the cooling fan (c). See section Replacing the fan of the D7T supply module on page 67.

8. Remove the side fastening screws of the module on the top (a) and bottom (b).

9. Attach a lifting device to the lifting eyes of the module (a).

10. Remove the upper support bracket of the module (a).

11. Pull the module out of the cabinet carefully. Keep the weight on the lifting device constantly.

12. Lift the module down onto a pallet.

13. Keep the lifting device attached to the module and attach the module safely to the pallet.

14. Remove the lifting from the module and move the module away.

15. Install a new module in reverse order. Tighten the fastening screws of the module to 22 N·m (16.2 lbf·ft) and the fastening bolts of the DC output busbars to 70 N·m (51.6 lbf·ft).

16. Close the cubicle door.

72 Maintenance

3 4 5

6

4a

4b

6a

6a

6b

7a

7c

7

7b

Maintenance 73

8

8a

8b

9 10

9a9a

10a

11

74 Maintenance

Replacing the D8T supply module


WARNING! Be very careful when you move a module that runs on wheels. The module is heavy (approximately 175 kg) and have a high center of gravity. It topples over easily. Ignoring the following instructions can cause physical injury or

death, or damage to the equipment.• Wear appropriate safety equipment.

• Be careful when removing bolts and washers on top of the module. Do not drop anything inside the module.

• Do not move the module carelessly.

• When you remove the module, use the module pull-out ramp. Pull the module carefully out of the cubicle along the ramp. While pulling on the handle, keep a constant pressure with one foot on the base of the module to prevent the module from falling on its back. We recommend that you attach a lifting device to the module before you remove the module and keep it attached while removing.

• When you install a module, use the module pull-out ramp. Keep your fingers away from the edge of the module front plate to avoid pinching them between the module and the cubicle. Also, keep a constant pressure with one foot on the base of the module to prevent the module from falling on its back. We recommend that you attach a lifting device to the module before you install the module and keep it attached while installing.

• Do not tilt the module. Do not leave the module unattended on a sloping floor.

• If you lift the module, use only the two lifting eyes on top of the module: one in front and the other in back. Never lift the module from the hole inside the module (visible from top). It cannot carry the weight of the whole module.

• Do not use the module pull-out ramp with plinth heights over 50 mm. The ramp is designed for a plinth height of 50 mm (the standard plinth height of ABB cabinets).

max 50 mm

Support the top and bottom of the module!

Do not tilt! Do not leave the module unattended on a sloping floor!

max. 50 mm

Maintenance 75

Refer to the drawings below.


2. Open the door of the supply module cubicle.

3. Undo the screws of the shroud in the upper part of the cubicle. Lift and remove the shroud.

4. Unplug the wires and optic cables from the module, and move them aside.

5. Attach the module extraction ramp (included) to the base of the cabinet so that the tabs on the mounting bracket (a) enter the slots on the ramp (b).

6. Be careful not to drop anything inside the module while you work on top of the module. Remove the bolts holding the DC busbars (a).

7. Remove the module fastening screws (a) at the top of the module.

8. Remove the module fastening screws (a) at the bottom of the module.

9. Pull the module carefully out of the cabinet along the ramp. Keep a constant pressure with one foot on the base of the module to prevent the module from falling on its back. We recommend that you attach a lifting device to the module before you remove the module and keep it attached while removing.

10. Install the new module into the cubicle:

• Push the module back in and fasten. Tighten the fastening screws of the module to 22 N·m (16.2 lbf·ft) and the fastening bolts of the DC output busbars to 70 N·m (51.6 lbf·ft).

• Reconnect the wires and fiber cables to the module.

• Reinstall the shrouding.

• Remove the module pull-out ramp and close the cubicle door.

Do not use this hole for lifting! Mind your fingers! Support the top and bottom of the module!

NO LIFTING!

76 Maintenance

5

5b

5a

Maintenance 77

6a

6a

7a

8a

6 7 8

78 Maintenance

9

Maintenance 79

Control panel

Replacing the control panel battery

1. Turn the lid on the back of the panel counter-clockwise until the lid opens.

2. Replace the battery with a new CR2032 battery.

3. Put the lid back and tighten it by turning it clockwise.

4. Dispose of the old battery according to local disposal rules or applicable laws.

80 Maintenance

Memory unitAfter replacing a supply module control unit, the existing parameter settings can be retained by transferring the memory unit from the defective unit to the new unit.

Replacing the memory unit


WARNING! Do not remove or insert the memory unit when the control unit is powered.


2. Make sure that the control unit is not powered.

3. Undo the fastening screw and pull the memory unit out.

4. Install a memory unit in reverse order.

Installed memory unit

Maintenance 81

LEDS and other status indicatorsThis section instructs how to interpret the status indications of the diode supply unit.

Information on warnings and faults reported by the control program and displayed on the drive/converter/inverter control panel on the cabinet door are contained within the Firmware manual delivered with the drive.

The ACS-AP-I control panel has a status LED. The control panel mounting platform has two LEDs - a red and a green one. For their indications, see the following table.

Location LED Indication

ACS-AP-I control panel (status LED)

Continuous green The drive/converter/inverter is functioning normally.

Flickering green Data is transfered between the PC tool and drive/converter/inverter through the USB connection of the control panel.

Blinking green There is an active warning in the drive/converter/inverter.

Continuous red There is an active fault in the drive/converter/inverter.

Control panel mounting platform (with the control panel removed)

Red There is an active fault in the drive/converter/inverter.

Green Power supply for the drive/converter/inverter control board is ok.

82 Maintenance

Technical data 83

7

Technical data

Contents of this chapterThis chapter shows the technical data valid for the ACS880-307 +A018 diode supply units.

RatingsSupply unit type Nominal No overload

useLight overload

useHeavy-duty use

Icontmax IN SN PN ILd PLd Ihd PHd

A DC A AC kVA kW A DC kW DC A DC kW DCUN = 400 V

6-pulseACS880-307-0650A-3+A018 800 653 453 432 768 415 598 323ACS880-307-0980A-3+A018 1200 980 679 648 1152 622 898 485ACS880-307-1210A-3+A018 1488 1215 842 804 1428 771 1113 601ACS880-307-1820A-3+A018 2232 1822 1263 1205 2143 1157 1670 902ACS880-307-2730A-3+A018 3348 2734 1894 1808 3214 1736 2504 1352ACS880-307-3640A-3+A018 4464 3645 2525 2411 4285 2314 3339 1803ACS880-307-4560A-3+A018 5580 4556 3157 3013 5357 2893 4174 2254ACS880-307-5470A-3+A018 6696 5467 3788 3616 6428 3471 5009 270512-pulseACS880-307-0910A-3+A004+A018 1116 911 631 603 1071 579 835 451ACS880-307-1210A-3+A004+A018 1488 1215 842 804 1428 771 1113 601ACS880-307-1820A-3+A004+A018 2232 1822 1263 1205 2143 1157 1670 902ACS880-307-2430A-3+A004+A018 2976 2430 1683 1607 2857 1543 2226 1202ACS880-307-3640A-3+A004+A018 4464 3645 2525 2411 4285 2314 3339 1803ACS880-307-5470A-3+A004+A018 6696 5467 3788 3616 6428 3471 5009 2705UN = 500 V

