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ABB ACS880-304LC Series Hardware Manual

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ABB INDUSTRIAL DRIVES
ACS880-304LC...+A019 diode supply modules
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Summary of Contents for ABB ACS880-304LC Series

  • Page 1 — ABB INDUSTRIAL DRIVES ACS880-304LC…+A019 diode supply modules Hardware manual...
  • Page 3 ACS880-304LC…+A019 diode supply modules Hardware manual Table of contents 4. Cabinet construction 5. Electrical installation 7. Start-up 3AXD50000045157 Rev C Original instructions EFFECTIVE: 2022-09-12...

  • Page 5: Table Of Contents

    Table of contents 5 Table of contents 1 Introduction to the manual Contents of this chapter ............... . Applicability .
  • Page 6 6 Table of contents 4 Cabinet construction Contents of this chapter ............... . Limitation of liability .
  • Page 7 Table of contents 7 Connecting power supply for the control unit ..........Connection diagram .
  • Page 8 8 Table of contents Frame D8D ..................Diode supply modules .
  • Page 9 Table of contents 9 Ratings ....................Derating .
  • Page 10 10 Table of contents CIO-01 module ..................AC fuse 170M6467 .

  • Page 11: Introduction To The Manual

    Introduction to the manual 11 Introduction to the manual Contents of this chapter This chapter describes the manual. It gives information on the markings and component designations, and also the terms and abbreviations that are used in the manual. This chapter also includes a list of related manuals.

  • Page 12: Categorization By Frame Size And Option Code

    Rittal Flat-PLS, a busbar system for standard, commercially available flat busbars Frame, frame size Physical size of the drive or power module Intermediate circuit DC circuit between rectifier and inverter Internal charging In this manual, internal charging stands for an ABB charging kit installed inside the supply unit cubicle.

  • Page 13: Related Documents

    Introduction to the manual 13 Term/ Description Abbreviation Inverter unit Inverter Converts direct current and voltage to alternating current and voltage. Inverter unit Inverter module(s) under control of one control unit, and related components. One inverter unit typically controls one motor. Multidrive Drive for controlling several motors which are typically coupled to the same machinery.
  • Page 14 Converter module lifting device for drive cabinets hardware manual 3AXD50000210268 Manuals and quick guides for I/O extension modules, fieldbus adapters, safety functions modules, etc. www.abb.com/drives/documents for all manuals on the Internet. You can find all documentation related to the multidrive modules on the Internet at...

  • Page 15: Operation Principle And Hardware Description

    Operation principle and hardware description 15 Operation principle and hardware description Contents of this chapter This chapter describes how the diode supply unit works and the hardware of the diode supply module. Operation principle The heart of the diode supply unit is a diode bridge. It rectifies three-phase AC current to direct current for the intermediate DC link of the drive.

  • Page 16: Main Circuit Diagram

    16 Operation principle and hardware description 16 Operation principle and hardware description Main circuit diagram Main circuit diagram ￭  The figure shows a simplified main circuit diagram of the rectifier bridge. The figure shows a simplified main circuit diagram of the rectifier bridge. AC fuses AC fuses Diodes...

  • Page 17: Dc Overvoltage And Undervoltage Protection

    ￭ AC fuses protect the supply unit against short circuit. The cabinet installer must acquire and install the fuses. Fuses are available from ABB. Note that the supply unit designs presented in this manual do not contain DC fuses. The cabinet installer must arrange for appropriate short circuit protection on the DC side.

  • Page 18: 12- And 24-Pulse Supply Units

    18 Operation principle and hardware description 6-, 12- and 24-pulse supply units ￭ The supply units can be connected either to 6-pulse, 12-pulse or 24-pulse connection. If 12-pulse or 24-pulse supply transformer is used, there can be a maximum of 4 diode supply modules in one drive system.

  • Page 19: Overview Diagrams

    The supply unit overview diagrams also show examples of division of components in cubicles, and indicate which components you can order from ABB and which you need to acquire separately.

  • Page 20: Overview Diagram - 1×D8D, 6-Pulse, Internal Charging

    Overview diagram – 1×D8D, 6-pulse, internal charging ￭ The diagram shows a supply unit with one D8D module and internal charging in a 6-pulse connection. In this manual, internal charging stands for ABB charging kit inside the supply unit cubicle. Note: Minimum length of the cables is 5 meters.

  • Page 21: Overview Diagram - 2×D8D, 6-Pulse, Internal Charging

    Dedicated supply unit switchgear including: • Disconnecting device • Breaker/contactor Overcurrent and short-circuit protection of input cabling AC fuses for protecting supply unit against short circuit Internal charging kit Diode supply modules DC link Available through ABB or third party Available through ABB...

  • Page 22: Overview Diagram - 2×D8D, 12-Pulse, Internal Charging

    Interlocked dedicated supply unit switchgear including: • Disconnecting device • Breaker/contactor • Overcurrent and short-circuit protection of input cabling AC fuses for protecting supply unit against short circuit Internal charging kit Diode supply modules DC link Available through ABB or third party Available through ABB...

  • Page 23: Overview Diagram - 2×D8D, 6-Pulse, External Charging And Pre-Magnetizing

    The diagram shows a supply unit with two D8D modules in a 6-pulse connection. The system has an external charging circuit combined with a transformer pre-magnetization circuit. For more information, contact ABB. Note: Each module must have its own input AC cable with the minimum length of 5 meters. Use symmetrical supply cabling to ensure equal current sharing between parallel diode bridges.

  • Page 24: Overview Diagram - 2×D8D, 12-Pulse, External Charging And Pre-Magnetizing

    The diagram shows a supply unit with two D8D modules in a 12-pulse connection. The system has an external charging circuit combined with a transformer pre-magnetization circuit. For more information, contact ABB. Note: Each module must have its own input AC cable with the minimum length of 5 meters.

  • Page 25: Hardware Of The Supply Modules

    Operation principle and hardware description 25 Hardware of the supply modules Layout drawing of the D8D module ￭ This figure shows the layout of the D8D module. External main supply connections U1, V1 and W1 Coolant connectors Unpainted grounding point (PE) Thermal switch [F6.1] DC+ and DC- connections Heatsink...

