ABB ACS880-204 Hardware Manual
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ABB ACS880-204 Hardware Manual

Igbt supply module
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ACS880-204 IGBT supply modules
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Summary of Contents for ABB ACS880-204

  • Page 1 — ABB INDUSTRIAL DRIVES ACS880-204 IGBT supply modules Hardware manual...
  • Page 3 ACS880-204 IGBT supply modules Hardware manual Table of contents 5. Electrical installation 7. Start-up © 2019 ABB Oy. All Rights Reserved. 3AUA0000131525 Rev H EFFECTIVE: 2019-06-30...

  • Page 5: Table Of Contents

    Table of contents 5 Table of contents 1 Introduction to the manual Contents of this chapter ................Applicability ..................Safety instructions ................Target audience ................... Categorization by frame size and option code ..........Use of component designations ..............Terms and abbreviations ................. Related documents ................
  • Page 6 Frames R1i…R4i ................Frame R6i ..................Frame R8i ..................Cabinet configuration overview ..............ACS880-204 configurations in Rittal VX25 enclosures ........ACS880-204 configurations in generic enclosures ........IGBT supply unit with frame R1i…R4i module ..........IGBT supply unit with frame R6i module ...........
  • Page 7 Table of contents 7 Kits for R8i module in 600 mm Rittal VX25 enclosure ........ Stage 1: Installation of common parts ..........Stage 2: Module installation parts ............Stage 3: BLCL AC busbars and quick connectors ........Stage 4: DC connection ..............Stage 5: Common mode filter busbars and DC connection flanges ....
  • Page 8 8 Table of contents Connection diagram (frame 1×R8i) ............Connection diagram (frame R8i multiples) ..........Connection procedure (frames R1i…R4i) ..........Frame R1i ................... Frame R2i ................... Frames R3i and R4i (connector covers removed) ........Connection procedure (frame R6i) ............Connection procedure (frame R8i) ............Connecting the LCL filter ................
  • Page 9 Replacing the fan of the LCL filter (BLCL-1x-x) ........... Replacing the fan of the LCL filter (BLCL-2x-x) ........... Replacing the cabinet cooling fans ............Cabinets with ABB air outlet kits ............Cabinets with other fan types ............IGBT supply module ................
  • Page 10 10 Table of contents Fuse bases for AC fuses (UL, CSA) ........... EMC/RFI filter ................Main contactors ................DC-side components ................. DC bus installation parts (for Rittal VX25 enclosures) ....... DC fuses ..................Fuse bases for DC fuses (IEC, UL, CSA) ..........Frame R6i ..................
  • Page 11 Table of contents 11 Main contactors ................Charging kits ................Varistor kit ACS880 for UL/CSA installations .......... AC connection of the LCL filter ............Busbars and quick connectors ............Quick connector ................DC-side components ................. DC bus installation parts (for Rittal VX25 enclosures) ....... DC busbars .................
  • Page 12 12 Table of contents Cable lugs ..................Typical power cable sizes ............... Electrical power network specification ............DC connection data ................Control unit connection data (ZCU/BCU) ............Efficiency ................... Protection classes ................Optical components ................Ambient conditions ................Materials ................... Auxiliary circuit current consumption ............
  • Page 13 Table of contents 13 Quick connector .................. Main switch-disconnector ................ R1i…R4i ..................OS160GD03 (IEC) ................ OT160E3 (UL, CSA) ..............R6i ....................OS400D03 (IEC) ................OS400J03 (UL, CSA) ..............R8i ....................OT1000E03 (IEC), OT1200U03 (UL, CSA) ........... OT2000E12 (IEC) ................. OT1250E12 (IEC) ................. OT1200U12 (UL, CSA) ..............
  • Page 14 14 Table of contents Fuse, 27 × 60 mm (IEC, UL, CSA) ............. Mersen (Ferraz-Shawmut) US271MI (R227600C) fuse disconnector (for 27 × 60 mm fuses) (IEC, UL, CSA) ............... R6i ....................170M4413 (IEC, UL, CSA) ............... R8i ....................170M6413, 170M6415, 170M6417, 170M6419 (IEC, UL, CSA) ....170M6544, 170M6546, 170M6549 (IEC, UL, CSA) .........

  • Page 15: Introduction To The Manual

    Introduction to the manual Contents of this chapter This chapter gives basic information on the manual. Applicability The manual is applicable to the ACS880-204 IGBT supply modules for user-defined cabinet installations. Safety instructions Follow all safety instructions delivered with the drive.

  • Page 16: Categorization By Frame Size And Option Code

    The module size can be identified from the basic code visible on the type designation label, for example, ACS880-204-0420A-3 where 0420A is the module size. The option codes of the module are listed after the plus sign.

  • Page 17: Related Documents

    Drive modules cabinet design and construction instructions 3AUA0000107668 BCU-02/12/22 control units hardware manual 3AUA0000113605 Supply module manuals ACS880-204 IGBT supply modules hardware manual 3AUA0000131525 ACS880 IGBT supply control program firmware manual 3AUA0000131562 ACS880 multidrives, Optimal grid control (option +N8053) supplement...
  • Page 18 Installation frames for ACS880 multidrive modules hardware manual 3AXD50000010531 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 19: Operation Principle And Hardware Description

    Contents of this chapter This chapter describes how the IGBT supply unit works and also the hardware of the ACS880-204 IGBT supply module. Operation principle IGBT supply unit rectifies three-phase AC current to direct current for the intermediate DC link of the drive.

  • Page 20: Simplified Main Circuit Diagram

    20 Operation principle and hardware description ￭ Simplified main circuit diagram The following figure shows the simplified main circuit diagram of the rectifier. AC voltage AC fuses LCL filter IGBT supply module DC fuses DC voltage ￭ Charging A charging circuit powers up the DC link capacitors of the drive system smoothly. Discharged capacitors cannot be directly connected to the full supply voltage.

  • Page 21: Overview Diagram Of The Drive System

    Operation principle and hardware description 21 Overview diagram of the drive system The following figure shows a simplified diagram of a common DC bus drive system. AC supply Input AC fuses LCL filter IGBT supply unit Supply unit DC fuses DC bus Inverter DC fuses (with or without DC switch-disconnector) Inverter units (in the example, one of the two units consists of two inverter modules connected in parallel)

  • Page 22: Single-Line Circuit Diagrams Of The Supply Unit

    They also indicate if the components can be ordered from ABB or if the customer needs to acquire them separately. customer can order the components from ABB or if the customer needs to acquire them For components, see the ordering information.

  • Page 23: Frame R6I

    The following figure shows a connection example of a supply unit with a frame size R6i module. module. AC supply network Cubicle Explanation Available through IGBT supply module cubicle Main switch-disconnector ABB or third party (ISU) AC supply network Charging switch-fuse ABB or third party IGBT supply Main switch-disconnector ABB or third party module cubicle...

  • Page 24: Frame 1×R8I

    The following figure shows a connection example of a supply unit with one frame R8i module. The following figure shows a connection example of a supply unit with one frame R8i module. AC supply network Incoming cubicle (ICU) Main switch-disconnector ABB or third party Cubicle Explanation Available through AC fuses ABB or third party...

  • Page 25: Frame R8I Multiples

    (2×8i). modules (2×R8i). AC supply network Cubicle Explanation Available through Incoming cubicle (ICU) Main switch-disconnector ABB or third party AC supply network Incoming Main switch-disconnector ABB or third party AC fuses ABB or third party cubicle (ICU) AC fuses...

  • Page 26: Igbt Supply Module Hardware

    26 Operation principle and hardware description 28 Operation principle and hardware description IGBT supply module hardware Layout drawings The following figures show the layout of the IGBT supply modules and LCL filters. The following figures show the layout of the IGBT supply modules and LCL filters. ￭...

  • Page 27: Frame R4I Layout

    Operation principle and hardware description 27 Operation principle and hardware description 29 ￭ Frame R4i layout IGBT supply module (frames R3i and R4i)  Frame R4i is pictured (frame R3i has a similar layout). Frame R4i is pictured (frame R3i has a similar layout). Item Explanation DC (output) connection (under connector cover)

  • Page 28: Frame R6I Layout

    30 Operation principle and hardware description 28 Operation principle and hardware description IGBT supply module (frame R6i)  ￭ Frame R6i layout Item Explanation Item Explanation DC connection AC connection DC (output) connection ZCU control unit (with slots for optional I/O modules) AC (input) connection I/O terminal blocks ZCU control unit (with slots for optional I/O...

  • Page 29: Frame R8I Hardware

    Operation principle and hardware description 29 ￭ Frame R8i hardware Frame R8i modules are used in single or parallel configurations. R8i modules run on wheels, and can easily be removed from the cubicle for cable installation or service. The quick connector at the back of the module couples when the module is inserted into the cubicle.
  • Page 30 30 Operation principle and hardware description This figure shows the layout of the R8i module. R8i module, front R8i module, back DC busbars Handle LEDs and fiber optic connectors Fan (standard speed-controlled fan shown; a direct-on-line fan is available as option +C188) Quick connector (three phases).

  • Page 31: Connectors X50

    Operation principle and hardware description 31 ￭ Connectors X50…X53 The cabinet builder must arrange an auxiliary voltage of 230 V AC (or 115 V AC with option +G304) to connector X50 to power the electronics of the power module. Also, the cabinet builder must arrange an auxiliary voltage of 230 V AC to connector X50 to power the main circuit interface board of the module during charging.
  • Page 32 32 Operation principle and hardware description Connectors X51, X52, X53 STO IN STO connectors of the mod- STO IN ule. Must be connected to 24 V DC for the module to start. 24V OUT 24 V DC for BCU and for 24V OUT STO IN to enable the mod- ule operation.

  • Page 33: Lcl Filter Module (Filter For Frames R1I

    34 Operation principle and hardware description Operation principle and hardware description 33 LCL filter module (filter for frames R1i…R4i)  ￭ LCL filter module (filter for frames R1i…R4i) WFU-xx Input terminals Cooling fan LCL filter Connector X102 Description Connector X103 Input terminals Pre-wired output cable Cooling fan...

  • Page 34: Connectors X102 And X103

    34 Operation principle and hardware description Operation principle and hardware description 35 Connectors X102 and X103 Connectors X102 and X103 WFU-xx module connector X102 Description WFU-xx module connector X102 Description Fan power supply, 24 V / 0 V Fan power supply, 24 V / 0 V WFU-xx module connector X103 Description WFU-xx module connector X103...

  • Page 35: Lcl Filter Module (Type Alcl-05-5 For Frame R6I)

    36 Operation principle and hardware description LCL filter module (type ALCL-05-5 for frame R6i)  Operation principle and hardware description 35 ￭ LCL filter module (type ALCL-05-5 for frame R6i) Input (AC) connection Output (AC) connection Cooling fan Terminal block X50 (power supply for module fan and temperature switch) Description Input (AC) connection Output (AC) connection...

  • Page 36: Connectors X50 And X1

    36 Operation principle and hardware description Connectors X50 and X1 ALCL-05-5 module connector X50 Description DOL fan L (230 V AC or option +G304: 115 V AC) DOL fan N (230 V AC or option +G304: 115 V AC) Temperature switch in Not in use Not in use Not in use...

  • Page 37: Lcl Filter Module (Type Blcl-1X-X For Frame 1×R8I)

    Operation principle and hardware description 37 38 Operation principle and hardware description ￭ LCL filter module (type BLCL-1x-x for frame 1×R8i) LCL filter module (type BLCL-1x-x for frame 1×R8i)  LCL filter module, front LCL filter module, back Description Input (AC) connection LCL filter module, front Output (AC) connection LCL filter module, back...

  • Page 38: Connectors X30 And X55

    38 Operation principle and hardware description Connectors X30 and X55 Connector X30 Description +C183: Heating element N (230 V AC or 115 V AC) +C183: Heating element L (230 V AC or 115 V AC) Not in use TP2, thermal cutoff circuit TP1, thermal cutoff circuit Not in use Not in use...

  • Page 39: Lcl Filter Module (Type Blcl-2X-X For Frame R8I Multiples)

    Operation principle and hardware description 39 40 Operation principle and hardware description ￭ LCL filter module (type BLCL-2x-x for frame R8i multiples) LCL filter module (type BLCL-2x-x for frame R8i multiples)  LCL filter module, front LCL filter module, back Description Input (AC) connection LCL filter module, front...

  • Page 40: Connectors X30 And X55

    40 Operation principle and hardware description Connectors X30 and X55 Connector X30 Description +C183: Heating element N (230 V AC or 115 V AC) +C183: Heating element L (230 V AC or 115 V AC) Not in use TP2, thermal cutoff circuit TP1, thermal cutoff circuit Not in use +C188: DOL fan W...

  • Page 41: Control Interfaces

    Operation principle and hardware description 41 Control interfaces ￭ Overview of control connections of ZCU-14 control unit It is possible to: • control the unit through the control panel and the fieldbus 26 Operation principle and hardware description • read the status information of the supply unit through the control panel, fieldbus and Overview of control connections of the control unit relay output.

  • Page 42: Overview Of The Control Connections Of The Bcu Control Unit

    42 Operation principle and hardware description ￭ Overview of the control connections of the BCU control unit The diagram shows the control connections and interfaces of the BCU control unit. Analog and digital I/O extension modules and Control panel. fieldbus communication modules can be inserted into slots 1, 2 and 3.

  • Page 43: Supply Unit Control Devices

    Operation principle and hardware description 43 Supply unit control devices ￭ Main disconnecting device You must equip the supply unit with a main disconnecting device. You can use either a main switch-disconnector [Q1.1] or a withdrawable main breaker [Q1]. With this switch, you can isolate the main circuit of the drive from the power line.

  • Page 44: Pc Connection

    44 Operation principle and hardware description • view actual signals • change parameter settings • change between local and external control. To be able to start and stop the unit by the control panel, you must have the parameter-defined Run enable signal and Start enable signal on (1). The control panel must also be in local control mode.