6-pulseACS880-307-0650A-5+A018 800 653 566 540 768 518 598 404ACS880-307-0980A-5+A018 1200 980 849 810 1152 778 898 606ACS880-307-1210A-5+A018 1488 1215 1052 1004 1428 964 1113 751ACS880-307-1820A-5+A018 2232 1822 1578 1507 2143 1446 1670 1127

84 Technical data

Definitions

ACS880-307-2730A-5+A018 3348 2734 2367 2260 3214 2170 2504 1690ACS880-307-3640A-5+A018 4464 3645 3157 3013 4285 2893 3339 2254ACS880-307-4560A-5+A018 5580 4556 3946 3767 5357 3616 4174 2817ACS880-307-5470A-5+A018 6696 5467 4735 4520 6428 4339 5009 338112-pulseACS880-307-0910A-5+A004+A018 1116 911 789 753 1071 723 835 563ACS880-307-1210A-5+A004+A018 1488 1215 1052 1004 1428 964 1113 751ACS880-307-1820A-5+A004+A018 2232 1822 1578 1507 2143 1446 1670 1127ACS880-307-2430A-5+A004+A018 2976 2430 2104 2009 2857 1928 2226 1503ACS880-307-3640A-5+A004+A018 4464 3645 3157 3013 4285 2893 3339 2254ACS880-307-5470A-5+A004+A018 6696 5467 4735 4520 6428 4339 5009 3381UN = 690 V

6-pulseACS880-307-0570A-7+A018 700 572 683 652 672 626 524 488ACS880-307-0820A-7+A018 1000 816 976 932 960 894 748 697ACS880-307-1060A-7+A018 1302 1063 1271 1213 1250 1164 974 907ACS880-307-1520A-7+A018 1860 1519 1815 1733 1786 1663 1391 1296ACS880-307-2280A-7+A018 2790 2278 2723 2599 2678 2495 2087 1944ACS880-307-3040A-7+A018 3720 3037 3630 3465 3571 3327 2783 2592ACS880-307-3800A-7+A018 4650 3797 4538 4331 4464 4158 3478 3240ACS880-307-4560A-7+A018 5580 4556 5445 5198 5357 4990 4174 388812-pulseACS880-307-0760A-7+A004+A018 930 759 908 866 893 832 696 648ACS880-307-1060A-7+A004+A018 1302 1063 1271 1213 1250 1164 974 907ACS880-307-1520A-7+A004+A018 1860 1519 1815 1733 1786 1663 1391 1296ACS880-307-2130A-7+A004+A018 2604 2126 2541 2426 2500 2329 1948 1814ACS880-307-3040A-7+A004+A018 3720 3037 3630 3465 3571 3327 2783 2592ACS880-307-4560A-7+A004+A018 5580 4556 5445 5198 5357 4990 4174 3888

3AXD00000601909.XLS.C

Nominal ratings

Icontmax continuous output (DC) current. No overload capability at 40 °C (104 °F).

IN continuous rms input (AC) current. No overload capability at 40 °C (104 °F).

SN nominal apparent power

PN nominal active power

Light-overload use (10% overload capability) ratings

ILd continuous current. 10% overload is allowed for one minute every 5 minutes.

PLd active power in light-overload use

Heavy-duty use (40% overload capability) ratings

IHd continuous current. 40% overload is allowed for one minute every 5 minutes.

PHd active power in heavy-duty use

Supply unit type Nominal No overload use

Light overload use

Heavy-duty use

Icontmax IN SN PN ILd PLd Ihd PHd

A DC A AC kVA kW A DC kW DC A DC kW DC

Technical data 85

Derating

Ambient temperature derating

In the temperature range +40…50 °C (+104…122 °F), the rated output current is derated by 1% 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):

Altitude derating

At altitudes 0 … 2000 m (6561.7 ft) - no derating. For derating at altitudes over 2000 m (6561.7 ft), contact ABB.

T

1.00

0.90

+40 °C+104 °F

+50 °C+122 °F

k

0.80

86 Technical data

Supply module types and frame sizesSupply unit type Basic module type Frame sizeUN = 400 V

6-pulseACS880-307-0650A-3+A018 ACS880-304-0650A-3+A018 D8TACS880-307-0980A-3+A018 ACS880-304-0980A-3+A018 D8TACS880-307-1210A-3+A018 ACS880-304-0650A-3+A018 2×D8TACS880-307-1820A-3+A018 ACS880-304-0980A-3+A018 2×D8TACS880-307-2730A-3+A018 ACS880-304-0980A-3+A018 3×D8TACS880-307-3640A-3+A018 ACS880-304-0980A-3+A018 4×D8TACS880-307-4560A-3+A018 ACS880-304-0980A-3+A018 5×D8TACS880-307-5470A-3+A018 ACS880-304-0980A-3+A018 6×D8T12-pulseACS880-307-0910A-3+A004+A018 ACS880-304-0490A-3+A018 2×D7TACS880-307-1210A-3+A004+A018 ACS880-304-0650A-3+A018 2×D8TACS880-307-1820A-3+A004+A018 ACS880-304-0980A-3+A018 2×D8TACS880-307-2430A-3+A004+A018 ACS880-304-0650A-3+A018 4×D8TACS880-307-3640A-3+A004+A018 ACS880-304-0980A-3+A018 4×D8TACS880-307-5470A-3+A004+A018 ACS880-304-0980A-3+A018 6×D8TUN = 500 V

6-pulseACS880-307-0650A-5+A018 ACS880-304-0650A-5+A018 D8TACS880-307-0980A-5+A018 ACS880-304-0980A-5+A018 D8TACS880-307-1210A-5+A018 ACS880-304-0650A-5+A018 2×D8TACS880-307-1820A-5+A018 ACS880-304-0980A-5+A018 2×D8TACS880-307-2730A-5+A018 ACS880-304-0980A-5+A018 3×D8TACS880-307-3640A-5+A018 ACS880-304-0980A-5+A018 4×D8TACS880-307-4560A-5+A018 ACS880-304-0980A-5+A018 5×D8TACS880-307-5470A-3+A018 ACS880-304-0980A-3+A018 6×D8T12-pulseACS880-307-0910A-5+A004+A018 ACS880-304-0490A-5+A018 2×D7TACS880-307-1210A-5+A004+A018 ACS880-304-0650A-5+A018 2×D8TACS880-307-1820A-5+A004+A018 ACS880-304-0980A-5+A018 2×D8TACS880-307-2430A-5+A004+A018 ACS880-304-0650A-5+A018 4×D8TACS880-307-3640A-5+A004+A018 ACS880-304-0980A-5+A018 4×D8TACS880-307-5470A-5+A004+A018 ACS880-304-0980A-5+A018 6×D8TUN = 690 V