  • Page 26: Overview Of Control Connections Of Zcu-14 Control Unit

    26 Operation principle and hardware description Overview of control connections of ZCU-14 control unit It is possible to: • control the unit through the control panel and fieldbus • read the status information of the supply unit through the control panel, fieldbus and relay output.

  • Page 27: Auxiliary Voltage Switch

    Operation principle and hardware description 27 installed on the supply module cubicle door, and wired to DI2. When the digital input DI2 is on, it is also possible to control the Run enable signal from a control panel, through fieldbus interface, or from the inverter unit. For other control signals, see the firmware manual and the default I/O connection diagram.

  • Page 28: Fieldbus Control

    28 Operation principle and hardware description Fieldbus control ￭ You can control the unit through a fieldbus interface if the unit is equipped with an optional fieldbus adapter and when you have configured the control program for the fieldbus control with the parameters. For information on the parameters, see the firmware manual.

  • Page 29: Type Designation Key

    Operation principle and hardware description 29 Type designation key The type designation describes the composition of the module in short. The complete designation code is divided in subcodes: • The first 1…18 digits form the basic code. It describes the basic construction of the unit.

  • Page 31: Moving And Unpacking The Module

    Moving and unpacking the module 31 Moving and unpacking the module Contents of this chapter This chapter gives basic information on unpacking and moving the module. Moving the module WARNING! Use the required personal protective equipment. Wear protective gloves and long sleeves.
  • Page 32 32 Moving and unpacking the module Lift off the module. Check that there are no signs of damage. Dispose of or recycle the packaging according to the local regulations. This illustration shows the layout of the transport package. Examine that all items are present and there are no signs of damage.
  • Page 33 Moving and unpacking the module 33 VCI sheet Screws Plywood support Plywood box Plywood cover...

  • Page 35: Cabinet Construction

    Limitation of liability The installation must always be designed and made according to applicable local laws and regulations. ABB does not assume any liability whatsoever for any installation which breaches the local laws and/or other regulations. Furthermore, if the recommendations given by ABB are not followed, the drive may experience problems...

  • Page 36: Switching, Disconnecting And Protecting Solution

    36 Cabinet construction Switching, disconnecting and protecting solution To arrange the switching, disconnection and protection of the supply module, you can use the following solution: Equip the main circuit with a disconnecting device which meets the local safety regulations. The disconnecting device must separate the whole drive cabinet from the AC power line, including the AC fuses which are placed inside the drive cabinet.

  • Page 37: 400 Mm Wide Rittal Vx25 And Generic Enclosures

    Cabinet construction 37 400 mm wide Rittal VX25 and generic enclosures ￭ These figures show 1×D8D and 2×D8D modules in 400 mm wide Rittal VX25 and generic enclosures. The figures show also pipe routing overviews. 1xD8D 2xD8D Blue lines Incoming pipes Red lines Outgoing pipes Lilac lines...

  • Page 38: Cabinet Layout Drawings

    38 Cabinet construction Cabinet layout drawings The cabinet layout drawings show examples of the supply units in the Rittal VX25 enclosure with external charging. The unit includes a D8D supply module/supply modules and bottom entries for cabling. The figures show also the cooling circuit inlet, outlet and the cooling circuit valves.The swing-out frame has space for installing the control unit and other electrical equipment.

  • Page 39: Cabinet Temperature Supervision

    Install the thermal switches on the hottest element of the cabinet. In this example, the thermal switches are on the DC busbar above the supply module (two thermal switches for 1×D8D and 2×D8D modules on the DC+ and DC- busbars). ABB recommends to use thermal switches with 100 °C temperature limit.

  • Page 40: Pipe Routing

    40 Cabinet construction A temperature sensor integrated into the control unit supervises the board operating temperature. In case of overtemperature, the control program generates a warning or trips the supply unit on a fault. The module has its own thermal switch for temperature supervision. See Module temperature supervision (page 17).
  • Page 41 Cabinet construction 41 Pipe routing example of 1×D8D unit in 400 mm wide Rittal VX25 ￭ enclosure 16/13 mm Heat exchanger Inlet manifold with stop and drain valves Outlet manifold with stop and drain valves Incoming pipes Outgoing pipes Intermediate pipes Drain pipes...

  • Page 42: Pipe Routing Example Of 2×D8D Unit In 400 Mm Wide Rittal Vx25 Enclosure

    42 Cabinet construction Pipe routing example of 2×D8D unit in 400 mm wide Rittal VX25 ￭ enclosure 8/6 mm 16/13 mm 16/13 mm 8/6 mm Heat exchanger Inlet manifold with stop and drain valves Outlet manifold with stop and drain valves Incoming pipes Outgoing pipes Intermediate pipes...

  • Page 43: Installation Examples

    Internet. Go to https://sites-apps.abb.com/sites/lvacdrivesengineeringsupport/content. If needed, contact your local ABB representative. The example includes also cabinet assembly drawings that show each stage listed in the table. More detailed steps of each stage are described in the kit-specific assembly drawings.

  • Page 44: D8D Modules In A 400 Mm Wide Rittal Vx25 Or Generic Enclosure

    44 Cabinet construction D8D modules in a 400 mm wide Rittal VX25 or generic enclosure Installation stages ￭ Installation stage Instruction code Kit code Kit ordering code Installation of common parts: Cable entry kit 3AXD50000004817 A-468-8-441 3AXD50000004385 Common DC Flat-PLS as- 3AUA0000115891 A-468-X-001-VX 3AXD50000333387...

  • Page 45: Kits For D8D Supply Modules In 400 Mm Rittal Vx25 Or Generic Enclosure

    Cabinet construction 45 Kits for D8D supply modules in 400 mm Rittal VX25 or generic ￭ enclosure...

  • Page 46: Stage 1: Installation Of Common Parts

    46 Cabinet construction Stage 1: Installation of common parts ￭...

  • Page 47: Stage 2: Module Installation Parts

    Cabinet construction 47 Stage 2: Module installation parts ￭...

