ABB ACS880-307LC (01) PDF MANUAL


Post questions, comments, reviews or errors in the comment box below.

Your File is Ready … Download PDF

CLICK HERE TO DOWNLOAD ABB ACS880-307LC (01) PDF MANUAL


PDF Content Summary: —ABB INDUSTRIAL DRIVES ACS880-307LC diode supply units Hardware manual ACS880-307LC diode supply units Hardware manual Table of contents 3. Electrical installation 6. Start-up 3AXD50000579662 Rev AEN EFFECTIVE: 2020-06-30 Table of contents 5 Table of contents 1 Introduction to the manual 9 Contents of this chapter ........................................................................... 9 Applicability ......................................................................................... 9 Safety instructions ................................................................................. 9 Target audience .................................................................................... 10 Categorization by frame size and option code ................................................. 10 Use of component designations ................................................................. 10 Terms and abbreviations .......................................................................... 11 Related documents ................................................................................ 2 Operation principle and hardware description 13 Contents of this chapter ........................................................................... 13 Operation principle ................................................................................. 14 Overview diagram of the rectifier bridge .................................................... 14 6- and 12-pulse supply connections ......................................................... 16 Overview diagram of the drive system .......................................................... 17 Layout drawings .................................................................................... 17 Overview layout drawing of the supply unit ................................................. 18 Auxiliary control cubicle layout ............................................................... 19 Incoming cubicle layout - bottom cable entry ............................................... 20 Supply module cubicle layout – frame 1×D8T ............................................. 20 Supply module cubicle layout – frame 1×D8T, electrical components .............. 20 Supply module cubicle layout – frame 1×D8T, cooling circuit ........................ 21 Supply module cubicle layout – frame 2×D8T ............................................. 21 Supply module cubicle layout – frame 2×D8T, electrical components .............. 22 Supply module cubicle layout – frame 2×D8T, cooling circuit ........................ 23 Supply module layout - frame D8T .......................................................... 24 Overview of the control connections of the BCU control unit ................................ 25 Supply unit control devices ....................................................................... 25 Overview of door switches and lights ........................................................ 25 Main disconnecting device [Q1.x] ............................................................ 26 Auxiliary voltage switch [Q21] ................................................................ 26 Grounding switch [Q9.x] ....................................................................... 26 Operating switch [S21] ........................................................................ 27 Emergency stop button [S61] ................................................................. 27 E-stop reset button [S62] and indication lamp [P62] ...................................... 27 Other optional door controls .................................................................. 27 Control panel .................................................................................... 27 PC connection .................................................................................. 28 Fieldbus control ................................................................................. 28 Type designation labels ........................................................................... 30 Type designation keys ............................................................................ 30 Type designation key of the supply unit ..................................................... 30 Basic code ................................................................................... 30 Option codes ................................................................................ 32 Type designation key of the diode supply module ......................................... 6 Table of contents 3 Electrical installation 35 Contents of this chapter ........................................................................... 36 Electrical safety precautions ..................................................................... 37 General notes ...................................................................................... 37 Static electricity ................................................................................. 37 Optical components ............................................................................ 38 Measuring the insulation .......................................................................... 38 Measuring the insulation of the drive ........................................................ 38 Measuring the insulation of the input power cable ........................................ 38 Connecting the input power cables .............................................................. 38 Connection diagram – 6-pulse supply unit .................................................. 38 Connection diagram – 12-pulse supply unit (option +A004) ............................. 39 Connection procedure – bottom cable entry ............................................... 42 Connecting the external power supply cable for the auxiliary circuit (option +G307) .... 42 Wiring the functional safety options ............................................................. 42 Connecting the control cables ................................................................... 42 Control cable connection procedure ......................................................... 42 Grounding the outer shields of the control cables at the cabinet entry ............. 44 Routing the control cables inside the cabinet ........................................... 44 Connecting control cabling ................................................................ 46 Connecting a PC ................................................................................... 4 The control unit 47 Contents of this chapter ........................................................................... 48 BCU-x2 layout ...................................................................................... 50 Default I/O diagram of the supply control unit ................................................. 52 External power supply for the control unit (XPOW) ........................................... 52 The X485 connector ............................................................................... 