  • Page 45: Type Designation Labels Of The Supply Module And Lcl Filter Module

    Operation principle and hardware description 45 Type designation labels of the supply module and LCL filter module Each IGBT supply module and LCL filter module has a type designation label attached to it. The type designation stated on the label contains information on the specifications and configuration of the unit.

  • Page 46: Type Designation Key

    IGBT supply module Type designation describes the composition of the module in short. Note that in the type designation label of an IGBT supply module (ACS880-204), the type of the module is ACS880-104. The complete designation code is divided in subcodes: •...

  • Page 47: Lcl Filter

    Operation principle and hardware description 47 ￭ LCL filter CODE DESCRIPTION Basic codes LCL filter for frames R1i…R4i IGBT supply modules. The delivery includes direct-on-line cooling fan as standard. ALCL LCL filter for frame R6i IGBT supply module. The delivery includes direct-on-line cooling fan as standard.

  • Page 49: Moving And Unpacking The Module

    Moving and unpacking the module 49 Moving and unpacking the module Contents of this chapter This chapter gives basic information on moving, unpacking and lifting the modules. WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur.

  • Page 50: Frames R6I

    50 Moving and unpacking the module ￭ Frames R6i…R8i The module is delivered on a wooden base, boxed in corrugated cardboard. The cardboard box is tied to the base with PET bands. 1. Cut off the bands. 2. Lift off the cardboard box. 3.

  • Page 51: Cabinet Construction

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

  • Page 52: Frame R6I

    52 Cabinet construction ￭ Frame R6i The switching, disconnecting and protecting equipment can be placed inside the drive cabinet in the following way: 1. The AC supply coming to the drive cabinet is first connected to the main switch-disconnector [Q1] containing AC fuses. 2.

  • Page 53: Cabinet Configuration Overview

     ￭ ACS880-204 configurations in Rittal VX25 enclosures The following figures show examples of ACS880-204 configurations that can be installed The following figures show examples of ACS880-204 configurations that can be installed in the Rittal TS 8 enclosure. in the Rittal VX25 enclosure.

  • Page 54: Acs880-204 Configurations In Generic Enclosures

    ACS880-204 configurations in generic enclosures ACS880-204 configurations in generic enclosures  The following figures show examples of ACS880-204 configurations that can be installed The following figures show examples of ACS880-204 configurations that can be installed in generic enclosure. in generic enclosure.

  • Page 55: Igbt Supply Unit With Frame R1I

    Cabinet construction 55 Cabinet construction 55 IGBT supply unit with frame R1i…R4i module  ￭ IGBT supply unit with frame R1i…R4i module The following figure shows an example of the R1i module in 400 mm wide Rittal TS 8 enclosure. The power cables are routed to the cabinet through the bottom. The following figure shows an example of the R1i module in 400 mm wide Rittal VX25 enclosure.

  • Page 56: Igbt Supply Unit With Frame R6I Module

    56 Cabinet construction IGBT supply unit with frame R6i module  56 Cabinet construction The following figure shows an example of the R6i module in 600 mm wide Rittal TS 8 enclosure. The power cables are routed to the cabinet through the bottom. ￭...

  • Page 57: Igbt Supply Unit With Frame R8I Module

    Cabinet constructio IGBT supply unit with frame R8i module  Cabinet construction 57 The following figure shows an example of the 1×R8i module in 600 mm wide Rittal TS enclosure. The customer must place the control equipment in a separate cabinet. ￭...

  • Page 58: Igbt Supply Unit With Frame 2×R8I Modules

    58 Cabinet construction 58 Cabinet construction IGBT supply unit with frame 2×R8i modules  ￭ IGBT supply unit with frame 2×R8i modules The following figure shows an example of the 2×R8i modules in 1000 mm wide Rittal TS 8 enclosure. The customer must place the control equipment in a separate cabinet. The following figure shows an example of the 2×R8i modules in 1000 mm wide Rittal VX25 enclosure.

  • Page 59: Incoming Cubicle

    Cabinet construction 59 ￭ Incoming cubicle Example of the AC fuse cooling The AC fuses must be cooled by forced cooling. If the fuses are not located in the same cubicle with the supply/rectifier module, the module cooling fan does not supply the cooling air for the fuses but you must use a separate cooling fan.

  • Page 60: Rfi Filter

    60 Cabinet construction Cabinet construction 61 RFI filter  ￭ RFI filter The following figure shows an example of installing RFI filter to the cabinet. For more The following figure shows an example of installing RFI filter to the cabinet. For more information about EMC requirements, see Electrical planning instructions for ACS880 information about EMC requirements, see Electrical planning instructions for ACS880 multidrive cabinets and modules (3AUA0000102324 [English]).

  • Page 61: Installation Examples

    You can find the kit-specific assembly drawings, step-by-step instructions and kit information on the 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 62: Kits For R1I

    62 Cabinet construction Kits for R1i…R4i modules...

  • Page 63: Example 1

    Cabinet construction 63 Example 1...

  • Page 64: Example 2

    64 Cabinet construction Example 2...

  • Page 65: R6I Module In A 600 Mm Wide Rittal Vx25 Enclosure

    Cabinet construction 65 ￭ R6i module in a 600 mm wide Rittal VX25 enclosure Installation stages Installation stage Instruction code Kit code Kit ordering code Installation of common parts: Baying parts 3AXD50000336340 PE busbar [PE] 3AXD50000336104 Divider panel 3AXD50000336692 Common DC Flat-PLS assembly 3AXD50000333639 A-468-X-001- 3AXD50000333387...

  • Page 66: Kits For R6I Module In 600 Mm Rittal Vx25 Enclosure

    66 Cabinet construction Kits for R6i module in 600 mm Rittal VX25 enclosure...

  • Page 67: Stage 1: Installation Of Common Parts

    Cabinet construction 67 Stage 1: Installation of common parts...

  • Page 68: Stage 2: Rittal Supports Installation

    68 Cabinet construction Stage 2: Rittal supports installation...

  • Page 69: Stage 3: Dc Kit Installation

    Cabinet construction 69 Stage 3: DC kit installation...

  • Page 70: Stage 4: Switching And Charging Installation

    70 Cabinet construction Stage 4: Switching and charging installation...

  • Page 71: Stage 5: Ac Supply, Varistor Board Location And Emc Shield Examples

    Cabinet construction 71 Stage 5: AC supply, varistor board location and EMC shield examples...

  • Page 72: Stage 6: Module Installation Parts

    72 Cabinet construction Stage 6: Module installation parts...

  • Page 73: Stage 7: Cabling Example For Main Cabling, Charging Cabling And Ground Cabling

    Cabinet construction 73 Stage 7: Cabling example for main cabling, charging cabling and ground cabling...

  • Page 74: Stage 8: Shroud Installation Parts

    74 Cabinet construction Stage 8: Shroud installation parts...

  • Page 75: 1×R8I Module In A 600 Mm Wide Rittal Vx25 Enclosure

    Cabinet construction 75 ￭ 1×R8i module in a 600 mm wide Rittal VX25 enclosure Installation stages Installation stage Instruction code Kit code Kit ordering code Installation of common parts: Baying parts 3AXD50000336340 PE busbar [PE] 3AXD50000336104 Divider panel 3AXD50000336692 Common AC Flat-PLS assembly 3AXD50000372782 A-468-X-011- 3AXD50000360772...

  • Page 76: Kits For R8I Module In 600 Mm Rittal Vx25 Enclosure

    76 Cabinet construction Kits for R8i module in 600 mm Rittal VX25 enclosure...

  • Page 77: Stage 1: Installation Of Common Parts

    Cabinet construction 77 Stage 1: Installation of common parts...

  • Page 78: Stage 2: Module Installation Parts

    78 Cabinet construction Stage 2: Module installation parts...

  • Page 79: Stage 3: Blcl Ac Busbars And Quick Connectors

    Cabinet construction 79 Stage 3: BLCL AC busbars and quick connectors...

  • Page 80: Stage 4: Dc Connection

    80 Cabinet construction Stage 4: DC connection...

  • Page 81: Stage 5: Common Mode Filter Busbars And Dc Connection Flanges

    Cabinet construction 81 Stage 5: Common mode filter busbars and DC connection flanges...

  • Page 82: Stage 6: Blcl Ac Connection

    82 Cabinet construction Stage 6: BLCL AC connection...

  • Page 83: Stage 7: Shroud Installation Parts

    Cabinet construction 83 Stage 7: Shroud installation parts...

  • Page 84: Stage 8: Module Installation

    84 Cabinet construction Stage 8: Module installation...

  • Page 85: 1×R8I Module In A 600 Mm Wide Generic Enclosure

    DC connection flanges 3AXD50000003403 A-468-8-232 3AXD50000003411 DC kit for fuses 3AXD50000025693 A-468-8-245 3AXD50000025659 1) This kit is not included in ABB’s standard design but may be used if you wish to have AC fuses on top of the LCL filter module.
  • Page 86 86 Cabinet construction...

  • Page 87: 2×R8I Modules In A 1000 Mm Wide Rittal Vx25 Enclosure

    Cabinet construction 87 ￭ 2×R8i modules in a 1000 mm wide Rittal VX25 enclosure Installation stages Installation stage Instruction code Kit code Kit ordering code Installation of common parts: Baying parts 3AXD50000336340 PE busbar [PE] 3AXD50000336104 Divider panel 3AXD50000336692 Common AC Flat-PLS assembly 3AXD50000372782 A-468-X-011- 3AXD50000360772...

  • Page 88: Kits For 2×R8I Modules In 1000 Mm Rittal Vx25 Enclosure

    88 Cabinet construction Kits for 2×R8i modules in 1000 mm Rittal VX25 enclosure...

  • Page 89: Stage 1: Installation Of Common Parts

    Cabinet construction 89 Stage 1: Installation of common parts...

  • Page 90: Stage 2: Module Installation Parts

    90 Cabinet construction Stage 2: Module installation parts...

  • Page 91: Stage 3: Rear Ac Busbars And Quick Connectors

    Cabinet construction 91 Stage 3: Rear AC busbars and quick connectors...

  • Page 92: Stage 4: Blcl Ac Busbars And Ac Flanges

    92 Cabinet construction Stage 4: BLCL AC busbars and AC flanges...

  • Page 93: Stage 5: Dc Connection

    Cabinet construction 93 Stage 5: DC connection...

  • Page 94: Stage 6: Common Mode Filter Busbars And Dc Connection Flanges

    94 Cabinet construction Stage 6: Common mode filter busbars and DC connection flanges...

  • Page 95: Stage 7: Shroud Installation Parts

    Cabinet construction 95 Stage 7: Shroud installation parts...

  • Page 96: Stage 8: Modules Installation

    96 Cabinet construction Stage 8: Modules installation...

  • Page 97: 2×R8I Modules In An 800 Mm Wide Generic Enclosure

    Cabinet construction 97 ￭ 2×R8i modules in an 800 mm wide generic enclosure Parts to be installed Parts to be installed Instruction code Kit code Kit ordering code Module installation parts 3AXD50000013143 A-8-8-325 3AXD50000011158 Quick connectors 3AUA0000118667 A-468-8-100 3AUA0000119227 AC busbars 3AXD50000013187 A-8-8-144 3AXD50000011156...
  • Page 98 98 Cabinet construction...

  • Page 99: 3×R8I Modules In A 1600 Mm Wide Rittal Vx25 Enclosure

    Cabinet construction 99 ￭ 3×R8i modules in a 1600 mm wide Rittal VX25 enclosure Installation stages Installation stage Instruction code Kit code Kit ordering code Installation of common parts: Baying parts 3AXD50000336340 PE busbar [PE] 3AXD50000336104 Divider panel 3AXD50000336692 Common AC Flat-PLS assembly 3AXD50000372782 A-468-X-011- 3AXD50000360772...

  • Page 100: Kits For 3×R8I Modules In 1600 Mm Rittal Vx25 Enclosure

    100 Cabinet construction Kits for 3×R8i modules in 1600 mm Rittal VX25 enclosure...

  • Page 101: Stage 1: Installation Of Common Parts

    Cabinet construction 101 Stage 1: Installation of common parts...

  • Page 102: Stage 2: Module Installation Parts

    102 Cabinet construction Stage 2: Module installation parts...

  • Page 103: Stage 3: Blcl Rear Ac Busbars And Quick Connectors

    Cabinet construction 103 Stage 3: BLCL rear AC busbars and quick connectors...

  • Page 104: Stage 4: Blcl Top Ac Busbars And Ac Flanges

    104 Cabinet construction Stage 4: BLCL top AC busbars and AC flanges...

  • Page 105: Stage 5: Dc Connection

    Cabinet construction 105 Stage 5: DC connection...

  • Page 106: Stage 6: Common Mode Filter Busbars And Dc Connection Flanges

    106 Cabinet construction Stage 6: Common mode filter busbars and DC connection flanges...

  • Page 107: Stage 7: Shroud Installation Parts

    Cabinet construction 107 Stage 7: Shroud installation parts...

  • Page 108: Stage 8: Modules Installation

    108 Cabinet construction Stage 8: Modules installation...

  • Page 109: 3×R8I Modules In A 1400 Mm Wide Generic Enclosure

    Cabinet construction 109 ￭ 3×R8i modules in a 1400 mm wide generic enclosure Parts to be installed Parts to be installed Instruction code Kit code Kit ordering code Module installation parts A-6-8-326 3AXD50000011159 A-8-8-327 3AXD50000011160 Quick connectors 3AUA0000118667 A-468-8-100 3AUA0000119227 AC busbars A-X-8-145 3AXD50000011157...
  • Page 110 110 Cabinet construction...

  • Page 111: Electrical Installation

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

  • Page 112: Electrical Safety Precautions

    112 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 electrician, do not do installation or maintenance work.