  • Page 48: Stage 3: Liquid-Cooling System Components

    48 Cabinet construction Stage 3: Liquid-cooling system components ￭...

  • Page 49: Stage 4: Ac And Dc Busbar Installation

    Cabinet construction 49 Stage 4: AC and DC busbar installation ￭...

  • Page 50: Stage 5: Ac And Dc Connection

    50 Cabinet construction Stage 5: AC and DC connection ￭...

  • Page 51: Stage 6: Cabinet Fan And Heat Exchanger

    Cabinet construction 51 Stage 6: Cabinet fan and heat exchanger ￭...

  • Page 52: Stage 7: Shroud Installation Parts

    52 Cabinet construction Stage 7: Shroud installation parts ￭...

  • Page 53: Stage 8: Door, Covers And Explosion Exhaust Kit

    Cabinet construction 53 Stage 8: Door, covers and explosion exhaust kit ￭...

  • Page 55: Electrical Installation

    [English]). Note: The installation must always be designed and made according to applicable local laws and regulations. ABB does not assume any liability whatsoever for any installation which breaches the local laws and/or other regulations. Furthermore, if the recommendations given by ABB are not followed, the drive system may experience...

  • Page 56: Electrical Safety Precautions

    56 Electrical installation Electrical safety precautions These electrical safety precautions are for all personnel who do work on the drive, motor cable or motor. WARNING! Obey these instructions. If you ignore them, injury or death, or damage to the equipment can occur. If you are not a qualified electrical professional, do not do installation or maintenance work.

  • Page 57: General Notes

    Electrical installation 57 Important! Repeat the measurement also with the DC voltage setting of the tester. Measure between each phase and ground. There is a risk of dangerous DC voltage charging due to leakage capacitances of the motor circuit. This voltage can remain charged for a long time after the drive power-off.

  • Page 58: Measuring The Insulation Resistance Of The Input Power Cable

    58 Electrical installation Measuring the insulation resistance of the input power cable ￭ Before you connect the input power cable to the drive, measure its insulation resistance according to local regulations.

  • Page 59: Selecting The Supply Transformer

    3-phase AC choke in addition to transformer (or generator) impedance to reach the necessary minimum impedance of 5%. Separate chokes are not available from ABB. Note: Since the supply modules do not have input chokes, the THD currents and voltages have to be taken into account when dimensioning the system.

  • Page 60: Selecting The Power Cables

    3-phase AC choke between each ACS880-304LC +A019 module and grid to ensure current balance between the phases. Separate chokes are not available from ABB. Symmetrical shielded cable with three phase conductors and a concentric PE conductor as shield. The shield must agree with the requirements of IEC 61800-5-1.

  • Page 61: Typical Power Cable Sizes

    Electrical installation 61 Typical power cable sizes ￭ This table gives aluminum and copper cable types. The cable sizing is based on max. 9 cables laid on the cable trays side by side, three ladder type trays one on top of the other, ambient temperature 30 °C (EN 60204-1 and IEC 60364-5-52).

  • Page 62: Connection Diagram - 2×D8D, 6-Pulse, Internal Charging

    Connection diagram – 2×D8D, 6-pulse, internal charging The diagram shows 2×D8D modules in a 6-pulse connection with internal charging. In this manual, internal charging stands for ABB charging kit inside the supply unit cubicle. External installation (outside supply module Supply unit cubicle...

  • Page 63: Connection Diagram - 2×D8D, 12-Pulse, Internal Charging

    Electrical installation 63 Connection diagram – 2×D8D, 12-pulse, internal charging The diagram shows 2×D8D modules in a 12-pulse connection with internal charging. In this manual, internal charging stands for ABB charging kit inside the supply unit cubicle. External installation (outside supply module...

  • Page 64: Connection Diagram - 2×D8D, 6-Pulse, External Charging And Pre-Magnetizing

    The diagram shows 2×D8D modules in a 6-pulse connection with external charging of the drive. The external charging circuit is combined with the transformer pre-magnetization circuit. For more information, contact ABB. In this manual, external charging stands for drive charging circuit outside the supply unit cubicle.

  • Page 65: Connection Diagram - 2×D8D, 12-Pulse, External Charging And Pre-Magnetizing

    The diagram shows 2×D8D modules in a 12-pulse connection with external charging of the drive. The external charging circuit is combined with the transformer pre-magnetization circuit. For more information, contact ABB. In this manual, external charging stands for drive charging circuit outside the supply unit cubicle.

  • Page 66: Connection Procedure

    DC busbars of the drive cabinet • supply module(s) • charging circuit components. The connections of the ABB-defined charging circuit with the terminal markings are shown in the example circuit diagrams • DC fuses, if necessary. Ground the module (if not made yet). If the grounding via the module fixing screws is not good enough, connect a separate cable between the module grounding point and the cabinet PE busbar.

  • Page 67: Charging Circuit Wire Recommendations

    PE (ground) busbar. Connect the phase conductors of the charging circuit supply cable to the charging circuit. The connections of the ABB-defined charging circuit with the terminal markings are shown in the example circuit diagrams. For tightening torques, see the technical data.

  • Page 68: Connecting The External Power Supply Cable For The Auxiliary Circuit

    124). Connection diagram ￭ See the final circuit diagrams for details. The ABB-defined installation example is shown in the example circuit diagrams. Connecting power supply for the control unit The cabinet builder must connect 24 V DC auxiliary power supply for the ZCU control unit.
  • Page 69 Electrical installation 69 Remove shrouding to access the cable entries and trunking inside the cubicle. Run the control cables into the cubicle. If possible, arrange for a 360° grounding of the cable shield at the cable entry. If the outer surface of the shield is non-conductive, turn the shield inside out as shown below and wrap copper foil around the cable to keep the shielding continuous.

  • Page 70: Connecting A Pc

    70 Electrical installation Connect the conductors to appropriate terminals. Refit any shrouds removed earlier. Connecting a PC WARNING! Do not connect the PC directly to the control panel connector of the control unit as this can cause damage. A PC (with, for example, the Drive composer PC tool) can be connected as follows: Connect a ACS-AP-…...