53 Safe torque off (XSTO, XSTO OUT) ............................................................ 53 FSO-xx safety functions module connection (X12) ........................................... 53 SDHC memory card slot .......................................................................... 54 Connector data ..................................................................................... 56 BCU-x2 ground isolation diagram ............................................................ 5 Installation checklist 57 Contents of this chapter ........................................................................... 57 Checklist ............................................................................................. 6 Start-up 59 Contents of this chapter ........................................................................... 60 Start-up procedure ................................................................................. 60 Basic checks with no voltage connected .................................................... 60 Starting and checking the cooling system .................................................. 60 Connecting voltage to input terminals and auxiliary ....................................... 61 Setting the supply unit parameters .......................................................... 61 Powering up the drive .......................................................................... 62 Safety function validation ...................................................................... 62 On-load checks ................................................................................. 62 Switching the supply unit off ...................................................................... 62 Disconnecting and temporary grounding the drive ............................................ Table of contents 7 7 Maintenance 63 Contents of this chapter ........................................................................... 63 Maintenance intervals ............................................................................. 65 Maintenance timers and counters ............................................................... 65 Internal liquid-cooling system .................................................................... 65 Power connections ................................................................................ 65 Retightening the power connections ........................................................ 65 Fans .................................................................................................. 65 Replacing the fan in the 600 mm wide incoming cubicle ................................. 67 Replacing the cooling fan of a D8T supply module ....................................... 68 Fuses ................................................................................................ 68 Checking and replacing the AC fuses ....................................................... 69 Checking and replacing the DC fuses ....................................................... 70 Supply module ..................................................................................... 70 Replacing the D8T supply module ........................................................... 74 Control panel ....................................................................................... 74 Cleaning the control panel .................................................................... 74 Replacing the control panel battery .......................................................... 75 Control unit .......................................................................................... 75 Replacing the memory unit ................................................................... 75 Replacing the BCU control unit battery ..................................................... 76 LEDs and other status indicators ................................................................ 76 Control panel and panel platform/holder LEDs ............................................ 77 Control unit LEDs ............................................................................... 8 Internal cooling circuit 79 Contents of this chapter ........................................................................... 79 Applicability ......................................................................................... 79 Internal cooling system ............................................................................ 81 Connection to a cooling unit ...................................................................... 81 Connection to an ACS880-1007LC cooling unit ........................................... 81 Connection to a custom cooling unit ......................................................... 81 General requirements ...................................................................... 81 Coolant temperature control ............................................................... 82 Filling up and bleeding the internal cooling circuit ............................................ 82 Drive line-ups with an ACS880-1007LC cooling unit ...................................... 82 Drive line-ups with a custom cooling unit ................................................... 84 Draining the internal cooling circuit .............................................................. 84 Maintenance intervals ............................................................................. 84 Technical data ...................................................................................... 84 Coolant specification ........................................................................... 84 Coolant type ................................................................................. 84 Temperature limits .............................................................................. 86 Pressure limits .................................................................................. 86 Coolant flow rate limits ........................................................................ 86 Cooling circuit materials ....................................................................... 9 Technical data 89 Contents of this chapter ........................................................................... 89 Ratings .............................................................................................. 8 Table of contents 90 Derating ............................................................................................. 90 Surrounding air temperature derating ....................................................... 91 Coolant temperature derating ................................................................ 91 Antifreeze content derating ................................................................... 91 Altitude derating ................................................................................ 91 Type equivalence table ............................................................................ 92 Fuses ................................................................................................ 92 Main circuit AC fuses .......................................................................... 