6-pulseACS880-307-0570A-7+A018 ACS880-304-0570A-7+A018 D8TACS880-307-0820A-7+A018 ACS880-304-0820A-7+A018 D8TACS880-307-1060A-7+A018 ACS880-304-0570A-7+A018 2×D8TACS880-307-1520A-7+A018 ACS880-304-0820A-7+A018 2×D8TACS880-307-2280A-7+A018 ACS880-304-0820A-7+A018 3×D8TACS880-307-3040A-7+A018 ACS880-304-0820A-7+A018 4×D8TACS880-307-3800A-7+A018 ACS880-304-0820A-7+A018 5×D8TACS880-307-4560A-7+A018 ACS880-304-0820A-7+A018 6×D8T12-pulseACS880-307-0760A-7+A004+A018 ACS880-304-0410A-7+A018 2×D7TACS880-307-1060A-7+A004+A018 ACS880-304-0570A-7+A018 2×D8TACS880-307-1520A-7+A004+A018 ACS880-304-0820A-7+A018 2×D8TACS880-307-2130A-7+A004+A018 ACS880-304-0570A-7+A018 4×D8TACS880-307-3040A-7+A004+A018 ACS880-304-0820A-7+A018 4×D8TACS880-307-4560A-7+A004+A018 ACS880-304-0820A-7+A018 6×D8T

3AXD00000601909.XLS.C

Technical data 87

Fuses

Module DC fuses (internal)

Supply unit type Type Pcs. Manuf. UN IN Size I2t V A A2sec

UN = 400 V

6-pulseACS880-307-0650A-3+A018 170M5499 4 Bussmann 1250 900 2 1750000 ACS880-307-0980A-3+A018 170M5499 4 Bussmann 1250 900 2 1750000ACS880-307-1210A-3+A018 170M5499 8 Bussmann 1250 900 2 1750000ACS880-307-1820A-3+A018 170M5499 8 Bussmann 1250 900 2 1750000ACS880-307-2730A-3+A018 170M5499 12 Bussmann 1250 900 2 1750000ACS880-307-3640A-3+A018 170M5499 16 Bussmann 1250 900 2 1750000ACS880-307-4560A-3+A018 170M5499 20 Bussmann 1250 900 2 1750000ACS880-307-5470A-3+A018 170M5499 24 Bussmann 1250 900 2 175000012-pulseACS880-307-0910A-3+A004+A018 170M4908 4 Bussmann 1000 700 1 755000ACS880-307-1210A-3+A004+A018 170M5499 8 Bussmann 1250 900 2 1750000ACS880-307-1820A-3+A004+A018 170M5499 8 Bussmann 1250 900 2 1750000ACS880-307-2430A-3+A004+A018 170M5499 16 Bussmann 1250 900 2 1750000ACS880-307-3640A-3+A004+A018 170M5499 16 Bussmann 1250 900 2 1750000ACS880-307-5470A-3+A004+A018 170M5499 24 Bussmann 1250 900 2 1750000UN = 500 V

6-pulseACS880-307-0650A-5+A018 170M5499 4 Bussmann 1250 900 2 1750000ACS880-307-0980A-5+A018 170M5499 4 Bussmann 1250 900 2 1750000ACS880-307-1210A-5+A018 170M5499 8 Bussmann 1250 900 2 1750000ACS880-307-1820A-5+A018 170M5499 8 Bussmann 1250 900 2 1750000ACS880-307-2730A-5+A018 170M5499 12 Bussmann 1250 900 2 1750000ACS880-307-3640A-5+A018 170M5499 16 Bussmann 1250 900 2 1750000ACS880-307-4560A-5+A018 170M5499 20 Bussmann 1250 900 2 1750000ACS880-307-5470A-5+A018 170M5499 24 Bussmann 1250 900 2 175000012-pulseACS880-307-0910A-5+A004+A018 170M4908 4 Bussmann 1000 700 1 755000ACS880-307-1210A-5+A004+A018 170M5499 8 Bussmann 1250 900 2 1750000ACS880-307-1820A-5+A004+A018 170M5499 8 Bussmann 1250 900 2 1750000ACS880-307-2430A-5+A004+A018 170M5499 16 Bussmann 1250 900 2 1750000ACS880-307-3640A-5+A004+A018 170M5499 16 Bussmann 1250 900 2 1750000ACS880-307-5470A-5+A004+A018 170M5499 24 Bussmann 1250 900 2 1750000UN = 690 V

6-pulseACS880-307-0570A-7+A018 170M5499 4 Bussmann 1250 900 2 1750000ACS880-307-0820A-7+A018 170M5499 4 Bussmann 1250 900 2 1750000ACS880-307-1060A-7+A018 170M5499 8 Bussmann 1250 900 2 1750000ACS880-307-1520A-7+A018 170M5499 8 Bussmann 1250 900 2 1750000ACS880-307-2280A-7+A018 170M5499 12 Bussmann 1250 900 2 1750000ACS880-307-3040A-7+A018 170M5499 16 Bussmann 1250 900 2 1750000ACS880-307-3800A-7+A018 170M5499 20 Bussmann 1250 900 2 1750000ACS880-307-4560A-7+A018 170M5499 24 Bussmann 1250 900 2 175000012-pulseACS880-307-0760A-7+A004+A018 170M4908 4 Bussmann 1000 700 755000ACS880-307-1060A-7+A004+A018 170M5499 8 Bussmann 1250 900 2 1750000ACS880-307-1520A-7+A004+A018 170M5499 8 Bussmann 1250 900 2 1750000ACS880-307-2130A-7+A004+A018 170M5499 16 Bussmann 1250 900 2 1750000ACS880-307-3040A-7+A004+A018 170M5499 16 Bussmann 1250 900 2 1750000ACS880-307-4560A-7+A004+A018 170M5499 24 Bussmann 1250 900 2 1750000

3AXD00000601909.XLS.C

88 Technical data

Qty

33669121218

666121218

33669121518

666121218

33669121518

666121218

Module-specific AC fuses

Fuses on CVAR board

Type: G330010 by Ferraz (10 A, 700 V AC Size: 10×38 mm). Note: The CVAR board is included in the UL versions only (option +C129).

Supply unit type Supply module FuseType Size Type Manuf.

UN = 400 V

6-pulseACS880-307-0650A-3+A018 ACS880-304-0650A-3+A018 D8T 170M6415 Cooper Buss.ACS880-307-0980A-3+A018 ACS880-304-0980A-3+A018 D8T 170M6419 Cooper Buss.ACS880-307-1210A-3+A018 ACS880-304-0650A-3+A018 2xD8T 170M6415 Cooper Buss.ACS880-307-1820A-3+A018 ACS880-304-0980A-3+A018 2xD8T 170M6419 Cooper Buss.ACS880-307-2730A-3+A018 ACS880-304-0980A-3+A018 3xD8T 170M6419 Cooper Buss.ACS880-307-3640A-3+A018 ACS880-304-0980A-3+A018 4xD8T 170M6419 Cooper Buss.ACS880-307-4560A-3+A018 ACS880-304-0980A-3+A018 5xD8T 170M6419 Cooper Buss.ACS880-307-5470A-3+A018 ACS880-304-0980A-3+A018 6xD8T 170M6419 Cooper Buss.12-pulseACS880-307-0910A-3+A004+A018 ACS880-304-0490A-3+A018 2xD7T 170M6412 Cooper Buss.ACS880-307-1210A-3+A004+A018 ACS880-304-0650A-3+A018 2xD8T 170M6415 Cooper Buss.ACS880-307-1820A-3+A004+A018 ACS880-304-0980A-3+A018 2xD8T 170M6419 Cooper Buss.ACS880-307-2430A-3+A004+A018 ACS880-304-0650A-3+A018 4xD8T 170M6415 Cooper Buss.ACS880-307-3640A-3+A004+A018 ACS880-304-0980A-3+A018 4xD8T 170M6419 Cooper Buss.ACS880-307-5470A-3+A004+A018 ACS880-304-0980A-3+A018 6xD8T 170M6419 Cooper Buss.UN = 500 V