  • Page 113: General Notes

    The RFI filter is not suitable for use in IT (ungrounded) systems. Disconnect the filter before connecting the drive to the supply network. For instructions on how to do this, contact your local ABB representative. WARNING! If a drive with an RFI filter is installed on an IT system (an ungrounded power system), the system will be connected to earth potential through the filter capacitors of the drive.

  • Page 114: Connecting The Input Power Cables

    114 Electrical installation Connecting the input power cables ￭ Connection diagram (frames R1i…R4i) IGBT filter adapter filter supply module (1a) (1b) ISU cubicle (1b) (1a) Note: If the LCL filter is mounted onto the WBCA adapter, the LCL filter can be grounded through the fastening screws of the WBCA adapter (no additional grounding conductors are needed).

  • Page 115: Connection Diagram (Frame R6I)

    Electrical installation 115 ￭ Connection diagram (frame R6i) LCL filter IGBT supply module (1a) Components for charging circuit (1b) ISU cubicle (1a) (1b) Note: Use a separate grounding PE cable (1a) or a cable with a separate PE conductor (1b) in addition if the conductivity of the shields does not meet the requirement for the PE conductor.

  • Page 116: Connection Diagram (Frame 1×R8I)

    116 Electrical installation ￭ Connection diagram (frame 1×R8i) LCL filter IGBT supply module (1a) Components for charging circuit (1b) ICU cubicle ISU cubicle (1b) (1a) Note: Use a separate grounding PE cable (1a) or a cable with a separate PE conductor (1b) in addition if the conductivity of the shields does not meet the requirement for the PE conductor.

  • Page 117: Connection Diagram (Frame R8I Multiples)

    Electrical installation 117 ￭ Connection diagram (frame R8i multiples) IGBT supply modules LCL filter Components (1a) for charging circuit (1b) ISU cubicle ICU cubicle ISU cubicle (1b) (1a) Note: Use a separate grounding PE cable (1a) or a cable with a separate PE conductor (1b) in addition if the conductivity of the shields does not meet the requirement for the PE conductor.

  • Page 118: Connection Procedure (Frames R1I

    118 Electrical installation ￭ Connection procedure (frames R1i…R4i) Electrical installation 121 WARNING! Read the safety instructions given in Safety instructions for ACS880 Connection procedure (frames R1i…R4i)  multidrive cabinets and modules (3AUA0000102301 [English]). If you ignore them, injury or death, or damage to the equipment can occur. WARNING! Repeat the steps described in section Electrical safety precautions...
  • Page 119 Electrical installation 119 Note: When the internal EMC filter is disconnected, the IGBT supply module is not EMC compatible. WARNING! If a supply module whose varistors are not disconnected is installed on an IT system (an ungrounded power system or a high resistance grounded [over 30 ohms] power system), the system is connected to earth potential through the varistors of the supply module.

  • Page 120: Frame R1I

    120 Electrical installation Electrical installation 123 Frame R1i Frame R1i 1.5 N·m (13 lbf·in) 0.5 … 0.6 N·m (4.4 … 5.3 lbf·in) 0.5 … 0.6 N·m (4.4 … 5.3 lbf·in) 1.5 N·m (13 lbf·in) DC output cable Cable clamp on bare shield, 1.5 N·m (13 lbf·in) Below cable clamp, cover bare shield with insulating tape Above cable clamp, cover bare shield with insulating tape Cable clamp on bare shield, 1.5 N·m (13 lbf·in)

  • Page 121: Frame R2I

    Electrical installation 121 124 Electrical installation Frame R2i Frame R2i 1.5 N·m (13 lbf·in) UDC+UDC- 1.2…1.5 N·m (10.6…13.3 lbf·in) 1.5 N·m (13 lbf·in) DC output cable Cable clamp on bare shield, 1.5 N·m (13 lbf·in) Below cable clamp, cover bare shield with insulating tape Above cable clamp, cover bare shield with insulating tape Cable clamp on bare shield, 1.5 N·m (13 lbf·in) AC input cable (from WFU-xx)

  • Page 122: Frames R3I And R4I (Connector Covers Removed)

    122 Electrical installation Electrical installation 125 Frames R3i and R4i (connector covers removed) Frames R3i and R4i (connector covers removed) 3 N·m (25 lbf·in) UDC+ 15 N·m (130 lbf·in) 3 N·m (25 lbf·in) U1 V1 W1 UDC+ UDC- UDC+ U2 V2 W2 R- R+ 3 N·m (25 lbf·in) 15 N·m (130 lbf·in)
  • Page 123 Electrical installation 123 Direct lug connection Screw lug detail Direct lug connection Instead of using the screw lugs included, the conductors of power 126 Electrical installation Instead of using the screw lugs included, the conduct- cables can be connected to the drive ors of power cables can be connected to the drive ter- terminals by removing the screw lugs and using crimp lugs.

  • Page 124: Connection Procedure (Frame R6I)

    124 Electrical installation ￭ Connection procedure (frame R6i) WARNING! Read the safety instructions given in Safety instructions for ACS880 multidrive cabinets and modules (3AUA0000102301 [English]). If you ignore them, injury or death, or damage to the equipment can occur. 1. Stop the drive and do the steps in section Electrical safety precautions (page 112) before you start the work.

  • Page 125: Connection Procedure (Frame R8I)

    Electrical installation 125 Note that figure 2 is an example of a cable lead-through that has to be acquired by the customer. ￭ Connection procedure (frame R8i) WARNING! Read the safety instructions given in Safety instructions for ACS880 multidrive cabinets and modules (3AUA0000102301 [English]). If you ignore them, injury or death, or damage to the equipment can occur.
  • Page 126 126 Electrical installation 2. Lead the cables into the inside of the cabinet. 360° grounding of the cable shield at the lead-through is recommended to suppress interference. 3. Twist the cable shields to bundles and connect to the cabinet PE (ground) busbar. Connect the separate ground conductors/cables to the cabinet PE (ground) busbar.
  • Page 127 Electrical installation 127 6. AC input of the LCL filter module BLCL-1x-x BLCL-2x-x BLCL-2x-x...
  • Page 128 Electrical installation 131 128 Electrical installation AC output of the LCL filter module 7. AC output of the LCL filter module BLCL-1x-x BLCL-2x-x...
  • Page 129 Electrical installation 129 BLCL-2x-x...

  • Page 130: Connecting The Lcl Filter

    For selecting a supply, see the auxiliary circuit current consumption in the technical data. WARNING! Use the LCL filter only with an ACS880-204 IGBT supply module. Use the filter only with an IGBT supply module of an appropriate frame size. WARNING!

  • Page 131: Connecting The Wbca Adapter To The Lcl Filter (Frames R1I

    Electrical installation 131 ￭ Connecting the WBCA adapter to the LCL filter (frames R1i…R4i) Connect the cable (included) of the WBCA adapter to the L1/L2/L3 input terminals of the WFU-xx LCL filter module. Connect the power input to the L1/L2/L3/PE terminals of the WBCA adapter. Tightening torques: WFU-01: 1.7…1.8 N·m WFU-11, -21, -22: 15 N·m...

  • Page 132: Connecting Wfu-Xx Lcl Filter Module (Frames R1I

    134 Electrical installation 132 Electrical installation Connecting WFU-xx LCL filter module (frames R1i…R4i)  ￭ Connecting WFU-xx LCL filter module (frames R1i…R4i) Input terminals (L1, L2, L3 and PE) Connection from the WBCA adapter and the main contactor Q2. Internal circuit diagrams for LCL filters ...

  • Page 133: Internal Circuit Diagrams For Lcl Filters

    Electrical installation 133 ￭ Internal circuit diagrams for LCL filters The following circuit diagrams show the internal connections of the LCL filter modules. WFU-01 and WFU-02...

  • Page 134: Wfu-11

    134 Electrical installation WFU-11...

  • Page 135: And Wfu-22

    Electrical installation 135 WFU-21 and WFU-22...

  • Page 136: Alcl-05-5

    136 Electrical installation ALCL-05-5...

  • Page 137: Blcl

    Electrical installation 137 BLCL...
  • Page 138 138 Electrical installation...

  • Page 139: Main Contactor

    IGBT supply modules of frames R1i…R4i are allowed to be used only with inverter modules that have charging circuit (eg, ABB inverter modules ACS880-104). The charging circuit data for each IGBT supply module (ACS880-204) and inverter module (ACS880-104) are shown in the following tables.

  • Page 140: Single Ac Input

    Installing the charging circuit (frames R6i and R8i) The cabinet builder must install and connect the charging circuit. For connections, see the example circuit diagrams. Consult ABB for more information on the components and wirings needed. Activate and tune the charging function in the control program. For information on tuning the parameters, see the firmware manual.

  • Page 141: Connecting The Control Cables

    Electrical installation 141 Connecting the control cables ￭ Default I/O connection diagrams 144 Electrical installation Control units of the drive. Connection procedure  ￭ Connection procedure Note: The instructions below are based on an example cabinet construction. They are Note: applicable to all possible solutions but only clarify the principles.

  • Page 142: Module Fiber Optic Connectors (Frame R8I)

    142 Electrical installation 6. Cut the cables to suitable length. Strip the cables and conductors. 7. Twist the cable shields into bundles and connect them to the ground terminal nearest to the terminal block. Keep the unshielded portion of the cables as short as possible. 8.
  • Page 143 Electrical installation 143 146 Electrical installation 146 Electrical installation The following figures show example fiber optic connections related to fan control. The following figures show example fiber optic connections related to fan control. The following figures show example fiber optic connections related to fan control. Direct-on-line cooling fan (option +C188) in IGBT supply module and LCL filter module Direct-on-line cooling fan (option +C188) in IGBT supply module and LCL filter module Direct-on-line cooling fan (option +C188) in IGBT supply module and LCL filter module...

  • Page 144: Connecting A Pc

    144 Electrical installation Note: Connection between BINT board and BDFC board in the module is ready-made at the factory. Connecting a PC A PC (with eg, the Drive composer PC tool) can be connected as follows: 1. Connect an ACx-AP-x control panel to the unit either •...

  • Page 145: Installing Optional Modules

    Electrical installation 145 Installing optional modules WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. Note: Pay attention to the free space required by the cabling or terminals coming to the optional modules.

  • Page 147: Installation Checklist Of The Drive

    Installation checklist of the drive 147 Installation checklist of the drive Contents of this chapter This chapter contains a checklist of 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.
  • Page 148 148 Installation checklist of the drive Make sure that … The enclosures of the equipment in the cabinet have proper galvanic connection to the cabinet protective earth (ground) busbar; The connection surfaces at the fastening points are bare (unpainted) and the connections are tight, or separate grounding conductors have been installed.

  • Page 149: Start-Up

    Contents of this chapter This chapter instructs how to start up the IGBT supply unit. The instructions are valid for the example IGBT supply unit with ACS880-204 IGBT supply modules. The default device designations (if any) are given in square brackets, for example, main contactor [Q2].

  • Page 150: Start-Up Procedure

    150 Start-up Start-up procedure Tasks Safety WARNING! Follow the safety instructions during the start-up procedure. See Safety instructions for ACS880 multidrive cabinets and modules (3AUA0000102301 [English]). Only qualified electricians are allowed to start-up the drive. Checks/Settings with no voltage connected WARNING! Ensure that the disconnector of the supply transformer is locked to the off (0) position, that means no voltage is, or can not be, connected to drive inadvertently.
  • Page 151 Start-up 151 Tasks If time relays, or relays with delayed make contact or break contact are used in emergency stop circuits, check the relay time settings. See delivery-specific circuit diagrams and safety function specific docu- mentation (if applicable). Check the voltage settings of the auxiliary voltage transformers (if any) are according to the actual power line voltage.
  • Page 152 • Then select the correct supply unit type with parameter 195.31 Parallel connection rating id. • Reboot the control unit by parameter 196.08 Control board boot. • Check the correct voltage range, parameter 195.01 Supply voltage. • Reboot the control unit by parameter 196.08 Control board boot. ACS880-204-… Frame Parameter 195.31 selection 1130A-3 2×R8i...

  • Page 153: Switching The Supply Unit Off

    Start-up 153 Tasks Drives with a charging switch [Q3]: Close the charging switch. Turn the operating switch [S21] to on (1) position to activate the Run enable signal and 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).

  • Page 155: Maintenance

    Contents of this chapter This chapter instructs how to maintain the IGBT supply module and how to interpret its fault indications. The information is valid for ACS880-204 IGBT supply modules and example cabinet installations of the modules. Note: The instructions do not cover all possible cabinet constructions.
  • Page 156 Cleaning IP22 and IP42 air inlet and outlet meshes Checking tightness of cable and busbar terminals. Tightening if needed. Checking ambient conditions (dustiness, corrosion, temperat- ure) Cleaning the heatsink of the sup- ply module ABB-SACE main circuit breaker maintenance Symbols...

  • Page 157: Maintenance Timers And Counters

    Performance of on/off-site work (commissioning, tests, measurements or other work) Replacement 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. Note: Long term operation near the specified maximum ratings or ambient conditions may require shorter maintenance intervals for certain components.

  • Page 158: Cleaning The Door Air Inlets (Ip22 And Ip42)

    158 Maintenance ￭ Cleaning the door air inlets (IP22 and IP42) Check the dustiness of the air inlet meshes. If the dust cannot be removed by vacuum cleaning from outside through the grating holes with a small nozzle, proceed as follows: 1.

  • Page 159: Replacing The Inlet Door Filters (Ip54)

    Maintenance 159 ￭ Replacing the inlet door filters (IP54) 1. Stop the drive and do the steps in section Electrical safety precautions (page 112) before you start the work. 2. Remove the fasteners at the top of the grating. 3. Lift the grating and pull it away from the door. 4.