  • Page 71: Installation Checklist

    Installation checklist 71 Installation checklist Contents of this chapter This chapter contains a checklist for the mechanical and electrical installation of the drive. Checklist Examine the mechanical and electrical installation of the drive before start-up. Go through the checklist together with another person. WARNING! Obey the safety instructions of the drive.
  • Page 72 72 Installation checklist Make sure that … The drive module is fastened properly to the enclosure. If the drive is connected to a network other than a symmetrically grounded TN-S system: You have done all the required modifications (for example, you may need to disconnect the EMC filter or ground-to-phase varistor).
  • Page 73 Installation checklist 73 Make sure that … There are no tools, foreign objects or dust from drilling inside the drive. The cover(s) of the motor connection box are in place. Cabinet shrouds are in place and doors are closed. The motor and the driven equipment are ready for power-up. The coolant connections between cubicles (if any) and to the cooling circuit are tight.

  • Page 75: Start-Up

    Start-up 75 Start-up Contents of this chapter This chapter contains start-up instructions of the diode supply unit. The underlined tasks are necessary only for certain cases. The symbols in brackets, for example [Q1], refer to the item designations used in the circuit diagrams. If a task is valid only for a certain option device or feature, the option code is given in brackets.

  • Page 76: Safety

    76 Start-up that is outside the supply unit cubicle. The drive switchgear is also outside the supply unit cubicle. The switchgear includes a main disconnector and main contactor or breaker. Safety ￭ Action WARNING! Obey the safety instructions during the start-up procedure. See ACS880 liquid- cooled multidrive cabinets and modules safety instructions (3AXD50000048633 [English]).

  • Page 77: Setting Up The Supply Unit Parameters

    Start-up 77 Action Make sure that it is safe to connect voltage: • nobody is working on the unit or circuits that are wired from outside into the cabinets • covers of the motor terminal boxes are on • cabinet doors are closed •...

  • Page 78: Validating The Safety Functions

    78 Start-up Action Switch the Run enable and Start signals at digital input DI2 on (1) to start the operation of the supply unit. Turn the operating switch [S21] on the cabinet door to ENABLE/RUN (1) position. Run enable starts the supply unit power up sequence. After the program has stepped through it (approximately 3 seconds), the drive DC link is charged, the main contactor/ is closed and the supply unit is in operation and ready to the supply inverters.

  • Page 79: Maintenance

    Maintenance intervals The tables below show the maintenance tasks which can be done by the end user. The complete maintenance schedule is available on the Internet (https://new.abb.com/drives/services/maintenance/preventive-maintenance). For more information, consult your local ABB Service representative (www.abb.com/searchchannels). Description of symbols ￭...

  • Page 80: Recommended Maintenance Intervals After Start-Up

    • Maintenance and component replacement intervals are based on the assumption that the equipment is operated within the specified ratings and ambient conditions. ABB recommends annual drive inspections to ensure the highest reliability and optimum performance. • Long term operation near the specified maximum ratings or ambient conditions may require shorter maintenance intervals for certain components.

  • Page 81: Maintenance Timers And Counters

    Maintenance 81 Maintenance timers and counters The control program has maintenance timers and counters that can be configured to generate a warning when a pre-defined limit is reached. Each timer/counter can be set to monitor any parameter. This feature is especially useful as a service reminder. For more information, see the firmware manual.

  • Page 82: Fuses

    82 Maintenance Fuses Checking and replacing the module AC fuses ￭ WARNING! Obey the safety instructions given in ACS880 liquid-cooled multidrive cabinets and modules safety instructions (3AXD50000048633 [English]). If you ignore the safety instructions, injury or death, or damage to the equipment can occur.

  • Page 83: Fans

    Reset the running time signal after fan replacement. See also CIO-01 I/O module for distributed I/O bus control user's manual (3AXD50000126880 [English]). Replacement fans are available from ABB. Do not use other than ABB-specified spare parts. Replacing the cabinet fan ￭ WARNING!
  • Page 84 84 Maintenance WARNING! Use the required personal protective equipment. Wear protective gloves and long sleeves. Some parts have sharp edges. Repeat the steps described in section Electrical safety precautions (page 56). Undo the locking screws of the swing-out frame and open the swing-out frame. Disconnect the fan wiring.

  • Page 85: Supply Module

    Maintenance 85 Supply module Replacing the supply module ￭ WARNING! Obey the safety instructions given in ACS880 liquid-cooled multidrive cabinets and modules safety instructions (3AXD50000048633 [English]). If you ignore the safety instructions, injury or death, or damage to the equipment can occur. If you are not a qualified electrical professional, do not do installation or maintenance work.
  • Page 86 86 Maintenance WARNING! For a reliable connection, the end of the pipe entering the connector must be completely intact for a length of at least 5 cm (2 in). Make sure that the pipe is perfectly round where it enters the connector, and not deformed eg.
  • Page 87 Maintenance 87...
  • Page 88 88 Maintenance...

  • Page 89: Control Panel

    Maintenance 89 Control panel Refer to ACS-AP-I, -S, -W and ACH-AP-H, -W Assistant control panels user’s manual (3AUA0000085685 [English]). Control unit Replacing the memory unit ￭ After replacing a control unit, you can keep the existing parameter settings by transferring the memory unit from the defective control unit to the new control unit. WARNING! Do not remove or insert the memory unit when the control unit is powered.

  • Page 90: Replacing The Zcu-14 Control Unit Battery

    90 Maintenance Remove the fastening screw and pull the memory unit out. Install a memory unit in reverse order. Replacing the ZCU-14 control unit battery ￭ WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur.

  • Page 91: Leds And Other Status Indicators

    Maintenance 91 LEDs and other status indicators Warnings and faults reported by the control program are displayed on the control panel or in the Drive composer PC tool. For further information, see the firmware manual. Control panel and panel platform/holder LEDs ￭...

  • Page 93: Ordering Information

    Note: • This chapter only lists the installation accessories available from ABB. All other parts must be sourced from a third party (such as Rittal) by the system integrator. For a listing, refer to the kit-specific installation instructions available at https://sites-apps.abb.com/sites/lvacdrivesengineeringsupport/content.
  • Page 94 94 Ordering information • A = air-cooled (some of these kits are also used with liquid-cooled drives) • L = liquid-cooled • w = cabinet width • 4 = 400 mm • 6 = 600 mm • 8 = 800 mm •...