6-pulseACS880-307-0650A-5+A018 ACS880-304-0650A-5+A018 D8T 170M6419 Cooper Buss.ACS880-307-0980A-5+A018 ACS880-304-0980A-5+A018 D8T 170M6419 Cooper Buss.ACS880-307-1210A-5+A018 ACS880-304-0650A-5+A018 2xD8T 170M6419 Cooper Buss.ACS880-307-1820A-5+A018 ACS880-304-0980A-5+A018 2xD8T 170M6419 Cooper Buss.ACS880-307-2730A-5+A018 ACS880-304-0980A-5+A018 3xD8T 170M6419 Cooper Buss.ACS880-307-3640A-5+A018 ACS880-304-0980A-5+A018 4xD8T 170M6419 Cooper Buss.ACS880-307-4560A-5+A018 ACS880-304-0980A-5+A018 5xD8T 170M6419 Cooper Buss.ACS880-307-5470A-5+A018 ACS880-304-0980A-5+A018 6xD8T 170M6419 Cooper Buss.12-pulseACS880-307-0910A-5+A004+A018 ACS880-304-0490A-5+A018 2xD7T 170M6412 Cooper Buss.ACS880-307-1210A-5+A004+A018 ACS880-304-0650A-5+A018 2xD8T 170M6419 Cooper Buss.ACS880-307-1820A-5+A004+A018 ACS880-304-0980A-5+A018 2xD8T 170M6419 Cooper Buss.ACS880-307-2430A-5+A004+A018 ACS880-304-0650A-5+A018 4xD8T 170M6419 Cooper Buss.ACS880-307-3640A-5+A004+A018 ACS880-304-0980A-5+A018 4xD8T 170M6419 Cooper Buss.ACS880-307-5470A-5+A004+A018 ACS880-304-0980A-5+A018 6xD8T 170M6419 Cooper Buss.UN = 690 V

6-pulseACS880-307-0570A-7+A018 ACS880-304-0570A-7+A018 D8T 170M6414 Cooper Buss.ACS880-307-0820A-7+A018 ACS880-304-0820A-7+A018 D8T 170M6417 Cooper Buss.ACS880-307-1060A-7+A018 ACS880-304-0570A-7+A018 2xD8T 170M6414 Cooper Buss.ACS880-307-1520A-7+A018 ACS880-304-0820A-7+A018 2xD8T 170M6417 Cooper Buss.ACS880-307-2280A-7+A018 ACS880-304-0820A-7+A018 3xD8T 170M6417 Cooper Buss.ACS880-307-3040A-7+A018 ACS880-304-0820A-7+A018 4xD8T 170M6417 Cooper Buss.ACS880-307-3800A-7+A018 ACS880-304-0820A-7+A018 5xD8T 170M6417 Cooper Buss.ACS880-307-4560A-7+A018 ACS880-304-0820A-7+A018 6xD8T 170M6417 Cooper Buss.12-pulseACS880-307-0760A-7+A004+A018 ACS880-304-0410A-7+A018 2xD7T PC31UD69V700TF MersenACS880-307-1060A-7+A004+A018 ACS880-304-0570A-7+A018 2xD8T 170M6414 Cooper Buss.ACS880-307-1520A-7+A004+A018 ACS880-304-0820A-7+A018 2xD8T 170M6417 Cooper Buss.ACS880-307-2130A-7+A004+A018 ACS880-304-0570A-7+A018 4xD8T 170M6414 Cooper Buss.ACS880-307-3040A-7+A004+A018 ACS880-304-0820A-7+A018 4xD8T 170M6417 Cooper Buss.ACS880-307-4560A-7+A004+A018 ACS880-304-0820A-7+A018 6xD8T 170M6417 Cooper Buss.

Technical data 89

Dimensions and weightsSupply unit type Height 1 Height 2 Width 1 Depth 1 Depth 2 Weight

mm mm mm mm mm kgUN = 400 V

6-pulseACS880-307-0650A-3+A018 2150 2315 1400 636 756 850ACS880-307-0980A-3+A018 2150 2315 1400 636 756 850ACS880-307-1210A-3+A018 2150 2315 1600 636 756 1130ACS880-307-1820A-3+A018 2150 2315 1600 636 756 1130ACS880-307-2730A-3+A018 2150 2315 2000 636 756 1560ACS880-307-3640A-3+A018 2150 2315 2800 636 756 2140ACS880-307-4560A-3+A018 2150 2315 3000 636 756 2420ACS880-307-5470A-3+A018 2150 2315 3200 636 756 270012-pulseACS880-307-0910A-3+A004+A018 2150 2315 1800 636 756 900ACS880-307-1210A-3+A004+A018 2150 2315 1800 636 756 1180ACS880-307-1820A-3+A004+A018 2150 2315 1800 636 756 1180ACS880-307-2430A-3+A004+A018 2150 2315 2400 636 756 1840ACS880-307-3640A-3+A004+A018 2150 2315 3000 636 756 2040ACS880-307-5470A-3+A004+A018 2150 2315 3400 636 756 2900UN = 500 V

6-pulseACS880-307-0650A-5+A018 2150 2315 1400 636 756 850ACS880-307-0980A-5+A018 2150 2315 1400 636 756 850ACS880-307-1210A-5+A018 2150 2315 1600 636 756 1130ACS880-307-1820A-5+A018 2150 2315 1600 636 756 1130ACS880-307-2730A-5+A018 2150 2315 2000 636 756 1560ACS880-307-3640A-5+A018 2150 2315 2800 636 756 2140ACS880-307-4560A-5+A018 2150 2315 3000 636 756 2420ACS880-307-5470A-5+A018 2150 2315 3200 636 756 270012-pulseACS880-307-0910A-5+A004+A018 2150 2315 1800 636 756 900ACS880-307-1210A-5+A004+A018 2150 2315 1800 636 756 1180ACS880-307-1820A-5+A004+A018 2150 2315 1800 636 756 1180ACS880-307-2430A-5+A004+A018 2150 2315 2400 636 756 1840ACS880-307-3640A-5+A004+A018 2150 2315 3000 636 756 2040ACS880-307-5470A-5+A004+A018 2150 2315 3400 636 756 2900UN = 690 V

6-pulseACS880-307-0570A-7+A018 2150 2315 1400 636 756 850ACS880-307-0820A-7+A018 2150 2315 1400 636 756 850ACS880-307-1060A-7+A018 2150 2315 1400 636 756 1130ACS880-307-1520A-7+A018 2150 2315 1600 636 756 1130ACS880-307-2280A-7+A018 2150 2315 2000 636 756 1560ACS880-307-3040A-7+A018 2150 2315 2400 636 756 1940ACS880-307-3800A-7+A018 2150 2315 3000 636 756 2420ACS880-307-4560A-7+A018 2150 2315 3200 636 756 270012-pulseACS880-307-0760A-7+A004+A018 2150 2315 1800 636 756 900ACS880-307-1060A-7+A004+A018 2150 2315 1800 636 756 1180ACS880-307-1520A-7+A004+A018 2150 2315 1800 636 756 1180ACS880-307-2130A-7+A004+A018 2150 2315 2400 636 756 1840ACS880-307-3040A-7+A004+A018 2150 2315 3000 636 756 2040ACS880-307-4560A-7+A004+A018 2150 2315 3400 636 756 2900

3AXD00000601909.XLS.C

Height 1 Height of IP22 cabinetHeight 2 Height of IP54 cabinetWidth 1 Width of supply unit including, auxiliary cubicle, incoming cubicle(s) and supply module cubicle(s)Depth 1 Depth if there is no Cooling air through bottom (option +C128). No door switches included.Depth 2 Depth if there is Cooling air through bottom (option +C128). No door switches included.