  • Page 160: Power Connections

    160 Maintenance Power connections ￭ Retightening the power connections WARNING! Read the safety instructions given in Safety instructions for ACS880 multidrive cabinets and modules (3AUA0000102301 [English]). If you ignore them, injury or death, or damage to the equipment can occur. 1.

  • Page 161: Fans

    Reset the running time signal after fan replacement. Replacement fans are available from ABB. Do not use other than ABB specified spare parts. ￭ Replacing the R1i and R2i module cooling fan...

  • Page 162: Replacing The R3I And R4I Module Cooling Fan

    162 Maintenance ￭ Replacing the R3i and R4i module cooling fan WARNING! Read the safety instructions given in Safety instructions for ACS880 multidrive cabinets and modules (3AUA0000102301 [English]). If you ignore them, injury or death, or damage to the equipment can occur. 1.

  • Page 163: Replacing The R6I Module Cooling Fan

    Maintenance 163 ￭ Replacing the R6i module cooling fan WARNING! Read the safety instructions given in Safety instructions for ACS880 multidrive cabinets and modules (3AUA0000102301 [English]). If you ignore them, injury or death, or damage to the equipment can occur. 1.

  • Page 164: Replacing R8I Module Cooling Fan (Speed-Controlled Version)

    164 Maintenance ￭ Replacing R8i module cooling fan (speed-controlled version) The module is equipped with a fan unit that contains two cooling fans. WARNING! Obey the safety instructions given in Safety instructions for ACS880 multidrive cabinets and modules (3AUA0000102301 [English]). If you ignore the safety instructions, injury or death, or damage to the equipment can occur.

  • Page 165: Replacing R8I Module Cooling Fan (Direct-On-Line Version)

    Maintenance 165 ￭ Replacing R8i module cooling fan (direct-on-line version) WARNING! Obey the safety instructions given in Safety instructions for ACS880 multidrive cabinets and modules (3AUA0000102301 [English]). If you ignore the safety instructions, injury or death, or damage to the equipment can occur.
  • Page 166 166 Maintenance...

  • Page 167: Replacing The Circuit Board Compartment Fan

    Maintenance 167 ￭ Replacing the circuit board compartment fan Frame R8i modules are equipped with a fan blowing air through the circuit board compartment. The fan is accessible from the front of the module. WARNING! Obey the safety instructions given in Safety instructions for ACS880 multidrive cabinets and modules (3AUA0000102301 [English]).
  • Page 168 168 Maintenance 8. Put the fan onto the threaded studs on the fan holder with the airflow direction arrow pointing towards the fan holder. 9. Install and tighten the four nuts removed earlier. 10. Connect the fan cable. 11. Align and push the fan holder into the module.
  • Page 169 Maintenance 169 12. Install and tighten the two M4×12 (T20) screws.

  • Page 170: Replacing The Fan Of The Lcl Filter (Filter For Frames R1I

    170 Maintenance ￭ Replacing the fan of the LCL filter (filter for frames R1i…R4i) WARNING! Read the safety instructions given in Safety instructions for ACS880 multidrive cabinets and modules (3AUA0000102301 [English]). If you ignore them, injury or death, or damage to the equipment can occur. 1.

  • Page 171: Replacing The Fan Of The Lcl Filter (Filter For Frame R6I)

    Maintenance 171 ￭ Replacing the fan of the LCL filter (filter for frame R6i) Maintenance 175 WARNING! Replacing the fan of the LCL filter (filter for frame R6i)  Read the safety instructions given in Safety instructions for ACS880 multidrive cabinets and modules (3AUA0000102301 [English]). If you WARNING! Only qualified electricians are allowed to carry out the work described below.

  • Page 172: Replacing The Fan Of The Lcl Filter (Blcl-1X-X)

    172 Maintenance ￭ Replacing the fan of the LCL filter (BLCL-1x-x) WARNING! Read the safety instructions given in Safety instructions for ACS880 multidrive cabinets and modules (3AUA0000102301 [English]). If you ignore them, injury or death, or damage to the equipment can occur. 1.

  • Page 173: Replacing The Fan Of The Lcl Filter (Blcl-2X-X)

    Maintenance 173 ￭ Replacing the fan of the LCL filter (BLCL-2x-x) WARNING! Read the safety instructions given in Safety instructions for ACS880 multidrive cabinets and modules (3AUA0000102301 [English]). If you ignore them, injury or death, or damage to the equipment can occur. 1.

  • Page 174: Replacing The Cabinet Cooling Fans

    174 Maintenance ￭ Replacing the cabinet cooling fans Cabinets with ABB air outlet kits WARNING! Read the safety instructions given in Safety instructions for ACS880 multidrive cabinets and modules (3AUA0000102301 [English]). If you ignore them, injury or death, or damage to the equipment can occur.

  • Page 175: Igbt Supply Module

    Maintenance 175 IGBT supply module ￭ Cleaning the heatsink The drive module heatsink fins pick up dust from the cooling air. The drive runs into overtemperature warnings and faults if the heatsink is not clean. When necessary, clean the heatsink as follows. WARNING! Read the safety instructions given in Safety instructions for ACS880 multidrive cabinets and modules (3AUA0000102301 [English]).

  • Page 176: Replacing The R6I Module

    10. Unplug the signal connector cable (if any) in front of the module. 11. Pull the module out enough to attach a lifting chain to chain holes on top of the module. A lifting device for R6i module is available from ABB (order code: 3AXD50000196661, instruction code: 3AXD50000210268). Pull the module out.
  • Page 177 Maintenance 177...
  • Page 178 178 Maintenance...

  • Page 179: Replacing R8I Module

    Maintenance 179 ￭ Replacing R8i module WARNING! Read the safety instructions given in Safety instructions for ACS880 multidrive cabinets and modules (3AUA0000102301 [English]). If you ignore them, injury or death, or damage to the equipment can occur. WARNING! • Do not use the module extraction/installation ramp with plinth heights which exceeds the maximum allowed height.
  • Page 180 180 Maintenance 4. Unplug the wiring on the front of the module. Unplug the connector (X50) at the top of the module. Move the wires aside. 5. Use a module pull out ramp or other lifting device to remove the module from the cabinet. If the ramp designed for Rittal enclosures is used, install it by placing the hooks of the ramp between the bottom plate and enclosure frame.
  • Page 181 Maintenance 181...

  • Page 182: Lcl Filter

    182 Maintenance LCL filter ￭ Replacing the LCL filter (frame R6i) WARNING! Read the safety instructions given in Safety instructions for ACS880 multidrive cabinets and modules (3AUA0000102301 [English]). If you ignore them, injury or death, or damage to the equipment can occur. 1.
  • Page 183 Maintenance 183...
  • Page 184 184 Maintenance...
  • Page 185 Maintenance 185...

  • Page 186: Replacing The Lcl Filter (Frame R8I)

    186 Maintenance ￭ Replacing the LCL filter (frame R8i) WARNING! Read the safety instructions given in Safety instructions for ACS880 multidrive cabinets and modules (3AUA0000102301 [English]). If you ignore them, injury or death, or damage to the equipment can occur. WARNING! •...
  • Page 187 Maintenance 187 4. Unplug the signal connector cable on top of the LCL filter module. 5. Remove the five screws in the upper part of the LCL filter module. 6. Remove the four screws in the lower part of the LCL filter module. 7.
  • Page 188 188 Maintenance...

  • Page 189: Capacitors

    Capacitor failure is usually followed by damage to the unit and an input cable fuse failure, or a fault trip. Contact ABB if capacitor failure is suspected. Replacements are available from ABB. Do not use other than ABB specified spare parts. Contact an ABB service representative for spare parts and repair services.

  • Page 190: Replacing The Lcl Filter Capacitor (Frames R3I And R4I)

    190 Maintenance ￭ Replacing the LCL filter capacitor (frames R3i and R4i) WARNING! Read the safety instructions given in Safety instructions for ACS880 multidrive cabinets and modules (3AUA0000102301 [English]). If you ignore them, injury or death, or damage to the equipment can occur. 1.

  • Page 191: Control Panel

    Maintenance 191 Control panel For detailed information on the control panel, see ACx-AP-x assistant control panels user’s manual (3AUA0000085685 [English]). ￭ Cleaning the control panel Use a soft damp cloth to clean the control panel. Avoid harsh cleaners which could scratch the display window.

  • Page 192: Replacing The Bcu Control Unit Battery

    192 Maintenance ￭ Replacing the BCU control unit battery Replace the real-time clock battery if the BATT OK LED is not illuminated when the control unit is powered. 1. Stop the drive and do the steps in section Electrical safety precautions (page 112) before you start the work.

  • Page 193: R8I Module Leds

    Maintenance 193 Location Indication Control panel Continuous green The unit is functioning normally. Flickering green Data is transferred between the PC and the unit through the USB connection of the control panel. Blinking green There is an active warning in the unit. Continuous red There is an active fault in the unit.

  • Page 194: Resuming Normal Operation

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

  • Page 195: 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 196 196 Ordering information • L = liquid-cooled • w = cabinet width • 4 = 400 mm • 6 = 600 mm • 8 = 800 mm • s = module frame size / sizes • 1 = R1i • 2 = R2i •...

  • Page 197: Frames R1I

    Contents size (see below for options) = 400 V (Range 380 … 415 V): • IGBT supply module with ZCU control unit (the module ACS880-204-008A0-3 ACS880-104-008A0-3+N2200 cooling fan has internal ACS880-204-0018A-3 ACS880-104-0018A-3+N2200 power supply) • ZMU memory unit with IGBT...

  • Page 198: Lcl Filters

    198 Ordering information ￭ LCL filters LCL filter module has to be ordered separately. IGBT supply unit type Frame LCL filter size ACS880-204-... Type Ordering code Contents = 400 V (Range 380 … 415 V): • WFU-xx filter module 008A0-3...

  • Page 199: Control Panel

    Ordering information 199 114 Ordering information ￭ Control panel Control panel  The control panel is not included with the module but must be ordered separately. One The control panel is not included with the supply module but must be ordered separately. control panel is required for the commissioning of an ACS880 drive system, even if the Drive One control panel is required for the commissioning of an ACS880 drive system, even if composer PC tool is used.

  • Page 200: Mechanical Installation Accessories And Tools

    200 Ordering information ￭ Mechanical installation accessories and tools Air guide kits for LCL filter modules Air guide kits are used on top of the modules to guide cooling air. WFU filter air guides are designed to be used together with WFU filter and WBCA bottom connection adapter. LCL filter ACS880- Ordering code...

  • Page 201: Air Guide Kits For Igbt Supply Modules

    Ordering information 201 Air guide kits for IGBT supply modules ACS880- Ordering code Kit code Illustration 204-… = 400 V (Range 380 … 415 V): 008A0-3 3AUA0000114398 A-468-1-422 0018A-3 3AUA0000114330 A-468-2-423 0035A-3 3AUA0000114404 A-468-3-424 0050A-3 3AUA0000114404 A-468-3-424 0093A-3 3AUA0000114405 A-468-4-425 = 500 V (Range 380 …...

  • Page 202: Wbca-Xx Bottom Connection Adapters

    Ordering code Illustration IGBT supply LCL filter Adapter Ordering code Illustration type type ACS880-204-… module type type type ACS880-204-... = 400 V (Range 380 … 415 V): = 400 V (Range 380 … 415 V) 008A0-3 WFU-01 WBCA-01 3AUA0000070424...

  • Page 203: Ac-Side Components

    Ordering information 203 ￭ AC-side components Main switch-disconnector kits You must equip the electric supply of a machinery with a main disconnecting device (IEC/EN60204-1). The main power line is equipped with a main switch-disconnector or a main circuit breaker [Q1]. This section lists suitable main switch-disconnectors. Frame size Main switch-disconnector Ordering code...

  • Page 204: Ac Fuses

    = 400 V (Range 380 … 415 V): 16 A, 690 V, 12 A, 600 V, Not available 008A0-3 170M1559D 3AUA0000115358 DFJ-12 class J from ABB gR, size 000 32 A, 690 V, 25 A, 600 V, Not available 0018A-3 170M1562D 10008131 DFJ-25...

  • Page 205: Emc/Rfi Filter

    = 400 V (Range 380 … 415 V): SCHAFFNER FN RFI filters are not available from 008A0-3 25 A (50 °C) 520 V AC 3120H-25-33 ABB. They must be acquired by the customer. SCHAFFNER FN 0018A-3 25 A (50 °C) 520 V AC For more specific information...

  • Page 206: Main Contactors

    The main power line is equipped with main contactors [Q2]. Contactors are used for the on-off control of the main AC input power. Contactors are suitable for both IEC and UL/CSA installations. Main contactor (IEC, UL, CSA) ACS880-204-… Ordering code Type Data = 400 V (Range 380 …...

  • Page 207: Dc Fuses

    Ordering information 207 DC fuses DC fuses protect the module and drive DC bus against short circuits. ACS880-204-… Fuse (IEC, UL, CSA) Type Data Ordering code = 400 V (Range 380 … 415 V): 008A0-3 FWP-15A14F 15 A, 660 V...

  • Page 208: Fuse Bases For Dc Fuses (Iec, Ul, Csa)

    208 Ordering information Fuse bases for DC fuses (IEC, UL, CSA) ACS880-204-… Fuse (IEC, UL, CSA) Type Data Ordering code = 400 V (Range 380 … 415 V): 008A0-3 US141 (Z331153F) 14 × 51 mm, 50 A, 690 V 3AUA0000089224...

  • Page 209: Frame R6I

    (see below for options) = 400 V (Range 380 … 415 V): • IGBT supply module with ZCU control unit (the module ACS880-204-0210A-3 1×R6i ACS880-104-0250A-3+N2200 cooling fan has internal = 500 V (Range 380 … 500 V): power supply) ACS880-204-0210A-5 1×R6i...