  • Page 95: Frame D8D

    Ordering information 95 • 300…399 = Kits related to module installation, for example, mechanical supports 300…330 Module supporting kits, basic mechanical support 350…379 Shroud kits • 400…499 = Other kits 400…419 Fan kits 420…439 Air guides 440…459 Cooling circuit kits •...

  • Page 96: Control Panel

    96 Ordering information Control panel ￭ The control panel is not included with the module but must be ordered separately. One control panel is required for the commissioning of an ACS880 drive system, even if the Drive Composer PC tool is used. The control panel can be flush mounted on the cabinet door with the help of a door mounting kit.

  • Page 97: Control Electronics

    Ordering information 97 For more information on the door mounting kits, such as the contents of the kit, see the installation manuals: • DPMP-01 mounting platform for control panels installation guide (3AUA0000100140 [English]) • DPMP-02/03 mounting platform for control panels installations guide (3AUA0000136205 [English]).

  • Page 98: Mechanical Installation Accessories

    98 Ordering information Type Data Ordering code CIO-01 I/O module for distributed I/O CIO-01 3AXD50000041983 bus control Mechanical installation accessories ￭ These kits include parts that are used for installing the module in the enclosure. Module installation mechanics kit Module installation mechanics kit includes parts for installing the D8D modules and the AC connection kits.

  • Page 99: Shrouding (For Rittal Vx25 Enclosures)

    Ordering information 99 Shrouding (for Rittal VX25 enclosures) The shroud kit contains plastic air guides and shrouds with the necessary brackets and screws. For details on the shroud kit, see the instructions available at https://sites-apps.abb.com/sites/lvacdrivesengineeringsupport/content. Used with … Ordering code Kit code...

  • Page 100: Explosion Exhaust Kit (For Rittal Vx25 Enclosures)

    100 Ordering information Explosion exhaust kit (for Rittal VX25 enclosures) The explosion exhaust plate acts as a pressure relief vent in case of arcing inside the cubicle. This part is installed on the roof of the cabinet. Used with … Ordering code Kit code Illustration...

  • Page 101: Ac Connection Kits

    Ordering information 101 AC connection kits AC connection kits are used for connecting supply units to AC. Used with … Ordering code Kit code Illustration 400 mm Rittal VX25 and 1 kit per 1×D8D 3AXD50000163274 L-468-8-146 generic and 2×D8D enclosure Instruction code: 3AXD50000164394 400 mm Rittal...

  • Page 102: Charging Kits

    4×ACS880-104LC-0850A-7 (R8i) DC capacitance (< 58 mF). If the total DC link capacitance exceeds these limits, the components must be re-dimensioned. Contact your local ABB representative for more information. The charging kit contains the main parts of the charging circuit. The following table shows the IEC charging kits available for each module type.

  • Page 103: Dc-Side Components

    Ordering information 103 • fuse holders 170H1007 (2 pcs) • normally-open auxiliary contact OA1G10 • mounting frame for auxiliary contacts OSZ4 (1…3×R8i, 4×R8i) • diode bridges SKKD 81/22H4 (3 pcs) • connection busbars (2 pcs) • terminal blocks DBL80 80A (6 pcs) •...

  • Page 104: Dc Busbars (For Rittal Vx25 Enclosures)

    104 Ordering information DC busbars (for Rittal VX25 enclosures) DC busbars provide connection from the module DC output to the common DC bus. Note: The bolts that connect the DC busbars to the DC link are not included in the kits. Used with …...
  • Page 105 Ordering information 105 The manifold kits contain: Inlet and outlet manifolds Inlet and outlet valves Drain valves Nipples for connecting the valves to manifolds Connectors for PA piping Plugs for unused piping connectors Chokes for flow limitation – not used with the ACS880-304LC +A019. You must order the following parts separately as they are not included in the manifold kits: •...

  • Page 106: Piping

    106 Ordering information Piping PA (polyamide) pipe is available in various diameters on 50-meter reels. Refer to the image for application. Item Data Ordering code PA12P40, 22/18 mm, 50 m 3AXD50000441419 PA12P40, 16/13 mm, 50 m 3AXD50000047488 PA11P40, 8/6 mm, 50 m 3AXD50000419302 Not part of standard product offering 1) Use 16/13 mm pipe between the modules and the manifolds.

  • Page 107: Cabinet Fan Support

    Ordering information 107 Cabinet fan support Note: Fans are not included in the kit. Used with … Ordering code Kit code Illustration 400 mm Rittal VX25 and 1 kit per cubicle 3AXD50000513642 L-4-8-402-VX generic enclosure Instruction code: 3AXD50000514830 Cooling fans The cubicle fan is needed for circulating the air inside the cubicle.

  • Page 109: Internal Cooling Circuit

    Each cubicle has an inlet and an outlet manifold, fitted with a stop valve and a drain valve. The stop valves can be closed to isolate all modules in the cubicle from the main cooling circuit. In cabinet line-ups built by ABB, valves are color-coded: • Blue – Open during operation •...
  • Page 110 110 Internal cooling circuit Supply modules. The drawing shows the configuration of a diode supply unit with two modules, ie. there is a common air-to-liquid exchanger in the cubicle. With an IGBT supply unit, each module has a dedicated air-to-liquid exchanger as shown for item 2. Inverter modules To/From cooling unit Air-to-liquid heat exchanger...

  • Page 111: Connection To A Cooling Unit

    Internal cooling circuit 111 Connection to a cooling unit Connection to an ACS880-1007LC cooling unit ￭ Refer to ACS880-1007LC cooling unit user’s manual (3AXD50000129607 [English]). Connection to a custom cooling unit ￭ General requirements Equip the system with an expansion vessel to damp pressure rise due to volume changes when the temperature varies.