90 Technical data

Free space requirements

Front 1) Side Above 2)

mm in. mm in. mm in.

150 5.91 - - 400 15.75

1) Includes the door switches. Does not include the space needed for the door opening.

2) measured from the base plate of the cabinet top. Note: 320 mm (12.28 in.) is required for fan replacement of IP54 cabinets.

320 mm (12.28 in.)

> 400 mm (15.75 in.)

IP22/42 IP54

Technical data 91

Losses, air flow, efficiency and noiseSupply unit type Losses Air flow Efficiency Noise Level

kW m3/h % dB

UN = 400 V

6-pulseACS880-307-0650A-3+A018 4.6 1300 99.0 72ACS880-307-0980A-3+A018 6.6 1300 99.0 72ACS880-307-1210A-3+A018 9.2 2600 98.9 74ACS880-307-1820A-3+A018 13.3 2600 99.0 74ACS880-307-2730A-3+A018 19.9 3900 99.0 76ACS880-307-3640A-3+A018 26.6 5200 99.0 76ACS880-307-4560A-3+A018 33.3 6500 99.0 77ACS880-307-5470A-3+A018 40.0 7800 99.0 7812-pulseACS880-307-0910A-3+A004+A018 8.4 1800 98.7 74ACS880-307-1210A-3+A004+A018 9.2 2600 98.9 74ACS880-307-1820A-3+A004+A018 13.3 2600 99.0 74ACS880-307-2430A-3+A004+A018 18.4 5200 98.9 76ACS880-307-3640A-3+A004+A018 26.6 5200 99.0 76ACS880-307-5470A-3+A004+A018 40.0 7800 99.0 78UN = 500 V

6-pulseACS880-307-0650A-5+A018 4.6 1300 99.2 72ACS880-307-0980A-5+A018 6.6 1300 99.2 72ACS880-307-1210A-5+A018 9.2 2600 99.1 74ACS880-307-1820A-5+A018 13.3 2600 99.2 74ACS880-307-2730A-5+A018 19.9 3900 99.2 76ACS880-307-3640A-5+A018 26.6 5200 99.2 76ACS880-307-4560A-5+A018 33.3 6500 99.2 77ACS880-307-5470A-5+A018 40.0 7800 99.2 7812-pulseACS880-307-0910A-5+A004+A018 8.4 1800 98.9 74ACS880-307-1210A-5+A004+A018 9.2 2600 99.1 74ACS880-307-1820A-5+A004+A018 13.3 2600 99.2 74ACS880-307-2430A-5+A004+A018 18.4 5200 99.1 76ACS880-307-3640A-5+A004+A018 26.6 5200 99.2 76ACS880-307-5470A-5+A004+A018 40.0 7800 99.2 78UN = 690 V

6-pulseACS880-307-0570A-7+A018 4.5 1300 99.3 72ACS880-307-0820A-7+A018 5.8 1300 99.4 72ACS880-307-1060A-7+A018 9.0 2600 99.3 74ACS880-307-1520A-7+A018 12.7 2600 99.3 74ACS880-307-2280A-7+A018 19.1 3900 99.3 76ACS880-307-3040A-7+A018 25.5 5200 99.3 76ACS880-307-3800A-7+A018 32.0 6500 99.3 77ACS880-307-4560A-7+A018 38.4 7800 99.3 7812-pulseACS880-307-0760A-7+A004+A018 7.7 1800 99.2 74ACS880-307-1060A-7+A004+A018 9.0 2600 99.3 74ACS880-307-1520A-7+A004+A018 12.7 2600 99.3 74ACS880-307-2130A-7+A004+A018 18.1 5200 99.3 76ACS880-307-3040A-7+A004+A018 25.5 5200 99.3 76ACS880-307-4560A-7+A004+A018 38.4 7800 99.3 78

3AXD00000601909.XLS.C

92 Technical data

Terminal and lead-through data for the input power cableThis section shows the terminal and lead-through dimensions for incoming cubicles. The size vary depending on the supply unit size and options.

400 mm incoming cubicle – main switch (+F253)

These drawings show the terminal and lead-through dimensions for the 400 mm wide incoming cubicle. This cubicle is used in 6-pulse supply units with main switch-disconnector (option +F253) and bottom cable entry. Two similar cubicles are used in 12-pulse supply units or one 600 mm cubicle. See also section Layout drawings of incoming cubicles on page 20.

The dimensions are given in millimeters. Tightening torque for the cable lug connection depends on the bolt size and type. See section Tightening torques on page 100.

Front Side

Above

Technical data 93

600 mm incoming cubicle – main switch (+F253), 6-pulse

These drawings show the terminal and lead-through dimensions for a 600 mm wide incoming cubicle. This cubicle is used in 6-pulse supply unit with main switch-disconnector (option +F253) and bottom cable entry.


Front Side

Above

94 Technical data

600 mm incoming cubicle – main switch (+F253), 12-pulse (+A004)

These drawings show the terminal and lead-through dimensions for a 600 mm wide incoming cubicle. This cubicle is used in 12-pulse supply unit (option +A004) with main switch-disconnector (option +F253) and bottom cable entry. See also section Layout drawing of a 600 mm incoming cubicle on page 21.


Front Side

Above

Technical data 95

600 mm incoming cubicle – main breaker (+F255)

These drawings show the terminal and lead-through dimensions for a 600 mm wide incoming cubicle. This cubicle is in supply units with a main breaker (option +F255) and bottom cable entry. There is one cubicle for a 6-pulse supply unit and two cubicles for a 12-pulse supply unit.


Front Side

Above

96 Technical data

1000 mm incoming cubicle – main breaker (+F255)

These drawings show the terminal and lead-through dimensions for a 1000 mm wide incoming cubicle. This cubicle is in high-power supply units with a main breaker (option +F255) and bottom cable entry. There is one cubicle for a supply unit with a 6-pulse configuration.