  • Page 210: Lcl Filters (+G304+A013)

    LCL filters (+G304+A013) IGBT supply unit Frame LCL filter type size Type Ordering code Contents ACS880-204-... (115 V) = 400 V (Range 380 … 415 V): • LCL filter module • +G304+A013: 0210A-3 1×R6i ALCL-05-5+G304+A013 68625131 115 V AC / 60 Hz = 500 V (Range 380 …...

  • Page 211: Control Panel

    Ordering information 211 114 Ordering information ￭ Control panel Control panel  The control panel is not included with the module but must be ordered separately. One The control panel is not included with the supply module but must be ordered separately. control panel is required for the commissioning of an ACS880 drive system, even if the Drive One control panel is required for the commissioning of an ACS880 drive system, even if composer PC tool is used.

  • Page 212: Mechanical Installation Accessories And Tools

    A-6-6-355-VX Rittal VX25 Instruction code: 3AXD50000479849 Lifting device The lifting device is used for replacing converter modules in the ABB drives ACx enclosure and the Rittal VX25 enclosure. Used with … Ordering code Instruction code R6i; 600 mm Rittal VX25...

  • Page 213: Ac-Side Components

    Ordering information 213 ￭ AC-side components AC bus installation parts (for Rittal VX25 enclosures) The brackets in this kit act as a mounting base for the busbar supports of the Rittal Flat-PLS AC bus and ensure its correct placement and alignment inside the cabinet line-up. Note: The designs presented in this manual for Rittal VX25 enclosures employ the Rittal Flat-PLS busbar system.

  • Page 214: Main Switch-Disconnector Kits

    214 Ordering information Main switch-disconnector kits You must equip the electric supply of a machinery with a main disconnecting device (IEC/EN60204-1). The main power line is equipped with a main switch-disconnector or a main circuit breaker [Q1]. This section lists suitable main switch-disconnectors. Frame size Main switch-disconnector (IEC) Ordering code...

  • Page 215: Rfi Filters

    RFI filter is used for improving the EMC characteristics of the unit and to fulfill category C2 requirements. See Electrical planning instructions for ACS880 multidrive cabinets and modules (3AUA0000102324 [English]). RFI filter ACS880-204-… Type Data Ordering code = 400 V (Range 380 … 415 V):...

  • Page 216: Switching And Charging Kit (Mechanical Parts)

    216 Ordering information Switching and charging kit (mechanical parts) The switching and charging kit contains mechanical parts for installing switching and charging components into frame R6i IGBT supply module cubicle. Used with … Ordering code Kit code Illustration R6i; 600 mm 3AXD50000477494 A-6-6-405-VX Rittal VX25...

  • Page 217: Charging Kits

    + 4×INU) and 7 × IGBT supply unit DC capacitance (1×ISU + 6×INU). If the total DC link capacitance (including IGBT supply and inverter module DC capacitances) exceeds these limits, the components must be redimensioned. Contact ABB representative for more information. The capacitances of the IGBT supply module types and the inverter module types are specified in their technical data tables.

  • Page 218: Varistor Kit Acs880 For Ul/Csa Installations

    218 Ordering information Use double-insulated wire. For more detailed information on the charging components, see the technical data. Varistor kit ACS880 for UL/CSA installations The CVAR varistor board is used to protect the supply/rectifier module against excessive voltages peaks. The board shunts the current created by high voltage. The CVAR board must be attached into the cabinet and connected to the main circuit after the main contactor [Q2] and must have a PE connection as well.

  • Page 219: Module And Common Mode Filter Busbars

    Ordering information 219 Module and common mode filter busbars Instruction code: 3AUA0000115891 A common mode filter is needed with IGBT supply module. There is space for up to four toroidal cores. See the dimension drawings. Module and common mode filter busbars A common mode filter is needed with IGBT supply module.

  • Page 220: Dc Fuses

    220 Ordering information DC fuses DC fuses protect the module and drive DC bus against short circuits. Fuse (IEC, UL, CSA) ACS880-204-… Type Data Ordering code = 400 V (Range 380 … 415 V): Cooper-Bussmann 0210A-3 450 A, 690 V, size 1...

  • Page 221: Frame R8I And Multiples

    Frame Ordering code Contents size (see below for options) = 400 V (Range 380 … 415 V): • IGBT supply module(s) (frame R8i) with speed-con- ACS880-204-0420A-3 ACS880-104-0470A-3+E205 trolled cooling fan(s) ACS880-204-0580A-3 ACS880-104-0640A-3+E205 • +E205: (internal du/dt ilters) ACS880-204-0810A-3 ACS880-104-0900A-3+E205 ACS880-204-1130A-3 2×R8i...
  • Page 222 222 Ordering information Ordering code format Option codes [Module type] +code [+code] … +C132: Marine type approval. For more information, see ACS880 +C132 marine type-approved drive modules and module packages For example, supplement (3AXD50000037752 [English]). ACS880-104-0470A-3 +E205 +C188 +C183: Heating element mounted to module base +C188: Direct-on-line cooling fan +E205: Internal du/dt filters (When the module is used as an IGBT supply module, it must always be ordered with +E205.)

  • Page 223: Lcl Filters (+C183+C188)

    LCL filter modules have to be ordered separately. IGBT supply Frame LCL filter unit type size Type Ordering code Contents ACS880-204-… = 400 V (Range 380 … 415 V): • +C183: Internal heating element 0420A-3 1×R8i BLCL-13-5+C183+C188 3AUA0000163493 • +C188: Direct-on-line 0580A-3 1×R8i...

  • Page 224: Lcl Filters (+C183+C188 And +G304 Or +G427)

    LCL filter modules have to be ordered separately. IGBT supply Frame LCL filter unit type size Type Ordering code Contents ACS880-204-… = 400 V (Range 380 … 415 V): • +C183: Internal heat- ing element 0420A-3 1×R8i BLCL-13-5+C183+C188+G304 3AUA0000179948 • +C188: Direct-on-line 0580A-3 1×R8i...

  • Page 225: Rfi Filters

    Ordering information 225 ￭ RFI filters RFI filter is used for improving the EMC characteristics of the unit and to fulfill category C2 requirements. See Electrical planning instructions for ACS880 multidrive cabinets and modules (3AUA0000102324 [English]). RFI filter Assembly kit for toroid ACS880- 204-...

  • Page 226: Control Panel

    226 Ordering information 114 Ordering information ￭ Control panel Control panel  The control panel is not included with the module but must be ordered separately. One The control panel is not included with the supply module but must be ordered separately. control panel is required for the commissioning of an ACS880 drive system, even if the Drive One control panel is required for the commissioning of an ACS880 drive system, even if composer PC tool is used.

  • Page 227: Control Electronics

    Ordering information 227 ￭ Control electronics Cabling of the electronics outside the module must be done by the customer. For the current consumption of the main components in the auxiliary circuit, see the technical data. Control unit You must equip each IGBT supply unit with one control unit (and memory unit). The delivery includes control unit.

  • Page 228: Control Circuit Plug Connectors

    228 Ordering information The following kits, each consisting of a pair of plastic fiber optic cables, are available from ABB: Length Kit type designation Ordering code NLWC-02 58988821 NLWC-03 58948233 NLWC-05 58948250 NLWC-07 58948268 10 m NLWC-10 58948276 Control circuit plug connectors The control circuit plug connector X50 is not included in the module kit and you must order it separately.

  • Page 229: Mechanical Installation Accessories And Tools

    Ordering information 229 ￭ Mechanical installation accessories and tools Module installation parts Module installation parts include, for example, top and bottom supports and air baffles for the supply and LCL filter modules. Used with … Ordering code Kit code Illustration 1×R8i;...
  • Page 230 230 Ordering information Used with … Ordering code Kit code Illustration 3×R8i; 800 mm 3AXD50000011160 A-8-8-327 generic Instruction code: 3AXD50000013813 2×R8i; 400 mm 3AXD50000360802 A-4-8-321-VX Rittal Instruction code: 3AXD50000349982 3×R8i; 600 mm 3AXD50000361700 A-6-8-322-VX Rittal Instruction code: 3AXD50000351930 3×R8i; 600 mm 3AXD50000011159 A-6-8-326 generic...

  • Page 231: Shrouds

    Ordering information 231 Used with … Ordering code Kit code Illustration 2×R8i; 800 mm 3AXD50000011158 A-8-8-325 generic Instruction code: 3AXD50000013143 Shrouds Shrouds are used for IP20 touch protection with the cabinet doors open. Used with … Ordering code Kit code Illustration 1 per R8i;...

  • Page 232: Ramp

    232 Ordering information Ramp The ramp can be used when installing or removing an R8i module. Note: Do not use the ramp with plinth heights over 100 mm. The ramp is designed for a plinth height of 100 mm (the standard plinth height of Rittal VX25 enclosures). Used with …...

  • Page 233: Main Switch-Disconnector Kits

    Ordering information 233 Main switch-disconnector kits You must equip the electric supply of a machinery with a main disconnecting device (IEC/EN60204-1). The main power line is equipped with a main switch-disconnector or a main circuit breaker [Q1]. This section lists suitable main switch-disconnectors. Note: For some of the IEC and UL high power units, you can use withdrawable main circuit breaker instead of the main switch-disconnector.
  • Page 234 234 Ordering information ACS880- Main switch-disconnector (UL, CSA) Ordering code 204-… Type Data 0310A-7 Switch kit OT-type UL 1200 U12 50 kA, 600 V, 1200 A 3AXD50000010814 0370A-7 Switch kit OT-type UL 1200 U12 50 kA, 600 V, 1200 A 3AXD50000010814 0540A-7 Switch kit OT-type UL 1200 U12...

  • Page 235: Main Circuit Breakers And Wagons

    In the table, these lower power units are marked with * in the first column. Note: UL-type air circuit breakers have IEC certification according to IEC 60947. See ABB SACE catalogs for further details. Main circuit breaker (IEC, 230 V) ACS880-204-…...
  • Page 236 236 Ordering information 1SDA073674R1 • YO E1.2..E6.2 220-240 Vac/dc 1SDA073687R1 • YC E1.2..E6.2 220-240 Vac/dc 1SDA073700R1 • YU E1.2..E6.2 220-240 Vac/dc 1SDA073725R1 • M E2.2..E6.2 220-250 Vac/dc 1SDA073781R1 • MOC E2.2..E6.2 1SDA073756R1 • AUX 6Q 400V E2.2..E6.2 1SDA073792R1 • KLC-S Key lock open N.20005 E2.2..E6.2 1SDA073807R1 •...
  • Page 237 Ordering information 237 Wagon (IEC, 230 V) ACS880-204-… Ordering code Type Data = 400 V (Range 380 … 415 V): E2.2-A_W_FP_2000HR- 1130A-3* 3-pole, rear hor. term., UL 3AXD50000048354 HR_UL E2.2-A_W_FP_2000HR- 1330A-3* 3-pole, rear hor. term., UL 3AXD50000048354 HR_UL E2.2-A_W_FP_2000HR- 1580A-3* 3-pole, rear hor.
  • Page 238 238 Ordering information Main circuit breaker (IEC, 115 V) ACS880-204-… Ordering code Type Data = 400 V (Range 380 … 415 V): 1130A-3* E2.2S-A 1200 1200 A, 690 V, 3P 3AXD50000048351 1330A-3* E2.2S-A 1600 1600 A, 690 V, 3P 3AXD50000048329 1580A-3* E2.2S-A 2000...
  • Page 239 Ordering information 239 Wagon (IEC, 115 V) ACS880-204-… Ordering code Type Data = 400 V (Range 380 … 415 V): E2.2-A_W_FP_2000HR- 1130A-3* 3-pole, rear hor. term., UL 3AXD50000048354 HR_UL E2.2-A_W_FP_2000HR- 1330A-3* 3-pole, rear hor. term., UL 3AXD50000048354 HR_UL E2.2-A_W_FP_2000HR- 1580A-3* 3-pole, rear hor.
  • Page 240 240 Ordering information Main circuit breaker (UL, CSA: 230 V) ACS880-204-… Ordering code Type Data = 400 V (Range 380 … 415 V): 1130A-3 E2.2S-A 1200 1200 A, 600 V, 65 kA, UL 3AXD50000048328 1330A-3 E2.2S-A 1600 1600 A, 600 V, 65 kA, UL...
  • Page 241 Ordering information 241 Main circuit breaker (UL, CSA: 115 V) ACS880-204-… Ordering code Type Data = 400 V (Range 380 … 415 V): 1130A-3 E2.2S-A 1200 1200 A, 600 V, 65 kA, UL 3AXD50000048351 1330A-3 E2.2S-A 1600 1600 A, 600 V, 65 kA, UL...
  • Page 242 242 Ordering information Wagon (UL, CSA) ACS880-204-… Ordering code Type Data = 400 V (Range 380 … 415 V): E2.2-A_W_FP_2000HR- 1130A-3 3-pole, rear hor. term., UL 3AXD50000048354 HR_UL E2.2-A_W_FP_2000HR- 1330A-3 3-pole, rear hor. term., UL 3AXD50000048354 HR_UL E2.2-A_W_FP_2000HR- 1580A-3 3-pole, rear hor. term., UL...

  • Page 243: Iec Bus Bar Shim Kit

    Ordering information 243 IEC bus bar shim kit The following shim kits are available for adapting E2.2S-A, E4.2S-A and E6.2V-A air circuit breakers to IEC bus bars. Type Data Ordering code Illustration EMAX2 E2.2 bus bar E2.2S-A 3AXD50000286324 shim kit Instruction code: 3AXD50000286072 EMAX2 E4.2 bus bar...

