ABB ACS880-204LC Manuals

ABB ACS880-204LC Manuals

Manuals and User Guides for ABB ACS880-204LC. We have 1 ABB ACS880-204LC manual available for free PDF download: Hardware Manual

ABB ACS880-204LC Hardware Manual

ABB ACS880-204LC Hardware Manual (278 pages)

IGBT Supply modules

Brand: ABB | Category: Control Unit | Size: 23.91 MB

Table of Contents

Table of Contents
5
Table of Contents
7
1 Introduction to the Manual

13
- Contents of this Chapter
  13
- Applicability
  13
- Safety Instructions
  13
- Target Audience
  13
- Categorization by Frame Size and Option Code
  14
- Use of Component Designations
  14
- Terms and Abbreviations
  14
- Related Documents
  15
2 Operation Principle and Hardware Description

17
- Contents of this Chapter
  17
- Operation Principle
  17
  - Simplified Main Circuit Diagram
    18
  - Charging
    18
- Overview Diagram of the Drive System
  19
- Cooling System
  19
- Single-Line Circuit Diagrams of the Supply Unit
  20
  - Frame 1×R8I
    20
  - Frame R8I Multiples
    21
- IGBT Supply Module Hardware
  22
  - Frame R8I Hardware
    22
    
    Module Layout
    22
    
    Coolant Connectors
    23
    
    Connectors X50
    23
    
    Fiber Optic Connectors
    24
- Control Interfaces
  25
  - BCU Control Unit of Frame R8I and Multiples
    25
  - Overview of the Control Connections of the BCU Control Unit
    26
- Supply Unit Control Devices
  27
  - Main Disconnecting Device
    27
  - Auxiliary Voltage Switch
    27
  - Operating Switch
    27
  - Emergency Stop and Emergency Stop Reset Buttons
    27
  - ACX-AP-X Control Panel
    27
  - Line-Up Charging Switch
    28
  - Local Charging Control Switch
    28
  - DC Switch-Disconnector
    28
  - Charging Switch for Unit Charging
    28
  - DC Switch-Disconnector for Line-Up Charging
    28
  - PC Connection
    29
  - Fieldbus Control
    29
- Type Designation Labels
  29
- Type Designation Key
  30
  - IGBT Supply Module
    30
  - LCL Filter
    30
3 Moving and Unpacking the Module

31
- Contents of this Chapter
  31
4 Cabinet Construction

33
5 Electrical Installation

99
- Contents of this Chapter
  99
- Safety and Liability
  99
- Electrical Safety Precautions
  100
- Isolation from AC Supply Networks
  101
- Isolation from Common DC Bus
  102
- General Notes
  102
  - Printed Circuit Boards
    102
  - Optical Components
    102
- Checking the Insulation of the Assembly
  103
  - Checking the Insulation of the Input Cable
    103
- Checking the Compatibility with IT (Ungrounded) Systems
  103
- Connecting the Input Power Cables/Busbars
  104
- Connecting the LCL Filter
  108
- Main Breaker / Contactor
  109
- Installing the Charging Circuit
  109
- Connecting the External Power Supply Cable for the Auxiliary Circuit
  109
- Connecting the Control Cables
  110
  - Connection Diagram
    110
  - Connection Procedure
    110
  - Connectors X50
    111
- Connecting a PC
  112
- Installing Optional Modules
  113
- Installing and Using CIO-01 I/O Module
  113
6 Installation Checklist of the Drive

115
- Contents of this Chapter
  115
- Checklist
  115
7 Start-Up

117
8 Maintenance

121
- Contents of this Chapter
  121
- Maintenance Intervals
  121
- Maintenance Timers and Counters
  123
- Cooling System
  123
- Cabinet
  123
  - Cleaning the Interior of the Cabinet
    123
- Power Connections
  124
  - Retightening the Power Connections
    124
- Cooling Fans
  124
  - Replacing the Cooling Fan of the IGBT Supply Module (Frame R8I)
    124
  - Replacing the Cooling Fan of the LCL Filter
    126
- IGBT Supply Module
  127
  - Replacing the IGBT Supply Module (Frame R8I)
    127
    
    Removing the Module
    127
    
    Reinstalling the Module
    129
- Capacitors
  130
  - Reforming the Capacitors
    130
- Control Panel
  130
  - Cleaning the Control Panel
    130
  - Replacing the Control Panel Battery
    130
- Control Unit
  130
  - Replacing the Memory Unit
    130
  - Replacing the BCU Control Unit Battery
    131
- Leds and Other Status Indicators
  131
  - Control Panel and Panel Platform/Holder Leds
    131
  - R8I Module Leds
    132
9 Ordering Information

133
- Contents of this Chapter
  133
- Kit Code Key
  134
- Frame R8I and Multiples
  135
  - IGBT Supply Modules
    135
  - LCL Filters
    136
  - Control Panel
    137
  - Control Electronics
    138
    