Front Side

Above

Technical data 97

Electrical power network specificationVoltage (U1) ACS880-307-xxxx-3: 380…415 VAC 3-phase +10%…-15%

ACS880-307-xxxx-5: 380…500 VAC 3-phase +10%…-15%

ACS880-307-xxxx-7: 525…690 VAC 3-phase +10%…-15%

Network type TN (grounded) and IT (ungrounded) systems

Short-circuit withstand strength (IEC 61439-1)

Supply units with air circuit breaker (option +F255) and without grounding/earthing switch (without option +F259):

Rated peak withstand current (Ipk): 143 kA

Rated short-time withstand current (Icw): 65 kA/1 s

All other supply units:

Rated peak withstand current (Ipk): 105 kA

Rated short-time withstand current (Icw): 50 kA/1 s

Short-circuit current protection (UL 508A)

The drive is suitable for use on a circuit capable of delivering not more than 100,000 rms symmetrical amperes at 600 V maximum when the input cable is protected with T class fuses.

Short-circuit current protection

(CSA C22.2 No. 14-05)

The drive is suitable for use on a circuit capable of delivering not more than 100,000 rms symmetrical amperes at 500 V maximum when the input cable is protected with T class fuses.

Frequency 47 to 63 Hz, maximum rate of change 17%/s

Imbalance Max. ± 3% of nominal phase to phase input voltage

Fundamental power factor (cos phi1)

0.98 (at nominal load)

Control unit connection dataSee chapter Control unit on page 101.

Efficiency > 99% See section Losses, air flow, efficiency and noise on page 91.

Protection classesDegrees of protection (IEC/EN 60529)

IP22 (standard), IP42 (option +B054), IP54 (option +B055)

Enclosure types (UL50) UL Type 1 (standard), UL Type 1 Filtered (option +B054), UL Type 12 (option +B055). For indoor use only.

Overvoltage category (IEC 60664-1)

III

Protective class (IEC/EN 61800-5-1)

I

Ambient conditionsThe unit is to be used in a heated indoor controlled environment.

Operation Storage Transportation

Altitude above sea level 0…2000 m - -

For altitudes over 2000 m, contact ABB. -

Temperature 0…+40°C (+32 …+104°F), no condensation allowed

-40…+70°C

(-104 … +158°F)

-40…+70°C

(-104 … +158°F)

+40…+50°C (+104…+122°F) derating 1% /1°C (+33.8°F) above 40°C (+104°F). For more information, see Ambient temperature derating on page 85.

Relative humidity Maximum 95%, no condensation allowed

Maximum 95%, no condensation allowed

Maximum 95%, no condensation allowed

98 Technical data

Vibration

IEC 60068-2-6:2007,

EN 60068-2-6:2008 Environmental testing Part 2-6: Tests -Test Fc: Vibration sinusoidal

10…58 Hz, max. 0.075 mm displacement

amplitude

58…150 Hz 10 m/s2

For modules and cabinets in packages: IEC/EN

60721-3-1:1997 Classification of

environmental conditions - Part 3: Classification of groups of environmental

parameters and their severities - Section 1:

Storage

For cabinet package:

IEC/EN 60721-3-1:1997 Classification of

environmental conditions - Part 3: Classification of groups of environmental

parameters and their severities - Section 2:

Transportation

Shock

IEC 60068-2-27:2008

EN 60068-2-27:2009 Environmental testing - Part 2-27: Tests - Test Ea and guidance: Shock

Not allowed With packing max.

100 m/s2 (330 ft./s2) 11 ms

With packing max.

100 m/s2 (330 ft./s2) 11 ms

Contamination IEC/EN 60721-3-3:2002: Classification of

environmental conditions - Part 3-3: Classification of groups of environmental

parameters and their severities Stationary use

of weather protected locations

IEC 60721-3-1 IEC 60721-3-2

Chemical gases: Class 3C2



Solid particles: Class 3S1 with IP20/21, 3S2 with

higher IP class

Solid particles: Class 1S3 (packing must support this,

otherwise 1S2)

Solid particles: Class 2S2

No conductive dust allowed.

CoolingMethod Forced air-cooling (fans)

Air flow See Losses, air flow, efficiency and noise, page 91

MaterialsCabinet Hot-dip zinc coated 1.5 mm thick steel sheet (thickness of coating approximately

20 micrometers). Polyester thermosetting powder coating (thickness approximately 80 micrometers) on visible surfaces, color RAL 7035 and RAL 9017. PC/ABS 3 mm, color NCS 1502-Y (RAL 9002 / PMS 1C Cool Grey).

Busbars Tin-plated copper

Air filters of IP54 units Inlet (door) Outlet (roof)

Camfil/airComp 300-50 288 mm x 521 mm688 mm x 521 mm

Camfil/airTex G1502 pcs: 398 mm x 312 mm

Fire safety of materials

(IEC 60332-1)

Insulating materials and non-metallic items mostly self-extinctive

Technical data 99

DisclaimerThe manufacturer shall have no obligation with respect to any product which (i) has been improperly repaired or altered; (ii) has been subjected to misuse, negligence or accident; (iii) has been used in a manner contrary to the manufacturer’s instructions; or (iv) has failed as a result of ordinary wear and tear.

Package Standard package:

• timber, polyethylene sheet (thickness 0.2 mm), stretch film (thickness 0.023 mm), PP tape, PET strap, sheet metal (steel)

• for land and air transport when planned storage time is less than 2 months or when storage can be arranged in clean and dry conditions less than 6 months

• can be used when products will not be exposed to corrosive atmosphere during transport or storage

Container package:

• timber, VCI sheet film (PE, thickness 0.15 mm), VCI stretch film (PE, thickness 0.04 mm), VCI emitter bags, PP tape, PET strap, sheet metal (steel)

• for sea transport in containers

• recommended for land and air transport when storage time prior to installation exceeds 6 months or storage is arranged in partially weather-protected conditions

Seaworthy package:

• timber, plywood, VCI sheet film (PE, thickness 0.15 mm), VCI stretch film (PE, thickness 0.04 mm), VCI emitter bags, PP tape, PET strap, sheet metal (steel)

• for sea transport with or without containerization

• for long storage periods in environments where roofed and humidity-controlled storage cannot be arranged

Cabinets are fastened to the pallet with screws and braced from the top end to the package walls to prevents swaying inside the package. Package elements are attached together with screws.

Disposal The main parts of the drive can be recycled to preserve natural resources and energy. Product parts and materials should be dismantled and separated.

Generally all metals, such as steel, aluminum, copper and its alloys, and precious metals can be recycled as material. Plastics, rubber, cardboard and other packaging material can be used in energy recovery. Printed circuit boards and DC capacitors (C1-1 to C1-x) need selective treatment according to IEC 62635 guidelines. To aid recycling, plastic parts are marked with an appropriate identification code.

Contact your local ABB distributor for further information on environmental aspects and recycling instructions for professional recyclers. End of life treatment must follow international and local regulations.

StandardsSee Electrical planning instructions for ACS880 multidrive cabinets and modules [3AUA0000102324 (English)].

MarkingsSee Electrical planning instructions for ACS880 multidrive cabinets and modules [3AUA0000102324 (English)].

100 Technical data

Tightening torquesUnless a tightening torque is specified in the text, the following torques can be used.

Cable lugs

Electrical connections

Mechanical connections

Insulation supports

Size Max. torque

N·m

Note

M8 15 Strength class 8.8



Size TorqueN·m

Note

M3 0.5 Strength class 4.6...8.8

M4 1 Strength class 4.6...8.8







Size Max. torque N·m

Note




Size Max. torque

N·m

Note





Control unit 101

8

Control unit

What this chapter containsThis chapter

• describes the connections of the control unit,

• contains the specifications of the inputs and outputs of the control unit.