  • Page 244: Main Ac Fuses In Incoming Cubicle

    The AC fuses protect the input cables, main contactor [Q2] and the module against short circuits. Main AC fuses are used only with the main contactor [Q2] solution. Module-specific AC fuses are used with the main circuit breaker [Q1] solution. Fuse (IEC) ACS880-204-… Frame size Ordering code Type Data = 400 V (Range 380 …...
  • Page 245 Ordering information 245 Fuse (UL, CSA) ACS880-204-… Frame size Ordering code Type Data = 690 V (Range 525 … 690 V): 0310A-7 1×R8i 170M6408 500 A, 690 V 3AUA0000136232 0370A-7 1×R8i 170M6410 630 A, 690 V 68335418 0540A-7 1×R8i 170M6413...

  • Page 246: Ac Fuses In Igbt Supply Module Cubicle Or Lcl Filter Cubicle

    246 Ordering information AC fuses in IGBT supply module cubicle or LCL filter cubicle When using main circuit breaker, the AC fuses protect the modules against short circuits. Fuse (IEC) ACS880-204-… Frame size Ordering code Type Data = 400 V (Range 380 … 415 V): 1130A-3 2×R8i...

  • Page 247: Main Contactors

    See also Main switch-disconnector kits (page 233) Main circuit breakers and wagons (page 235). Main contactor (IEC) ACS880-204-… Ordering code Type Data = 400 V (Range 380 … 415 V): 800 A(I ), 1000 V (U...
  • Page 248 248 Ordering information Main contactor (IEC) ACS880-204-… Ordering code Type Data 2050 A (I ), 1000 V (U 1570A-7 AF2050-30-22-70 3AUA0000051805 100 … 250 V/50 … 60 Hz Main contactor (UL/CSA) ACS880-204-… Ordering code Type Data = 400 V (Range 380 … 415 V):...

  • Page 249: Charging Kits

    + 4×INU) and 7 × IGBT supply unit DC capacitance (1×ISU + 6×INU). If the total DC link capacitance (including IGBT supply and inverter module DC capacitances) exceeds these limits, the components must be redimensioned. Contact ABB representative for more information. The capacitances of the IGBT supply module types and the inverter module types are specified in their technical data tables.
  • Page 250 250 Ordering information 1×ISU + 2×INU 1×ISU + 4×INU 1×ISU + 6×INU Max. Max. Max. ACS880- Ordering code Ordering code Ordering code capacit- capacit- capacit- 204-… ance ance ance (IEC) (IEC) (IEC) (mF) (mF) (mF) 1050A-7 3AXD50000016056 54.00 3AXD50000016057 90.00 3AXD50000016057 126.00 1570A-7...

  • Page 251: Varistor Kit Acs880 For Ul/Csa Installations

    OHB65J6 or OHB45J6 with ON/OFF indication, see also content of OS_P switches. Minimum recommended wire sizes for the charging kits: • Consult ABB. Use double-insulated wire. For more detailed information on the charging components, see the technical data. Varistor kit ACS880 for UL/CSA installations The CVAR varistor board is used to protect the supply/rectifier module against excessive voltages peaks.

  • Page 252: Ac Connection Of The Lcl Filter

    Instruction code: 3AXD50000002577 3AXD50000416509 Note: This kit is not included 1 per in ABB’s standard BLCL-1x-x; Rittal A-6-8-110-VX design but may be module used if you wish to have AC fuses on top of the LCL filter mod- ule.
  • Page 253 Ordering information 253 Used with … Ordering code Kit code Illustration 1 per BLCL-2x-x; Rittal 3AXD50000360796 A-4-8-107-VX module Instruction code: 3AXD50000353491 1 per BLCL-2x-x; generic 3AXD50000011155 A-468-8-109 module Instruction code: 3AXD50000013246 1 per BLCL-2x-x; 3×R8i 3AXD50000371143 A-6-8-108-VX Rittal module Instruction code: 3AXD50000352999...

  • Page 254: Busbars And Quick Connectors

    254 Ordering information Busbars and quick connectors The power input of the supply module is connected to the module through a quick connector. Used with … Ordering code Kit code Illustration 1×R8i; 600 mm 3AXD50000416493 A-6-8-130-VX Rittal Instruction code: 3AXD50000384945 1×R8i;...

  • Page 255: Quick Connector

    Ordering information 255 Used with … Ordering code Kit code Illustration 3×R8i; 1600 mm 3AXD50000371129 A-X-8-143-VX Rittal Instruction code: 3AXD50000360444 3×R8i; 1400 mm 3AXD50000011157 A-X-8-145 generic Instruction code: 3AXD50000013810 Quick connector Used with Ordering codes Kit code Illustration 1 per All enclosure types 3AUA0000119227 A-468-8-100...

  • Page 256: Dc-Side Components

    256 Ordering information ￭ DC-side components DC bus installation parts (for Rittal VX25 enclosures) The brackets in this kit act as a mounting base for the busbar supports of the Rittal Flat-PLS DC bus and ensure its correct placement and alignment inside the cabinet line-up. Note: The designs presented in this manual for Rittal VX25 enclosures employ the Rittal Flat-PLS busbar system.

  • Page 257: Module And Common Mode Filter Busbars

    Ordering information 257 Used with … Ordering code Kit code Illustration R8i; All enclosures 3AXD50000003411 A-468-8-232 Instruction code: 3AXD50000003403 Module and common mode filter busbars A common mode filter is needed with each IGBT supply module. There is space for up to four toroidal cores.

  • Page 258: Dc Fuses

    258 Ordering information DC fuses DC fuses protect the module and drive DC bus against short circuits. ACS880-204-… Fuse (IEC, UL, CSA) Ordering code 2nd type fuse Type Data = 400 V (Range 380 … 415 V): 0420A-3 Cooper-Bussmann 900 A, 690 V,...
  • Page 259 Ordering information 259 ACS880-204-… Fuse (IEC, UL, CSA) Ordering code 2nd type fuse Type Data 0370A-7 Cooper-Bussmann 800 A, 1250 V, 63919128 size 3 170M6546 0540A-7 Cooper-Bussmann 1100 A, 1000 V, 68736021 size 3 170M6549 0720A-7 Cooper-Bussmann 800 A, 1250 V,...

  • Page 260: Cabinet Ventilation

    260 Ordering information Cabinet ventilation ￭ Air inlet kits Air inlet kits 400 mm cabinet Used with … Ordering code Kit code Illustration IP20 3AUA0000117002 A-4-X-021 Instruction code: 3AUA0000116879 IP42 3AUA0000117007 A-4-X-024 Instruction code: 3AUA0000116873 IP54 3AXD50000009184 A-4-X-027 Instruction code: 3AXD50000009989...

  • Page 261: Air Inlet Kits 600 Mm Cabinet

    Ordering information 261 Air inlet kits 600 mm cabinet Used with … Ordering code Kit code Illustration IP20 3AUA0000117003 A-6-X-022 Instruction code: 3AUA0000116880 IP42 3AUA0000117008 A-6-X-025 Instruction code: 3AUA0000116874 IP54 3AXD50000009185 A-6-X-028 Instruction code: 3AXD50000009990...

  • Page 262: Air Inlet Kits 800 Mm Cabinet

    262 Ordering information Air inlet kits 800 mm cabinet Used with … Ordering code Kit code Illustration IP20 3AUA0000117005 A-8-X-023 Instruction code: 3AUA0000116887 IP42 3AUA0000117009 A-8-X-026 Instruction code: 3AUA0000116875 IP54 3AXD50000009186 A-8-X-029 Instruction code: 3AXD50000010001...

  • Page 263: Air Outlet Kits

    Ordering information 263 ￭ Air outlet kits Air outlet kits 400 mm cabinet Used with … Ordering code Kit code Illustration IP20 (IEC) 3AUA0000125203 A-4-X-042 Instruction code: 3AXD50000001983 IP20 (IEC) 3AUA0000125201 A-4-X-062 Instruction code: 3AXD50000001982 Note: Fan to be ordered separ- ately IP42 (IEC) 3AUA0000114968...

  • Page 264: Air Outlet Kits 600 Mm Cabinet

    264 Ordering information Used with … Ordering code Kit code Illustration IP54 (IEC) 3AXD50000009187 A-4-X-064 Instruction code: 3AXD50000010001 Note: Fan to be ordered separ- ately IP54 (UL) 3AXD50000010362 A-4-X-067 Instruction code: 3AXD50000010284 Note: Fan to be ordered separ- ately Air outlet kits 600 mm cabinet Used with …...

  • Page 265: Air Outlet Kits 800 Mm Cabinet

    Ordering information 265 Used with … Ordering code Kit code Illustration IP54 (IEC) 3AXD50000009189 A-6-X-065 Instruction code: 3AXD50000010004 Note: Fan to be ordered separ- ately IP54 (UL) 3AXD50000010327 A-6-X-066 Instruction code: 3AXD50000010004 Note: Fan to be ordered separ- ately Air outlet kits 800 mm cabinet Used with …...
  • Page 266 266 Ordering information Used with … Ordering code Kit code Illustration IP54 (IEC) 3AXD50000009187 A-4-X-064 Instruction code: 3AXD50000010001 Note: Fan to be ordered separ- ately IP54 (UL) 3AXD50000010362 A-4-X-067 Instruction code: 3AXD50000010284 Note: Fan to be ordered separ- ately...

  • Page 267: Cooling Fans (Frames R1I

    Ordering information 267 ￭ Cooling fans (frames R1i…R4i) Enclosure / Degree of Component Ordering code protection Name Data 400 mm, 600 mm / R3G225-RH17-23 (230 V) 3AXD50000000592 IP20, IP42 / 230 V, Connector SPB2,5/7 (2.5 mm , 12AWG) 3AXD50000000723 50/60 Hz Connector SC 2,5-RZ/7 (2.5 mm 3AXD50000000724...

  • Page 268: Cooling Fans (Frame R6I)

    268 Ordering information • Relpol PI84-24DC-M41G relay • Rated load (capacity): 8 A / 24 V DC • Rated power consumption: 0.4 … 0.48 W DC • GZT80 relay socket • 600 mm of AWG24, 300 V, UL1569 (or equivalent material, valid for PVC insulation only) wire •...

  • Page 269: Cooling Fans (Frame R8I)

    Ordering information 269 ￭ Cooling fans (frame R8i) Enclosure / Degree of Component Ordering code protection Name Data 400 mm / IP54 / 230 V, RB4C-355/170 3AXD50000006934 50/60 Hz Capacitor MSB MKP 6/603/E1679 3AXD50000006959 Connector SPB2,5/7 (2.5 mm , 12AWG) 3AXD50000000723 Connector SC 2,5-RZ/7 (2.5 mm...

  • Page 271: Technical Data

    Technical data 271 Technical data Contents of this chapter This chapter contains the technical data for ACS880-204 IGBT supply modules.

  • Page 272: Ratings

    272 Technical data Ratings Light-overload Capa- No-overload use Heavy-duty use citance ACS880- Frame 204-… A (DC) A (AC) A (DC) A (DC) A (DC) (DC) (DC) = 400 V (with U = 3~400 V AC and U = 566 V DC) input output 008A0-3...

  • Page 273: Definitions

    Technical data 273 Light-overload Capa- No-overload use Heavy-duty use citance ACS880- Frame 204-… A (DC) A (AC) A (DC) A (DC) A (DC) (DC) (DC) 1570A-7 3×R8i 1899 1566 2848 1853 1872 1823 1779 1420 1386 27.00 2070A-7 4×R8i 2510 2070 3765 2449...

  • Page 274: Derating

    274 Technical data ￭ Derating Ambient temperature derating In the temperature range +40…50 °C (+104…122 °F), the rated output current is derated by 1 percentage point for every added 1 °C (1.8 °F). The output current can be calculated by multiplying the current given in the rating table by the derating factor (k): 1.00 0.90 0.80...

  • Page 275: Type Equivalence Table

    Derating factor 0.80 For a more accurate derating, use the DriveSize PC tool. Type equivalence table Cabinet-installed type IGBT supply unit type Basic module type Frame ACS880-207-… ACS880-204-… ACS880-104… = 400 V (Range 380 … 415 V) 008A0-3 ACS880-104-008A0-3 1×R1i 0018A-3 ACS880-104-0018A-3 1×R2i...

  • Page 276: Fuses

    3080A-7 ACS880-104-0600A-7 6×R8i Cabinet-installed units available from ABB IGBT supply unit types available from ABB as modules IGBT supply modules used. The quantity of the modules is shown in the Frame column. Fuses For fuse types, see the ordering information.
  • Page 277 Technical data 277 Charging fuses Charging contactor Charging kit code Type Rating Info Type Rating 3AXD50000002846 OFAA000GG50 50 A, 690 V, HRC fuse AF96-30-22- 100 … 250 V AC/DC, 50/60 Hz IEC 000 link 3AXD50000015666 OFAA000GG16 16 A, 690 V, HRC fuse AF96-30-22- 100 …...
  • Page 278 278 Technical data Charging fuses Charging contactor Charging kit code Type Rating Info Type Rating 3AXD50000022525 OFAA000GG40 40 A, 690 V, HRC fuse AF52-30-22- 100 … 250 V AC/DC, 50/60 Hz IEC 000 link 3AXD50000022529 OFAA000GG35 35 A, 690 V, HRC fuse AF52-30-22- 100 …...

  • Page 279: Ul, Csa

    Technical data 279 Charging kit code Charging switch Charging resistor Type Rating Type Rating 3AXD50000022535 OS160GD04F 160 A, 690 V, 50 kA, 4-pole CBH 215 C H 414 5R0 5 ohm 3AXD50000025574 OS160GD04F 160 A, 690 V, 50 kA, 4-pole CBH 215 C H 414 5R0 5 ohm 3AXD50000025575...
  • Page 280 280 Technical data Charging fuses Charging contactor Charging kit code Type Rating Info Type Rating 3AXD50000017083 LPJ-200SP 200 A, 600 V AC Class J AF205-30-22 100 … 250 V AC/DC, 50/60 Hz 3AXD50000017084 LPJ-100SP 100 A, 600 V AC Class J AF305-30-11 100 …...