  • Page 112: Filling Up And Bleeding The Internal Cooling Circuit

    112 Internal cooling circuit Filling up and bleeding the internal cooling circuit Both the drive and coolant must be at room temperature before filling up the cooling circuit. WARNING! Make sure that the maximum permissible operating pressure is not exceeded. When necessary regulate the pressure to appropriate level by draining excess coolant out of the system.
  • Page 113 Internal cooling circuit 113 Close the bleed valve at the cooling unit. 10. Continue to fill in coolant until a base pressure of 100…150 kPa is achieved. 11. Open the bleed valve of the pump to let out any air. 12.

  • Page 114: Draining The Internal Cooling Circuit

    Coolant type Antifrogen® L (by Clariant International Ltd, www.clariant.com) 25% or 50% mixture, available from Clariant distributors and ABB Service representatives. Note: Do not dilute the coolant. It is ready to use. Antifrogen® L 25% mixture is usable in storage temperatures down to -16 °C (3.2 °F).
  • Page 115 Internal cooling circuit 115 The higher the concentration of heat transfer fluid, the higher the viscosity of the coolant. This results in a higher pressure loss in the system. See Pressure limits (page 116). The nominal current ratings of drive system modules apply to an Antifrogen® L / water solution of 25/75% (volume).

  • Page 116: Pressure Limits

    116 Internal cooling circuit Min. T (°C) coolant (°C) RH = 95% RH = 80% RH = 65% RH = 50% RH = 40% -0.9 -4.5 -7.4 -0.1 -3.0 14.2 11.5 19.2 16.5 13.2 24.1 21.4 17.9 13.8 10.5 29.1 26.2 22.7 18.4...
  • Page 117 Internal cooling circuit 117 Note: PVC hoses are not suitable for use with antifreeze. • rubber gasketing NBR (nitrile rubber). WARNING! If you connect external piping to the internal cooling circuit, use only materials that are specified above. Other materials can cause galvanic corrosion.

  • Page 119: Technical Data

    Technical data 119 Technical data Contents of this chapter This chapter contains the technical data for the supply modules. Ratings Module type No overload use Light overload Heavy-duty use ACS880- 304LC-... max_1 max_2 A (AC) A (DC) A (DC) A (AC) A (DC) A (DC) (DC)

  • Page 120: Derating

    For the coolant temperature derating, see Temperature limits (page 114). Antifreeze content derating For the antifreeze content derating, see Temperature limits (page 114). Altitude derating At altitudes 0…2000 m (6561.7 ft), no derating. For altitudes over 2000 m (6561.7 ft), contact ABB.

  • Page 121: Type Equivalence Table And Frame Sizes

    Technical data 121 Type equivalence table and frame sizes Module type Basic module type Frame size = 690 V ACS880-304LC-0820A-7+A019 ACS880-304LC-0820A-7-A019 1×D8D ACS880-304LC-1540A-7+A019 ACS880-304LC-0820A-7-A019 2×D8D ACS880-304LC-2290A-7+A019 ACS880-304LC-0820A-7-A019 3×D8D ACS880-304LC-3040A-7+A019 ACS880-304LC-0820A-7-A019 4×D8D Fuses AC fuses ￭ For the AC fuse types and ordering codes, see section AC fuses (page 101).

  • Page 122: Free Space Requirements

    122 Technical data Free space requirements Leave 20 mm (0.79 in) free space in front of the module for smooth installation and to enable cooling air flow and also 30 mm (1.18 in) above the module for air flow. Leave also enough space for installing the pipes to the coolant connectors. For a reliable connection, the end of the pipe entering the connector must be completely intact for a length of at least 5 cm (2 in).

  • Page 123: Losses, Cooling Circuit Data And Efficiency

    Technical data 123 Losses, cooling circuit data and efficiency Coolant volume Coolant flow rate Pres- Noise Power Effi- Modules Modules sure Module type level loss ciency Modules Modules loss Frame ACS880- cabinet cabinet 304LC-… l/min (US l (US qt) l (US qt) gal/min) = 690 V 0820A-7+A019...

  • Page 124: Auxiliary Circuit Current Consumption

    124 Technical data Auxiliary circuit current consumption Device Control unit ZCU-14 with options 24 V DC 2.05 Cabinet fan 200…240 V AC 50/60 Cabinet fan 100…130 V AC 50/60 CIO-01 I/O module 24 V DC Definitions Supply frequency Maximum current consumption Nominal current consumption Nominal voltage...

  • Page 125: Tightening Torques

    Technical data 125 Tightening torques Unless a tightening torque is specified in the text, the following torques can be used. Electrical connections ￭ Size Torque Strength class 0.5 N·m (4.4 lbf·in) 4.6...8.8 1 N·m (9 lbf·in) 4.6...8.8 4 N·m (35 lbf·in) 9 N·m (6.6 lbf·ft) 22 N·m (16 lbf·ft) 42 N·m (31 lbf·ft)

  • Page 126: Electrical Power Network Specification

    126 Technical data Electrical power network specification Supply voltage ( U 6-pulse, 12-pulse and 24-pulse supply modules: ACS880-304LC-xxxxx-7+A019: 525 … 690 V AC (525 … 600 V AC for UL/CSA) 3-phase ± 10%. This is indicated in the type designation label as typical input voltage levels 3~525/600/690 V AC (600 V AC for UL/CSA).

  • Page 127: Coolant Connection Data

    Maximum long-term tensile load: 1 N (3.6 ozf) • Flexing: Max. 1000 cycles ABB drive products in general utilize 5 and 10 MBd (megabaud) optical components from Avago Technologies’ Versatile Link range. Note that the optical component type is not directly related to the actual communication speed.
  • Page 128 Altitude above sea level 0 … 2000 m (0 … 6561.7 ft) no derat- ing. For altitudes over 2000 m (6561.7 ft), contact ABB. Air temperature 0 … +45 °C -40 … +70 °C -40 … +70 °C (+32 … +113 °F), no con- (-40 …...

  • Page 129: Cooling

    IEC 62635 guidelines. To aid recycling, plastic parts are marked with an appropriate identification code. Contact your local ABB distributor for further information on environmental aspects and recycling instructions for professional recyclers. End of life treatment must follow international and local regulations. See...
  • Page 130 Notwithstanding any other provision to the contrary and regardless of whether the contract is terminated or not, ABB and its affiliates are under no circumstances liable for damages and/or losses related to such security breaches, any unauthorized access,...