GeneralThe ACS880 drive utilizes BCU-x2 control units. The BCU-x2 consists of a BCON-12 control board (and a BIOC-01 I/O connector board and power supply board) built in a metal housing.

The supply and inverter units are each controlled by a dedicated BCU-x2 control unit. The designation of the supply control unit is A51; the inverter control unit is A41. The supply control unit is located in the auxiliary control cubicle (see the layout drawings in chapter Layout drawing of an auxiliary control cubicle on page 18), and connect to the supply module(s) by fiber optic cables.

In this manual, the name “BCU-x2” represents the control unit types BCU-02 and BCU-12 These have a different number of power module connections but are otherwise similar.

102 Control unit

Control unit layout and connections

Description

I/O I/O terminals (see following diagram)

SLOT 1 I/O extension or fieldbus adapter module connection. (This is the sole location for an FDPI-02 diagnostics and panel interface.)

SLOT 2 I/O extension or fieldbus adapter module connection

SLOT 3 I/O extension, fieldbus adapter or FSO-xx safety functions module connection

SLOT 4 RDCO-0x DDCS communication option module connection

X205 Memory unit connection

BATTERY Holder for real-time clock battery (CR 2032)

AI1 Mode selector for analog input AI1 (I = current, U = voltage)

AI2 Mode selector for analog input AI2 (I = current, U = voltage)

D2D TERM Termination switch for drive-to-drive link (D2D)

DICOM = DIOGND

Ground selection. Determines whether DICOM is separated from DIOGND (ie. the common reference for the digital inputs floats).

7-segment displayMulticharacter indications are displayed as repeated sequences of characters

(“U” is indicated briefly before “o”.)Control program startup in progress

(Flashing) Firmware cannot be started. Memory unit missing or corrupted

Firmware download from PC to control unit in progress

At power-up, the display may show short indications of eg. “1”, “2”, “b” or “U”. These are normal indications immediately after power-up. If the display ends up showing any other value than those described, it indicates a hardware failure.

Control unit 103

Description

XAI Analog inputs

XAO Analog outputs

XDI Digital inputs, Digital input interlock (DIIL)

XDIO Digital input/outputs

XD2D Drive-to-drive link

XD24 +24 V output (for digital inputs)

XETH Ethernet port (eg. for PC communication)

XPOW External power input

XRO1 Relay output RO1



XSTO Safe torque off connection (input signals)

XSTO OUT Not in use

X13 Control panel / PC connection

X485 Not in use

V1T/V1R, V2T/V2R

Fiber optic connection to inverter modules 1 and 2 (VxT = transmitter, VxR = receiver)

V3T/V3R…V7T/V7R

Fiber optic connection to inverter modules 3…7 (BCU-12/22 only)(VxT = transmitter, VxR = receiver)

V8T/V8R…V12T/V12R

Fiber optic connection to inverter modules 8…12 (BCU-22 only)(VxT = transmitter, VxR = receiver)

SD CARD Data logger memory card for inverter module communication

BATT OK Real-time clock battery voltage is higher than 2.8 V. If the LED is off when the control unit is powered, replace the battery.

FAULT The control program has generated a fault. See the firmware manual of the inverter unit.

PWR OK Internal voltage supply is OK

WRITE Writing to memory card in progress. Do not remove the memory card.

XDI

XSTO

X485

XD2D

XRO1

XRO2

XRO3

XDIO

XD24

XSTOOUT

XAI

XAO

XPOW

104 Control unit

Default I/O connectionsThis diagram shows the default I/O connections and describes the use of the signals in the supply unit. Do not change the factory-made wiring.

XD2D Drive-to-drive link1 B

Drive-to-drive link (not in us as default)2 A3 BGND4 ShieldX485 RS485 connection5 B

Not in use (not in us as default)6 A7 BGND8 ShieldXRO1…XRO3 Relay outputs11 NC XRO1: Running 2) (energized = running)

250 V AC / 30 V DC / 2 A12 COM13 NO21 NC XRO2: Fault(-1) 2) (Energized = no fault)

250 V AC / 30 V DC / 2 A22 COM23 NO31 NC XRO3: MCB ctrl 1) (Energized = closes main contactor/breaker)

250 V AC / 30 V DC / 2 A32 COM33 NOXSTO Safe torque off1 OUT Safe torque off. Both circuits must be closed for the supply unit to start. 8)

2 SGND3 IN14 IN25 IN1

Not in use6 SGND7 IN28 SGNDXDI Digital inputs1 DI1 Temp fault 2) (0 = overtemperature)2 DI2 Run / enable 2) (1 = run enable)3 DI3 MCB fb 1) (0 = main contactor/breaker open)4 DI4 Not in use as default. Can be used for eg, auxiliary circuit breaker fault.5 DI5 Not in use as default. Can be used for eg, earth fault monitoring.6 DI6 Reset 2) (0 -> 1 = fault reset)7 DIIL Not in use as default. Can be used for eg, emergency stop.XDIO Digital input/outputs1 DIO1 Not in use as default2 DIO2 Not in use as default3 DIOGND Digital input/output ground4 DIOGND Digital input/output groundXD24 Auxiliary voltage output5 +24VD +24 V DC 200 mA 6)

6 DICOM Digital input ground7 +24VD +24 V DC 200 mA 6)

8 DIOGND Digital input/output groundDICOM=DIOGND Ground selection switch 7)

XAI Analog inputs, reference voltage output1 +VREF 10 V DC, RL 1…10 kohm2 -VREF -10 V DC, RL 1…10 kohm3 AGND Ground4 AI1+ Not in use as default.

0(4)…20 mA, Rin = 100 ohm 4)5 AI1-6 AI2+ Not in use as default.

0(2)…10 V, Rin > 200 kohm 3)7 AI2-XAO Analog outputs1 AO1

Zero 2) 0…20 mA, RL < 500 ohm2 AGND3 AO2

Zero 2) 0…20 mA, RL < 500 ohm4 AGNDXPOW External power input1 +24VI

24 V DC, 2.05 A2 GND3 +24VI4 GNDX12 Safety functions module connectionX13 Control panel connectionX205 Memory unit connection

Control unit 105

1) Use of the signal in the control program. The use is fixed and it cannot be changed by a parameter.

2) Default use of the signal in the control program. The use can be changed by a parameter. For the delivery-specific use, see the delivery-specific circuit diagrams.

3) Current [0(4)…20 mA, Rin = 100 ohm] or voltage [0(2)…10 V, Rin > 200 kohm] input selected by switch AI1.

Change of setting requires reboot of control unit.

4) Current [0(4)…20 mA, Rin = 100 ohm] or voltage [0(2)…10 V, Rin > 200 kohm] input selected by switch AI2.

Change of setting requires reboot of control unit.

5) Must be set to ON when the unit is the first or last unit on the drive-to-drive (D2D) link.

6) Total load capacity of these outputs is 4.8 W (200 mA at 24 V) minus the power taken by DIO1 and DIO2.