  • Page 281: Dimensions And Weights

    Technical data 281 Dimensions and weights ￭ IGBT supply module Height Width Depth Weight ACS880-204-… = 400 V (Range 380 … 415 V) 008A0-3 14.3 0018A-3 15.0 12.3 13.2 0035A-3 18.4 12.3 24.3 0050A-3 18.4 12.3 24.3 0093A-3 18.4 12.3 39.7...

  • Page 282: Lcl Filter Module

    282 Technical data Height Width Depth Weight ACS880-204-… 2070A-7 1397 9.45 22.95 3080A-7 1397 9.45 22.95 With module covers and without strain relief clamps (R1i to R4i). ￭ LCL filter module Height Width Depth Weight ACS880-204-… LCL filter type = 400 V (Range 380 … 415 V)
  • Page 283 Technical data 283 Height Width Depth Weight ACS880-204-… LCL filter type 0370A-7 BLCL-13-7+C183+C188 1397 55.0 9.45 504.9 19.88 177.7 391.8 0540A-7 BLCL-15-7+C183+C188 1397 55.0 9.45 504.9 19.88 217.5 479.5 0720A-7 BLCL-24-7+C183+C188 1397 55.0 9.45 22.9 663.6 1050A-7 BLCL-25-7+C183+C188 1397 55.0 9.45...

  • Page 284: Free Space Requirements

    284 Technical data Free space requirements Above Front Left Right ACS880-204-… = 400 V (Range 380 … 415 V) 008A0-3 0018A-3 0035A-3 0050A-3 0093A-3 0210A-3 0420A-3 0580A-3 0810A-3 1130A-3 1330A-3 1580A-3 2350A-3 3110A-3 4620A-3 = 500 V (Range 380 … 500 V)

  • Page 285: Allowable Mounting Orientations

    Technical data 285 Above Front Left Right ACS880-204-… 3080A-7 Definitions Above Free space to enable cooling air flow Front Free space for cabling Left Free space for smooth installation Right Free space for smooth installation Allowable mounting orientations The modules must be mounted upright unless other orientations are expressly allowed below.

  • Page 286: Losses, Cooling Data And Noise

    286 Technical data Losses, cooling data and noise ACS880-204-… Air flow for IGBT supply mod- Noise lossISU lossLCL /min = 400 V (Range 380 … 415 V) 008A0-3 0.09 0.13 0018A-3 0.17 0.33 0035A-3 0.30 0.67 0050A-3 0.41 0.98 0093A-3 0.74...

  • Page 287: Tightening Torques

    Technical data 287 ACS880-204-… Air flow for IGBT supply mod- Noise lossISU lossLCL /min 3080A-7 60.9 33.0 12300 7240 Definitions Heat dissipation. Total losses of the ISU module at nominal power lossISU Heat dissipation. Total losses of the LCL filter module at nominal power...

  • Page 288: Cable Lugs

    288 Technical data ￭ Cable lugs Size Max. torque Note 15 N·m (11 lbf·ft) Strength class 8.8 32 N·m (23.5 lbf·ft) Strength class 8.8 50 N·m (37 lbf·ft) Strength class 8.8...

  • Page 289: Typical Power Cable Sizes

    Technical data 289 Typical power cable sizes The tables below give current carrying capacity (I ) for aluminum and copper PVC/XLPE Lmax insulated cables. A correction factor K = 0.70 is used. Time const is the temperature time constant of the cable. The cable sizing is based on max.
  • Page 290 290 Technical data Copper cable PVC insulation XLPE insulation Conductor temperature 70° Conductor temperature 90° Size ⌀ [mm] Time const. [s] Time const. [s] Lmax Lmax 3 × 1.5 + 1.5 3 × 2.5 + 2.5 (3 × 4 + 4) 3 ×...

  • Page 291: Electrical Power Network Specification

    *) Type gG according to IEC 60269 Maximum allowed operating time is <0.1 s for fuses mentioned above. For supply units with R8i module(s): Supply units with the ABB-defined main switch-disconnector and fuses: • Rated peak withstand current I = 105 kA •...

  • Page 292: Dc Connection Data

    ACS880-204-xxxxA-5: 513…675 V DC. This is indicated in the type designation label as typical output voltage levels 540/648/675 V DC ACS880-204-xxxxA-7: 709…932 V DC (709…810 V DC for UL/CSA). This is indic- ated in the type designation label as typical output voltage levels 709/810/932 V DC (810 V DC for UL/CSA).

  • Page 293: Protection Classes

    Maximum long-term tensile load: 1 N • 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 294: Ambient Conditions

    58 … 150 Hz 1 g Classification of environ- IEC 60068-2-6:2007, tion of environmental con- mental conditions - Part 3: Tested in ABB multidrive EN 60068-2-6:2008 Envir- ditions - Part 3: Classifica- Classification of groups of cabinet (ACS880-x07) ac- onmental testing Part 2-6:...

  • Page 295: Materials

    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.

  • Page 296: Cooling Fans

    296 Technical data Type cont start cont LCL filter module (ALCL-05-5) fan (+C188) 230 V AC 0.23 0.37 • Options +A013+C188+G304 230 V AC 0.29 0.37 115 V AC 0.59 LCL filter module (BLCL-1x-x) fan (+C188) 230 V AC 0.68 1.25 •...

  • Page 297: Markings

    ABB and its affiliates are not liable for damages and/or losses related to such security breaches, any unauthorized...

  • Page 299: Control Units Of The Drive

    Control units of the drive 299 Control units of the drive Contents of this chapter This chapter • describes the connections of the control unit, • contains the specifications of the inputs and outputs of the control unit. General The ZCU-14 control unit is used with IGBT supply module frame sizes R1i…R4i and R6i. The ZCU units consists of a ZCON control board contained in a plastic housing.

  • Page 300: Zcu-14 Layout And Connections

    300 Control units of the drive 146 Supply control unit Layout and connections ZCU-14 layout and connections The layout and connections of the ZCU-14 are shown below. The layout and connections of the ZCU-14 are shown below. Description Description XPOW External power input XPOW External power input X202...

  • Page 301: Bcu-X2 Control Unit Layout And Connections

    Control units of the drive 301 BCU-x2 control unit layout and connections Description I/O terminals (see following diagram) SLOT 1 I/O extension, encoder interface or fieldbus adapter module connection. (This is the sole location for an FDPI-02 diagnostics and panel interface.) SLOT 2 I/O extension, encoder interface or fieldbus adapter module connection...
  • Page 302 302 Control units of the drive Description Analog inputs Analog outputs Digital inputs, Digital input interlock (DIIL) XRO3 XD24 XPOW XDIO Digital input/outputs XD2D Drive-to-drive link XRO2 XDIO XD24 +24 V output (for digital inputs) XETH Ethernet port – Not in use XRO1 XPOW External power input...

  • Page 303: Default I/O Diagram Of The Supply Control Unit

    Control units of the drive 303 Default I/O diagram of the supply control unit The diagram below shows the default I/O connections on the supply control unit (A51), and describes the use of the connections in the supply unit. The wire size accepted by all screw terminals (for both stranded and solid wire) is 0.5 … 2.5 mm (24…12 AWG).

  • Page 304: External Power Supply For The Control Unit (Xpow)

    (nominal impedance 100 to 165 ohm, for example Belden 9842) for the wiring. For best immunity, ABB recommends high quality cable. Keep the cable as short as possible. Avoid unnecessary loops and parallel runs near power cables such as motor cables.

  • Page 305: Safe Torque Off (Xsto, Xsto Out)

    The BCU-x2 has an on-board data logger that collects real-time data from the power modules to help fault tracing and analysis. The data is stored onto the SDHC memory card inserted into the SD CARD slot and can be analyzed by ABB service personnel.

  • Page 306: Connector Data

    wer supply Connector pitch 5 mm, wire size 2.5 mm 24 V (±10%) DC, 2 A 306 Control units of the drive External power input. Two supplies can be connected for redundancy. ay outputs RO1…RO3 Connector data Connector pitch 5 mm, wire size 2.5 mm O1…XRO3) 250 V AC / 30 V DC, 2 A Power supply (XPOW)
  • Page 307 Control units of the drive 307 Analog inputs AI1 and AI2 Connector pitch 5 mm, wire size 2.5 mm (XAI:4 … XAI:7). Current input: –20…20 mA, R = 100 ohm Current/voltage input mode selection by Voltage input: –10…10 V, R >...

  • Page 308: Bcu-X2 Ground Isolation Diagram

    308 Control units of the drive Control units of the drive 137 ￭ BCU-x2 ground isolation diagram Ground isolation diagram XPOW +24VI +24VI +VREF -VREF AGND AI1+ Common mode voltage AI1- AI2+ between each AI input and AI2- AGND is +30 V AGND AGND XD2D...

  • Page 309: Zcu-1X Ground Isolation Diagram

    Control units of the drive 309 Supply control unit 155 ￭ ZCU-1x ground isolation diagram Ground isolation diagram (ZCU) XPOW +24VI +VREF -VREF AGND AI1+ Common mode voltage between AI1- channels ±30 V AI2+ AI2- AGND AGND XD2D BGND XRO1, XRO2, XRO3 XD24 DIIL +24VD...

  • Page 311: Dimension Drawings

    Dimension drawings 311 Dimension drawings Contents of this chapter This chapter shows dimensions of the ACS880-204 IGBT supply modules and accessories.

  • Page 312: Igbt Supply Module (Frame R1I)

    312 Dimension drawings IGBT supply module (frame R1i)

  • Page 313: Igbt Supply Module (Frame R2I)

    Dimension drawings 313 IGBT supply module (frame R2i)

  • Page 314: Igbt Supply Module (Frame R3I)

    314 Dimension drawings IGBT supply module (frame R3i)

  • Page 315: Igbt Supply Module (Frame R4I)

    Dimension drawings 315 IGBT supply module (frame R4i)

  • Page 316: Igbt Supply Module (Frame R6I)

    316 Dimension drawings IGBT supply module (frame R6i)

  • Page 317: Igbt Supply Module (Frame R8I)

    Dimension drawings 317 IGBT supply module (frame R8i)
  • Page 318 318 Dimension drawings...

  • Page 319: Quick Connectors Of Igbt Supply Module (Frame R8I)

    Dimension drawings 319 Quick connectors of IGBT supply module (frame R8i)

  • Page 320: Lcl Filter Module (Filter For Frames R1I And R2I)

    320 Dimension drawings LCL filter module (filter for frames R1i and R2i)

  • Page 321: Lcl Filter Module (Filter For Frame R3I)

    Dimension drawings 321 LCL filter module (filter for frame R3i)

  • Page 322: Lcl Filter Module (Filter For Frames R3I And R4I)

    322 Dimension drawings LCL filter module (filter for frames R3i and R4i)

  • Page 323: Lcl Filter Module (Filter For Frame R6I)

    Dimension drawings 323 LCL filter module (filter for frame R6i)

  • Page 324: Lcl Filter Module (Filter For Frame 1×R8I)

    324 Dimension drawings LCL filter module (filter for frame 1×R8i)

  • Page 325: Lcl Filter Module (Filter For Frame R8I Multiples)

    Dimension drawings 325 LCL filter module (filter for frame R8i multiples)

  • Page 326: Wbca-01

    326 Dimension drawings WBCA-01...

  • Page 327: Wbca-11

    Dimension drawings 327 WBCA-11...

  • Page 328: Wbca-21

    328 Dimension drawings WBCA-21...

  • Page 329: Quick Connector

    Dimension drawings 329 Quick connector...

  • Page 330: Main Switch-Disconnector

    330 Dimension drawings Main switch-disconnector ￭ R1i…R4i OS160GD03 (IEC) www.abb.com Dimensions in mm 1 mm = 0.0394 in...

  • Page 331: Ot160E3 (Ul, Csa)

    Dimension drawings 331 OT160E3 (UL, CSA)

  • Page 332: R6I

    332 Dimension drawings Dimension drawings 325 ￭ OS400D03 (IEC) www.abb.com Dimensions in mm 1 mm = 0.0394 in OS400J03 (UL, CSA)

  • Page 333: Os400J03 (Ul, Csa)

    Dimension drawings 333 OS400J03 (UL, CSA)

  • Page 334: R8I

    334 Dimension drawings 326 Dimension drawings ￭  OT1000E03 (IEC), OT1200U03 (UL, CSA) www.abb.com Dimensions in mm 1 mm = 0.0394 in OT 1000/ 1250/ 1600E_ OT 800/ 1200U_ 03W4 04W4 03W8 04W8 174,50 254,50 334,50 414,50 254,50 334,50 414,50...

  • Page 335: Ot2000E12 (Iec)

    Dimension drawings 335 OT2000E12 (IEC) 472.5 www.abb.com Dimensions in mm 1 mm = 0.0394 in...

  • Page 336: Ot1250E12 (Iec)

    336 Dimension drawings OT1250E12 (IEC) 324.0 www.abb.com Dimensions in mm 1 mm = 0.0394 in...

  • Page 337: Ot1200U12 (Ul, Csa)

    0,89 6,93 7,44 0,79 1,97 334.5 5.71 1.69 50.5 1.97 www.cooperindustries.com www.abb.com Dimensions in mm 1 mm = 0.0394 in Auxiliary contact OA1G10 Auxiliary contact OA1G10 Auxiliary contact 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) OA1G10 0.8 N·m (7 lb.in)

  • Page 338: Main Contactor

    338 Dimension drawings Main contactor ￭ R1i…R4i AF09-30-10-13 (IEC, UL, CSA)

  • Page 339: Af26-30-00-13 (Iec, Ul, Csa)

    Dimension drawings 339 AF26-30-00-13_contactor dimensions.pdf AF26-30-00-13 AF26-30-00-13 (IEC, UL, CSA) 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 340: Af96-30-22-13 (Iec, Ul, Csa)

    AF96-30-22-13 (IEC, UL, CSA) AF96-30-22-13 (IEC, UL, CSA) 149 5.87" 116 4.57" 70 2.76" 0.39" 7 0.28" 5.5 0.22" 5.5 0.22" www.abb.com ￭ AF205-30-22-13 (IEC, UL, CSA) 152 5.98" AF205-30-22-13 (IEC, UL, CSA) 10 0.39" 105 4.13" ø 8.5 0.33" 35.5 1.40"...