  • Page 131: The Control Unit

    The control unit of D8D modules is a separate unit and it is always installed in the cabinet (on the cabinet wall etc), NOT on the module. For the connections, see chapter Example circuit diagrams (page 153). ABB does not offer ready cables or cable sets for connecting the control unit.

  • Page 132: Zcu-14 Layout

    132 The control unit ZCU-14 layout Description XPOW External power input Analog inputs XRO1 Analog outputs XD2D Drive-to-drive link XRO2 XRO1 Relay output RO1 XRO2 Relay output RO2 XRO3 Relay output RO3 XRO3 XD24 Digital input interlock (DIIL) and +24 V output XPOW XDIO...

  • Page 133: Zcu-14 Default I/O Connection Diagram

    The control unit 133 ZCU-14 default I/O connection diagram The diagram shows the control connections of the supply unit, and the default meaning or use of the signals in the supply unit control program. The wire size accepted by all screw terminals (for both stranded and solid wire) is 0.5 …...
  • Page 134 134 The control unit Terminal Description XD2D Drive-to-drive link SHIELD BGND Not in use by default XSTO Safe torque off Factory connection. Both circuits must be closed for the unit to start (IN1 and IN2 must be connected to OUT). SGND Digital inputs Reset...

  • Page 135: External Power Supply For The Control Unit (Xpow)

    The control unit 135 8) Determines whether DICOM is separated from DIOGND (ie, common reference for digital inputs floats). DICOM connected to DIOGND DICOM and DIOGND separate External power supply for the control unit (XPOW) The control unit is powered from a 24 V DC, 2 A supply through terminal block XPOW. Using an external supply is recommended, if: •...

  • Page 136: Connector Data

    136 The control unit Connector data Power supply (XPOW) Connector pitch 5 mm, wire size 0.5 … 2.5 mm (22…12 AWG) 24 V (±10%) DC, 2 A External power input. Relay outputs RO1…RO3 (XRO1…XRO3) Connector pitch 5 mm, wire size 0.5 … 2.5 mm (22…12 AWG) 250 V AC / 30 V DC, 2 A Protected by varistors...
  • Page 137 The control unit 137 Analog outputs AO1 and AO2 (XAO) Connector pitch 5 mm, wire size 0.5 … 2.5 mm (22…12 AWG) 0…20 mA, R < 500 ohm load Frequency range: 0…300 Hz Resolution: 11 bit + sign bit Inaccuracy: 2% of full scale range XD2D connector Connector pitch 5 mm, wire size 0.5 …...

  • Page 138: Zcu-1X Ground Isolation Diagram

    138 The control unit ZCU-1x ground isolation diagram ￭ XPOW +24VI +VREF -VREF AGND AI1+ Common mode voltage between AI1- AI2+ channels ±30 V AI2- AGND AGND XD2D BGND XRO1, XRO2, XRO3 XD24 DIIL +24VD DICOM +24VD DIOGND XDIO DIO1 DIO2 XSTO OUT1...

  • Page 139: Dimension Drawings

    Dimension drawings 139 Dimension drawings Contents of this chapter This chapter shows dimensions of the supply modules and accessories.

  • Page 140: Liquid-Cooled D8D Module

    140 Dimension drawings Liquid-cooled D8D module Dimensions in mm 1 mm = 0.0394 in...

  • Page 141: Dpmp-01 Mounting Kit

    ACX-AP-x_dimensions control panel with door mount kit.pdf Dimension drawings 155 Dimension drawings 141 ACX-AP-x control panel with door mounting kit DPMP-01 mounting kit 81.0 [3.19] 86.5 [3.41] 123.1 [4.85] 125.0 [4.92]...

  • Page 142: Zcu-14 Control Unit

    142 Dimension drawings ZCU-14 control unit...

  • Page 143: Support Plate For Zcu-14

    Dimension drawings 143 Support plate for ZCU-14...

  • Page 144: Cio-01 Module

    144 Dimension drawings CIO-01 module...

  • Page 145: Ac Fuse 170M6467

    170M6467_fuse dimensions.pdf 158 Dimension drawings Dimension drawings 145 AC fuse 170M6467 AC fuse 170M6467 170M6467_fuse dimensions.pdf 158 Dimension drawings AC fuse 170M6467 ø30 1 mm = 0.0394 in ø30 1 mm = 0.0394 in Microswitch 170H0069 Microswitch 170H0069 Microswitch 170H0069 170H0069_ micro dimensions.pdf Microswitch mounted on the fuse...

  • Page 146: Charging Circuit Components

    Dimension drawings 159 146 Dimension drawings Charging circuit components Charging circuit components OS40FD12000_switch dimensions.pdf Charging switch OS40FD12000 Charging switch OS40FD12000 ￭ EN 50022 14...133 OA 3G01 OSZ 4 OA4B1C OA 1G10 max 1+1 max 3+3 Ø66 75...80 Test 14,3 30,8 27,6 135...210 Dimensions in mm 1 mm = 0.0394 in...

  • Page 147: Contactors

    160 Dimension drawings Dimension drawings 147 Contactors AF16-30-10-13_contactor dimensions.pdf AF16-30-10-13 Contactors ￭ AF16-30-10-13 77 3.03" 71 2.80" 45 1.77" 5.5 0.22" 5.5 0.22" 10 0.39" 35 1.38" ø 4.2 0.17" M4 8-32 UNC Drilling pattern 5 0.20" www.abb.com...

  • Page 148: Af26-30-00-13

    Dimension drawings 161 148 Dimension drawings AF26-30-00-13_contactor dimensions.pdf AF26-30-00-13 AF26-30-00-13 86 3.39" 45 1.77" 80 3.15" 5.5 0.22" 5.5 0.22" 10 0.39" AF26, AF30, AF38 35 1.38" ø 4.2 0.17" M4 8-32 UNC Drilling pattern 5 0.20" www.abb.com AF26, AF30, AF38...