    Control Unit
    138
    
    Fiber Optic Cables
    138
    
    Auxiliary Measurement Unit (BAMU)
    138
    
    CIO-01 I/O Module
    139
  - Mechanical Installation Accessories
    139
    
    Adapter Kit (for Rittal VX25 Enclosures)
    139
    
    Module Top/Bottom Guides
    140
    
    Shrouding
    141
    
    Marine Support Kit for LCL Filters
    142
  - AC-Side Components
    142
    
    Main Circuit Breakers and Wagons
    142
    
    IEC Busbar Shim Kits
    150
    
    Main Circuit Breaker and Wagon Cover
    150
    
    AC Fuses
    151
    
    AC-DC Charging Kits for Line-Up Charging
    152
    
    AC Busbars for LCL Filters
    153
    
    LCL Fuse Busbars
    153
    
    LCL Choke Installation Kits
    154
    
    LCL Capacitor Installation Kits
    156
    
    LCL ISU Connection Kits
    157
    
    AC Busbars
    157
    
    Quick Connector
    158
  - DC-Side Components
    158
    
    DC Bus Installation Parts (for Rittal VX25 Enclosures)
    158
    
    DC Connection Parts 1 of 2 (for Rittal VX25 Enclosures)
    159
    
    DC Fuses
    160
    
    DC Switch-Disconnector Kits for Unit Charging
    161
    
    DC Charging Kits for Unit Charging (for Units with DC Switch-Disconnector)
    162
    
    Charging Resistors or Unit Charging (for Units with DC Switch-Disconnector)
    162
    
    DC Switch-Disconnector for Line-Up Charging
    162
    
    DC Connection Parts 2 of 2 (for Rittal VX25 Enclosures)
    163
    
    Flat-PLS Busbars (Common DC) for LCL Filters
    163
    
    Charging Mechanics
    164
    
    DC Connection Charging Mechanics
    164
    
    Common Mode Filter Busbars
    165
    
    Common Mode Filters
    165
  - Cooling System Parts
    165
    
    Coolant Distribution Manifold Kits
    165
    
    Piping
    167
    
    Heat Exchanger
    168
    
    Cooling System Parts for LCL Filters
    168
    
    Cooling Fans for LCL Filters
    169
    
    Cooling Fans for IGBT Supply Modules
    170
10 Internal Cooling Circuit

171
- Contents of this Chapter
  171
- Applicability
  171
- Internal Cooling System
  171
- Connection to a Cooling Unit
  173
  - Connection to an ACS880-1007LC Cooling Unit
    173
  - Connection to a Custom Cooling Unit
    173
    
    General Requirements
    173
    
    Coolant Temperature Control
    173
- Filling up and Bleeding the Internal Cooling Circuit
  174
  - Drive Line-Ups with an ACS880-1007LC Cooling Unit
    174
  - Drive Line-Ups with a Custom Cooling Unit
    174
- Draining the Internal Cooling Circuit
  176
- Maintenance Intervals
  176
- Technical Data
  176
  - Coolant Specification
    176
    
    Coolant Type
    176
  - Temperature Limits
    176
  - Pressure Limits
    178
  - Coolant Flow Rate Limits
    178
  - Cooling Circuit Materials
    178
11 Technical Data

181
- Contents of this Chapter
  181
- Ratings
  182
  - Definitions
    182
  - Derating
    183
    
    Ambient Temperature Derating
    183
    
    Altitude Derating
    183
- Type Equivalence Table
  183
- Fuses
  184
- LCL Filters
  184
  - Kit Contents
    184
  - Technical Data
    185
- Charging Kit Contents
  185
- Dimensions and Weights
  185
- Free Space Requirements
  185
- Allowable Mounting Orientations
  185
- Losses, Cooling Data and Noise
  186
- Tightening Torques
  188
  - Electrical Connections
    188
  - Mechanical Connections
    188
  - Insulation Supports
    188
  - Cable Lugs
    188
- Typical Power Cable Sizes
  189
- Electrical Power Network Specification
  191
- Control Unit Connection Data
  191
- Coolant Connections
  191
- Efficiency
  191
- Protection Classes
  191
- Optical Components
  192
- Ambient Conditions
  193
- Cooling
  194
- Materials
  194
  - Internal Cooling Circuit
    194
- Auxiliary Circuit Current Consumption
  195
  - Control Equipment
    195
  - Cooling Fans
    195
  - Definitions
    195
- Standards and Markings
  195
- Disclaimers
  196
  - Generic Disclaimer
    196
  - Cybersecurity Disclaimer
    196
12 Control Units of the Drive

197
- Contents of this Chapter
  197
- General
  197
- BCU-X2 Control Unit Layout and Connections
  198
- Default I/O Diagram of the Supply Control Unit
  200
- External Power Supply for the Control Unit (XPOW)
  201
- The XD2D Connector
  201
- The X485 Connector
  202
- Safe Torque off (XSTO, XSTO OUT)
  202
- FSO-XX Safety Functions Module Connection (X12)
  202
- SDHC Memory Card Slot
  202
- Connector Data
  203
  - BCU-X2 Ground Isolation Diagram
    205
13 Dimension Drawings

207
- Contents of this Chapter
  207
- Frame R8I Module
  208
  - Quick Connector
    209
- LCL Filter Components
  210
- Control Electronics
  215
  - BCU Control Unit
    215
  - DPMP-01 Door Mounting Kit
    216
- Main Circuit Breaker
  217
  - E2.2S-A (Iec/Ul/Csa)
    217
  - E4.2S-A (Iec/Ul/Csa)
    218
- AC Fuses
  219
  - Fuses of Type 170M64Xx
    219
  - Fuses of Type 170M70Xx
    219
- DC Fuses
  220
14 Example Circuit Diagrams

221
- Contents of this Chapter
  221
- Contents of Example Circuit Diagrams
  221
  - ACS880-204LC IGBT Supply Unit 2×R8I (3AXD10000695767)
    221
  - ACS880-204LC IGBT Supply Unit 4×R8I (3AXD10000695768)
    222
- Frame 2×R8I
  223
- Frame 4×R8I
  247

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