  • Page 341: R8I

    332 Dimension drawings  Dimension drawings 341 ￭ AF580-30-22-70 and AF750-30-22-70 (IEC, UL, CSA) AF580-30-22-70 and AF750-30-22-70 (IEC, UL, CSA) www.abb.com...

  • Page 342: Af1250-30-22-70 (Iec, Ul, Csa)

    342 Dimension drawings AF1250-30-22-70 (IEC, UL, CSA) 48,5 72 2.83" M6 1/4-20 UNC AF1250 Dimensions in mm www.abb.com 1 mm = 0.0394 in...

  • Page 343: Af2050-30-22-70 (Iec, Ul, Csa)

    Dimension drawings 343 AF2050-30-22-70 (IEC, UL, CSA) ø 13 0.51" 1.57" 17 0.67" 30 1.18" 0.51" 10 0.39" AF2050 312 340 Dimensions in mm www.abb.com 1 mm = 0.0394 in...

  • Page 344: Af1650-30-22-70 (Iec, Ul, Csa)

    344 Dimension drawings AF1650-30-22-70 (IEC, UL, CSA) 312 340 Dimensions in mm www.abb.com 1 mm = 0.0394 in...

  • Page 345: Charging Switches

    Dimension drawings 345 Charging switches ￭ OS30FAJ22F OA 3G01 OSZ 4 OA 1G10 OA4B1C max 3+3 max 1+1 75...80 Test 35,6 27,6 30,8 14,3 EN 50022 14...85 Ø66 135...210 Dimensions in mm 1 mm = 0.0394 in...

  • Page 346: Os60Gj22Fp

    346 Dimension drawings ￭ OS60GJ22FP 138...205 (OXP 6x161) 1,77 5,43...8,07 100/3,94 4,41 45/1,77 >14 0,35 3/16 0,31 1,14 0,28 OS60GJ mm (in) 74.5 (2.93) 148 (5.82) 183.5 (7.20) 179.5/8.58 118 (4.65) 118 (4.65) 118 (4.65) 118 (4.65) 35 (1.38) 35 (1.38) 35 (1.38) 71.5 (2.81) 71.5 (2.81)

  • Page 347: Os100Gj22Fp

    Dimension drawings 347 ￭ OS100GJ22FP 138...205 (OXP 6x161) 1,77 5,35...8,07 33,4 81/3,19 1,31 69/2,72 0,79 2,36 0,33 95,5 1,42 3,76 0,10 0,43 4,81 1,50 8,66 0,24 125,5 1,42 4,94 138,5 6,77 5,45 2,56 >14 71,5 0,55 2,81 104,5/4,11 1,38 4,49 3,31 4,33 OS100GJ...

  • Page 348: Os160Gd04F

    348 Dimension drawings ￭ OS160GD04F 138...205 (OXP 6x161) 33,4 53,3 95,5 8,5 7,2 17,5 114,5 Back connection types: Ø9 >14 17,5 OS160GD04F 181.5 mm 130 mm 100 mm 160 mm 175 mm 190 mm Dimensions in mm 1 mm = 0.0394 in...

  • Page 349: Os200J04Fp

    Dimension drawings 349 ￭ OS200J04FP 2,95 0,79 1,57 110/46 40,5 4,33/1,81 0,34 1,59 0,12 3/16 0,33 0,79 0,24 1,77 10,5 36,5 0,43 1,44 0,22 2,83 164,5 6,26 4,96 198,5 6,48 7,82 8,59 2,56 8,4/0,33 33,5/1,32 >14 0,55 8,6/0,34 0,40 48,5 1,91 1,81 0,79...

  • Page 350: Resistors

    350 Dimension drawings Resistors ￭ CBH 215 C H 414 5R0 60 [2.36”] 5.3 [0.21”] 196.0+2 [7.72”+0.08”] 215+2 [8.46”+0.08”]...

  • Page 351: Handles

    Dimension drawings 351 Handles ￭ OH45-275 Ø66 Ø5 Ø31 45º Handle type (A) L (mm) B (mm) OHB 45J6 OHB 45J10 OHB 65J6 OHB 65J8 OHB 65J10 OHB 80J6 OHB 80J8 OHB 80J10 OHB 95J10 OHB 95J12 OHB 125J10 OHB 125J12 OHB 145J12 OHB 175J12 OHB 274J12...

  • Page 352: Ohb150J12P

    352 Dimension drawings ￭ OHB150J12P Ø 5 Ø 31 ø 69,4 45° Handle type L (mm) Shaft (mm) Notes OHB150J12P * (12 × 395 mm) or ** (12 Used with OT1250E12 *, OT2000E12 ** × 465 mm) and OT1200U12 * Dimensions in mm 1 mm = 0.0394 in...

  • Page 353: Ac Fuses

    Dimension drawings 353 AC fuses ￭ R1i…R4i 170M1559D, 170M1562D, 170M1565D, 170M1566D, 170M1569D (IEC)

  • Page 354: Ul, Csa)

    354 Dimension drawings DFJ-12, DFJ-25, DFJ-50, DFJ-70, DFJ-125 (UL, CSA) 2.38˝ 2.25˝ 0.63˝ 1.06˝ 0.50˝ 0.81˝ 4.63" (± 0.03) 3.63" 1.13" .75" 2.63" 1" .28" .13" .43" 70A to 100A 5.75" (± 0.03) 4.38" 1.13" 3.0" .28" 1 in = 25.4 mm 110A to 1.63"...

  • Page 355: R6I

    Dimension drawings 355 ￭ 170M5808D (IEC) Size Size 68 + 2.5 150 + 2.5 68 + 2.5 150 + 2.5 1 mm = 0.0394 in 1 mm = 0.0394 in www.cooperindustries.com DFJ-300 (UL, CSA) 7.13" (± 0.03) 5.25" 3.38" .41" 225A to 1.63"...

  • Page 356: R8I

    356 Dimension drawings ￭ 1170M6408, 170M6410, 170M6414, 170M6416 Size ø30 1 mm = 0.0394 in www.cooperindustries.com...

  • Page 357: 170M7059, 170M7062, 170M7063

    Dimension drawings 357 170M7059, 170M7062, 170M7063 Indicator www.cooperindustries.com Size 1 mm = 0.0394 in www.cooperindustries.com...

  • Page 358: Dc Fuses

    358 Dimension drawings DC fuses ￭ R1i…R4i Fuse, 14 × 51 mm (IEC, UL, CSA) 14.3 mm (0.563”) 50.8 mm (2.000”) 15.5 mm (0.610”) Mersen (Ferraz-Shawmut) US141 (Z331153F) fuse disconnector (for 14 × 51 mm fuses) (IEC, UL, CSA)

  • Page 359: Fuse, 27 × 60 Mm (Iec, Ul, Csa)

    Dimension drawings 359 Fuse, 27 × 60 mm (IEC, UL, CSA) 60,3 60,3 Ø 5 7 mm indicator travel Mersen (Ferraz-Shawmut) US271MI (R227600C) fuse disconnector (for 27 × 60 mm fuses) (IEC, UL, CSA) Fixation Fixation 5.25 Fixation 25.5...

  • Page 360: R6I

    360 Dimension drawings ￭ 170M4413 (IEC, UL, CSA) Size ø20 1 mm = 0.0394 in www.cooperindustries.com...

  • Page 361: R8I

    Dimension drawings 361 ￭ 170M6413, 170M6415, 170M6417, 170M6419 (IEC, UL, CSA) Size ø30 ø30 *For size 3 1600 … 2000 A 1 mm = 0.0394 in www.cooperindustries.com...

  • Page 362: 170M6544, 170M6546, 170M6549 (Iec, Ul, Csa)

    362 Dimension drawings 170M6544, 170M6546, 170M6549 (IEC, UL, CSA) Size ø30 1 mm = 0.0394 in www.cooperindustries.com...

  • Page 363: Air Circuit Breakers

    Dimension drawings 363 Air circuit breakers ￭ E2.2S-A (UL/CSA/IEC) Horizontal terminals 1600 A … 2000 A Moving part Vertical terminals 1600 A … 2000 A Fixed part Tightening torque 8.6 Nm - 76 lb in Segregation Door position Connected, test, disconnected distances Grounding Roof insulation or insulated material Mounting fixed part screws...

  • Page 364: E4.2S (Iec)

    364 Dimension drawings ￭ E4.2S (IEC) Horizontal terminals 3200 A Door position Vertical terminals 3200 A Earthing device Horizontal terminals 4000 A Mobile part Vertical terminals 4000 A Fixed part Tightening torque 3200 A 20 Nm Segregation (where envisaged) Tightening torque 4000 A 20 Nm Distance from connected for testing to isolated...

  • Page 365: E4.2S-A (Ul/Csa/Iec)

    Dimension drawings 365 ￭ E4.2S-A (UL/CSA/IEC) Horizontal terminals 2500 A Moving part Vertical terminals 2500 A Fixed part Tightening torque 20 Nm - 177 lb in Segregation Door position Connected, test, disconnected distances Grounding Roof insulation or insulated material Mounting fixed part screws...

  • Page 366: E6.2V-A (Ul/Csa/Iec)

    366 Dimension drawings ￭ E6.2V-A (UL/CSA/IEC) Horizontal terminals 5000 A Moving part Vertical terminals 5000 A Fixed part Tightening torque 20 Nm - 177 lb in Segregation Door position Roof insulation or insulated material Mounting fixed part screws M8×25 provided Tightening torque 20 Nm - 177 lb in...

  • Page 367: Zcu Control Unit

    156 Dimension drawings Dimension drawings 367 ZCU-14_dimensions.pdf ZCU-14 control unit ZCU control unit 44.7 54.5 Dimensions in mm 1 mm = 0.0394 in...

  • Page 368: Bcu Control Unit

    368 Dimension drawings BCU control unit...

  • Page 369: Bamu Voltage/Current Measurement Unit

    Dimension drawings 369 BAMU voltage/current measurement unit 119.5 [4.70] 134.8 [5.31]...

  • Page 370: Acs-Ap-X Control Panel With Dpmp-01 Door Mounting Kit

    ACX-AP-x_dimensions control panel with door mount kit.pdf Dimension drawings 155 370 Dimension drawings ACX-AP-x control panel with door mounting kit ACS-AP-x control panel with DPMP-01 door mounting kit 81.0 [3.19] 86.5 [3.41] 123.1 [4.85] 125.0 [4.92] Cutting in the cabinet door: 109 mm × 223 mm (4.29 in × 8.78 in) Plate thickness: 1.5 …...

  • Page 371: Ramp

    Dimension drawings 371 Ramp...
  • Page 372 372 Dimension drawings...

  • Page 373: Cvar Board

    Dimension drawings 373 CVAR board 28.3 Common mode filter...

  • Page 374: Rfi Filter And Related Accessories

    374 Dimension drawings RFI filter and related accessories ￭ RFI filter...

  • Page 375: Oval Toroid Kit

    Dimension drawings 375 ￭ Oval toroid kit...

  • Page 376: Oval Toroid

    376 Dimension drawings ￭ Oval toroid...

  • Page 377: Example Circuit Diagrams

    • understanding the internal connections and operation of the cabinet-installed drive with an IGBT supply unit, and • learning how to wire an (ACS880-204) IGBT supply module when installed in a user-defined cabinet. Component designations used in the diagrams ￭...

  • Page 378: Frame R6I

    ACS-AP-x control panel Fxx.xx Fuses Main switch-disconnector Main contactor Rx.x Common mode filter LCL filter module (type ALCL-05-5) Supply module (type ACS880-204) ￭ Frame R8i and multiples Designation Component Varistor board CVAR-01C in UL/CSA installations BCU control unit ACS-AP-x control panel Fxx.xx...

  • Page 379: Circuit Diagram Set Contents

    Example circuit diagrams 379 Circuit diagram set contents The contents of each circuit diagram set are listed below: ACS880-204 IGBT supply unit R1i…R4i with one supply module (3AXD10000314213) • Main fuse switch • IGBT supply module • LCL filter module WFU-xx •...

  • Page 380: Frames R1I

    380 Example circuit diagrams Frames R1i…R4i...
  • Page 381 Example circuit diagrams 381...
  • Page 382 382 Example circuit diagrams...
  • Page 383 Example circuit diagrams 383...
  • Page 384 384 Example circuit diagrams...

  • Page 385: Frame R6I

    Example circuit diagrams 385 Frame R6i...
  • Page 386 386 Example circuit diagrams...
  • Page 387 Example circuit diagrams 387...
  • Page 388 388 Example circuit diagrams...
  • Page 389 Example circuit diagrams 389...

  • Page 390: Frame 1×R8I

    390 Example circuit diagrams Frame 1×R8i...
  • Page 391 Example circuit diagrams 391...
  • Page 392 392 Example circuit diagrams...
  • Page 393 Example circuit diagrams 393...
  • Page 394 394 Example circuit diagrams...
  • Page 395 Example circuit diagrams 395...

  • Page 396: Frame 4×R8I

    396 Example circuit diagrams Frame 4×R8i...
  • Page 397 Example circuit diagrams 397...
  • Page 398 398 Example circuit diagrams...
  • Page 399 Example circuit diagrams 399...
  • Page 400 400 Example circuit diagrams...
  • Page 401 Example circuit diagrams 401...
  • Page 402 402 Example circuit diagrams...

  • Page 403: 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 404 3AUA0000131525H © 2019 ABB Oy. All Rights Reserved. Specifications subject to change without notice.

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