  • Page 149: Fuse Holders

    Dimension drawings 149 166 Dimension drawings Fuse holders ￭ Fuse holders  170H1007 170H1007 www.cooperindustries.com 5.71 1.69 50.5 1.97 www.cooperindustries.com 5.71 1.69 50.5 1.97 Auxiliary contact OA1G10 ￭ Auxiliary contact OA1G10  2×0.75…2.5 mm (2×18…14 AWG) 2×0.75…2.5 mm (2×18…14 AWG) 0.8 N·m (7 lb.in) 0.8 N·m (7 lbf·in) Pozidriv M3.5 Form 2...

  • Page 150: Diode Bridge Skkd 81/22H4

    SKKD 81 22H4_diode bridge dimensions.pdf Dimension drawings 163 150 Dimension drawings Diode bridge SKKD 81/22H4 Diode bridge SKKD 81/22H4 ￭ Dimensions in mm 1 mm = 0.0394 in www.semikron.com...

  • Page 151: Charging Resistor Cbh165 C

    Dimension drawings 151 164 Dimension drawings CBH165 C_resistor dimensions.pdf Charging resistor CBH165 C Charging resistor CBH165 C ￭...

  • Page 153: Example Circuit Diagrams

    (ABB charging kit inside supply unit cubicle) • external 115/230 V AC control and fan supply organized by the cabinet builder • cabinet fan • customer terminal connections (in the circuit diagrams referring to ABB SACE Emax 2 main breaker) • ZCU-14 control unit. Notes: •...

  • Page 154: Component Designations Used In The Diagrams

    154 Example circuit diagrams • understanding the internal connections and operation of the cabinet-installed drive with a diode supply unit, and • learning how to wire a (ACS880-304LC…+A019) diode supply module when installed in a user-defined cabinet. Component designations used in the diagrams The circuit diagrams include: Designation Component...

  • Page 155: Frame 1×D8D - Main Line Connections (Sheet 001A)

    Example circuit diagrams 155 Frame 1×D8D – Main line connections (sheet 001a)

  • Page 156: Frame 1×D8D - Charging Circuit (Sheet 001B)

    156 Example circuit diagrams Frame 1×D8D – Charging circuit (sheet 001b)

  • Page 157: Frame 1×D8D - Auxiliary Voltage Distribution (Sheet 020A)

    Example circuit diagrams 157 Frame 1×D8D – Auxiliary voltage distribution (sheet 020a)

  • Page 158: Frame 1×D8D - 115/230 V Ac Distribution (Sheet 021A)

    158 Example circuit diagrams Frame 1×D8D – 115/230 V AC distribution (sheet 021a)

  • Page 159: Frame 1×D8D - 24 V Dc Distribution (Sheet 022A)

    Example circuit diagrams 159 Frame 1×D8D – 24 V DC distribution (sheet 022a)

  • Page 160: Frame 1×D8D - Cabinet Fans (Sheet 026A)

    160 Example circuit diagrams Frame 1×D8D – Cabinet fans (sheet 026a)

  • Page 161: Frame 1×D8D - Customer Terminals (Sheet 031A)

    Example circuit diagrams 161 Frame 1×D8D – Customer terminals (sheet 031a)

  • Page 162: Frame 1×D8D - Supply Control Board (Sheet 050A)

    162 Example circuit diagrams Frame 1×D8D – Supply control board (sheet 050a)

  • Page 163: Frame 1×D8D - Supply Control Board (Sheet 050B)

    Example circuit diagrams 163 Frame 1×D8D – Supply control board (sheet 050b)

  • Page 164: Frame 1×D8D - Supply Control Board (Sheet 050C)

    164 Example circuit diagrams Frame 1×D8D – Supply control board (sheet 050c)

  • Page 165: Frame 1×D8D - Option Cards (Sheet 051A)

    Example circuit diagrams 165 Frame 1×D8D – Option cards (sheet 051a)

  • Page 166: Frames 2×D8D - Main Line Connections (Sheet 001A)

    166 Example circuit diagrams Frames 2×D8D – Main line connections (sheet 001a)

  • Page 167: Frames 2×D8D - Charging Circuit (Sheet 001B)

    Example circuit diagrams 167 Frames 2×D8D – Charging circuit (sheet 001b)

  • Page 168: Frames 2×D8D - Auxiliary Voltage Distribution (Sheet 020A)

    168 Example circuit diagrams Frames 2×D8D – Auxiliary voltage distribution (sheet 020a)

  • Page 169: Frames 2×D8D - 115/230 V Ac Distribution (Sheet 021A)

    Example circuit diagrams 169 Frames 2×D8D – 115/230 V AC distribution (sheet 021a)

  • Page 170: Frames 2×D8D - 24 V Dc Distribution (Sheet 022A)

    170 Example circuit diagrams Frames 2×D8D – 24 V DC distribution (sheet 022a)

  • Page 171: Frames 2×D8D - Cabinet Fan (Sheet 026A)

    Example circuit diagrams 171 Frames 2×D8D – Cabinet fan (sheet 026a)

  • Page 172: Frames 2×D8D - Customer Terminals (Sheet 031A)

    172 Example circuit diagrams Frames 2×D8D – Customer terminals (sheet 031a)

  • Page 173: Frames 2×D8D - Supply Control Board (Sheet 050A)

    Example circuit diagrams 173 Frames 2×D8D – Supply control board (sheet 050a)

  • Page 174: Frames 2×D8D - Supply Control Board (Sheet 050B)

    174 Example circuit diagrams Frames 2×D8D – Supply control board (sheet 050b)

  • Page 175: Frames 2×D8D - Supply Control Board (Sheet 050C)

    Example circuit diagrams 175 Frames 2×D8D - Supply control board (sheet 050c)

  • Page 176: Frames 2×D8D - Option Cards (Sheet 051A)

    176 Example circuit diagrams Frames 2×D8D – Option cards (sheet 051a)

  • Page 177: Further Information

    Product and service inquiries Address any inquiries about the product to your local ABB representative, quoting the type designation and serial number of the unit in question. A listing of ABB sales, support and service contacts can be found by navigating to www.abb.com/searchchannels.
  • Page 178 3AXD50000045157C © Copyright 2022 ABB. All rights reserved. Specifications subject to change without notice.

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