7) Determines whether DICOM is separated from DIOGND (ie. common reference for digital inputs floats).DICOM = DIOGND ON: DICOM connected to DIOGND. OFF: DICOM and DIOGND separate. See section Ground isolation diagram on page 108.

8) This input only acts as a true Safe torque off input in control units controlling a motor. In other applications (such as a supply or brake unit), de-energizing the IN1 and/or IN2 terminal will stop the unit but not constitute a true safety function.

Additional remarks

Additional DIIL input (XDI:7)

On both the supply and inverter units, the DIIL input is used for the connection of safety circuits. The input is parametrized to stop the unit when the input signal is lost.

Drive-to-drive link (X2D2)

The drive-to-drive link is a daisy-chained RS-485 transmission line that allows basic master/follower communication with one master drive and multiple followers.

Set termination activation switch D2D TERM to the ON position on the drives at the ends of the drive-to-drive link. On intermediate drives, set the switch to the OFF position.

Use shielded twisted-pair cable (~100 ohm, for example, PROFIBUS-compatible cable) for the wiring. For best immunity, high quality cable is recommended. Keep the cable as short as possible; the maximum length of the link is 50 meters (164 ft). Avoid unnecessary loops and running the cable near power cables (such as motor cables). Ground the cable shields as described in section Connecting the control cables on page 46.

The following diagram shows the wiring of the drive-to-drive link.

1 2 3 4

B A

BG

ND

Sh

ieldXD

2D

Termination OFF

1 2 3 4

B A

BG

ND

Sh

ieldXD

2D

1 2 3 4

B A

BG

ND

Sh

ieldXD

2D

Termination ONTermination ON

106 Control unit

Safety functions (X12)

See the safety function manuals, and FSO-11 user’s manual [3AUA0000097054 (English)].

SDHC memory card slot (X205)

The BCU-x2 has an on-board data logger that collects real-time data from the inverter module power stages 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.

Control unit connector data

Power supply(XPOW)

Connector pitch 5 mm, wire size 2.5 mm2

24 V (±10%) DC, 2 AExternal power input. Two supplies can be connected for redundancy.

Relay outputs RO1…RO3 (XRO1…XRO3)


250 V AC / 30 V DC, 2 AProtected by varistors

+24 V output(XD24:2 and XD24:4)


Total load capacity of these outputs is 4.8 W (200 mA / 24 V) minus the power taken by DIO1 and DIO2.

Digital inputs DI1…DI6(XDI:1…XDI:6)


24 V logic levels: “0” < 5 V, “1” > 15 VRin: 2.0 kohmInput type: NPN/PNP (DI1…DI5), NPN (DI6)Hardware filtering: 0.04 ms, digital filtering up to 8 msDI6 (XDI:6) can alternatively be used as an input for a PTC sensor.“0” > 4 kohm, “1” < 1.5 kohmImax: 15 mA (DI1…DI5), 5 mA (DI6)

Start interlock input DIIL(XD24:1)


24 V logic levels: “0” < 5 V, “1” > 15 VRin: 2.0 kohmInput type: NPN/PNPHardware filtering: 0.04 ms, digital filtering up to 8 ms

Digital inputs/outputs DIO1 and DIO2 (XDIO:1 and XDIO:2)Input/output mode selection by parameters.DIO1 can be configured as a frequency input (0…16 kHz with hardware filtering of 4 microseconds) for 24 V level square wave signal (sinusoidal or other wave form cannot be used). DIO2 can be configured as a 24 V level square wave frequency output. See the firmware manual, parameter group 11.


As inputs:24 V logic levels: “0” < 5 V, “1” > 15 VRin: 2.0 kohmFiltering: 0.25 ms (ZCU-13), 1 ms (BCU-x2)As outputs:Total output current from +24VD is limited to 200 mA

Reference voltage for analog inputs +VREF and -VREF(XAI:1 and XAI:2)


10 V ±1% and –10 V ±1%, Rload 1…10 kohm

RL

DIOx

DIOGND

+24VD

Control unit 107

Analog inputs AI1 and AI2 (XAI:4 … XAI:7).Current/voltage input mode selection by jumpers.


Current input: –20…20 mA, Rin = 100 ohmVoltage input: –10…10 V, Rin > 200 kohmDifferential inputs, common mode range ±30 VSampling interval per channel: 0.25 msHardware filtering: 0.25 ms, adjustable digital filtering up to 8 msResolution: 11 bit + sign bitInaccuracy: 1% of full scale range

Analog outputs AO1 and AO2(XAO)


0…20 mA, Rload < 500 ohmFrequency range: 0…500 HzResolution: 11 bit + sign bitInaccuracy: 2% of full scale range

Drive-to-drive link(XD2D)


Physical layer: RS-485Termination by jumper

RS-485 connection(X485)


Physical layer: RS-485

Safe torque off connection(XSTO)


Input voltage range: -3…30 V DCLogic levels: “0” < 5 V, “1” > 17 VFor the unit to start, both connections must be “1”Current consumption: 55 mA (continuous)EMC (immunity) according to IEC 61326-3-1

Safe torque off output(XSTO OUT)


To STO connector of inverter module.

Control panel connection(X13)

Connector: RJ-45Cable length < 3 m

Ethernet connection(XETH)

Connector: RJ-45

SDHC memory card slot(SD CARD)

Memory card type: SDHCMaximum memory size: 4 GB

108 Control unit

Ground isolation diagram

XPOW+24VI 1GND 2+24VI 3GND 4

XAI+VREF 1-VREF 2AGND 3AI1+ 4AI1- 5AI2+ 6AI2- 7

XAOAO1 1

AGND 2AO2 3

AGND 4XD2D

B 1A 2

BGND 3SHIELD 4

XRO1, XRO2, XRO3NC 11

COM 12NO 13NC 21

COM 22NO 23NC 31

COM 32NO 33

XD24+24VD 1DICOM 2+24VD 3

DIOGND 4XDIO

DIO1 1DIO2 2

DIOGND 3DIOGND 4

XDIDI1 1DI2 2DI3 3DI4 4DI5 5DI6 6DIIL 7

XSTOOUT1 1SGND 2

IN1 3IN2 4

*

Ground

Common mode voltage between each AI input and AGND is +30 V

*Ground selector (DICOM = DIOGND) settings

All digital inputs and outputs share a common ground.

Ground of digital inputs DI1…DI5 and DIIL (DICOM) is isolated from the

DIO signal ground (DIOGND) (insulation voltage 50 V).

Further information

Product and service inquiries

Address any inquiries about the product to your local ABB representative, quoting the type designation and serial number of the unit in question. A listing of ABB sales, support and service contacts can be found by navigating to www.abb.com/searchchannels.

Product training

For information on ABB product training, navigate to www.abb.com/drives and select Training courses.

Providing feedback on ABB Drives manuals

Your comments on our manuals are welcome. Go to www.abb.com/drives and select Document Library – Manuals feedback form (LV AC drives).

Document library on the Internet

You can find manuals and other product documents in PDF format on the Internet. Go to www.abb.com/drives and select Document Library. You can browse the library or enter selection criteria, for example a document code, in the search field.

http://www.abb.com/drives


http://www.abb.com/searchchannels


www.abb.com/driveswww.abb.com/drivespartners

3AXD50000011408 Rev A (EN) 2014-01-02

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