93 Main circuit DC fuses .......................................................................... 94 Dimensions, weights and free space requirements ........................................... 95 Cooling data and noise ............................................................................ 95 Terminal and cable entry data for the input power cable ..................................... 96 400 mm wide input cubicle .................................................................... 97 600 mm wide incoming cubicle or input cubicle ........................................... 98 Tightening torques ................................................................................. 98 Electrical connections .......................................................................... 98 Mechanical connections ....................................................................... 98 Insulation supports ............................................................................. 98 Cable lugs ....................................................................................... 99 Typical power cable sizes .........................................................................101 Electrical power network specification ..........................................................101 Control unit (board) connection data ............................................................101 Auxiliary circuit current consumption ............................................................101 Efficiency ............................................................................................101 Protection classes .................................................................................102 Ambient conditions ................................................................................103 Materials .............................................................................................103 Color .................................................................................................103 Package .............................................................................................103 Vertical package ................................................................................103 Disposal .............................................................................................103 Applicable standards ..............................................................................104 Markings .............................................................................................104 Disclaimers .........................................................................................104 Generic disclaimer .............................................................................104 Cybersecurity disclaimer ...................................................................... Further information Introduction to the manual 9 Introduction to the manual Contents of this chapter This chapter contains general information on the manual. Applicability The manual is applicable to the cabinet-installed ACS880-307LC...+A018 diode supply units that form a part of an ACS880 multidrive system. Safety instructions Obey all safety instructions delivered with the drive. • Read the complete safety instructions before you install, commission, use or service the drive. The complete safety instructions are given in ACS880 liquid-cooled multidrive cabinets and modules safety instructions (3AXD50000048633 [English]). • Read the software-function-specificwarningsand notes before changing the default settings of a function. For each function, the warnings and notes are given in the section describing the related user-adjustable parameters. • Read the task-specific safety instructions before starting the task. See the section describing the task. Target audience This manual is intended for people who plan the installation, install, start up and do maintenance work on the drive, or create instructions for the end user of the drive concerning the installation and maintenance of the drive. Read the manual before working on the drive. You are expected to know the fundamentals of electricity, wiring, electrical components and electrical schematic symbols.1 10 Introduction to the manual Categorization by frame size and option code The frame size identifies information which concerns only a certain frame size of the drive. The frame size is shown on the type designation label. All frame sizes are listed in the technical data. The option code (for example, option +E200) identifies information which concerns only a certain optional selection. The options included in the drive are listed on the type designation label. Use of component designations Some device names in the manual include the item designation in brackets, for example [Q20], to make it possible to identify the components in the circuit diagrams of the drive. Terms and abbreviations Term Description ACU Auxiliary control unit. Contains control electronics, auxiliary voltage circuitry, etc. BCU Type of control unit CIO I/O module for controlling cooling fans Control board Circuit board in which the control program runs Control unit Control board built in a housing (often rail-mountable) Cubicle One section of a cabinet-installed drive. A cubicle is typically behind a door of its own. D8T Frame size designation of the diode supply module DC link DC circuit between rectifier and inverter DI Digital input Diode supply module Diode rectifier and related components enclosed in a metal frame or enclosure. Inten- ded for cabinet installation. Diode supply unit Diode supply modules under control of one control board, and related components. Drive Frequency converter for controlling AC motors DSU Diode supply unit Frame, frame size Physical size of the drive or power module ICU Incoming unit Intermediate circuit DC circuit between rectifier and inverter INU Inverter unit Inverter module Inverter bridge, related components and drive DC link capacitors enclosed in a metal frame or enclosure. Intended for cabinet installation. Inverter unit Inverter module(s) under control of one control unit, and related components. One inverter unit typically controls one motor. Multidrive Drive for controlling several motors which are typically coupled to the same machinery. Includes one supply unit, and one or several inverter units. Parameter In the drive control program, user-adjustable operation instruction to the drive, or signal measured or calculated by the drive. In some (for example fieldbus) contexts, a value that can be accessed as an object, eg, variable, constant, or signal. Rectifier Converts alternating current and voltage to direct current and voltage Single drive Drive for controlling one motor Introduction to the manual 11 Related documents Code Manual General manuals 3AXD50000048633 ACS880 liquid-cooled multidrive cabinets and modules safety instructions 3AXD50000048634 ACS880 liquid-cooled multidrive cabinets and modules electrical planning instructions 3AXD50000048635 ACS880 liquid-cooled multidrive cabinets mechanical installation instructions 3AXD50000126880 CIO-01 I/O module for distributed I/O bus control user's manual Supply unit manuals 3AXD50000174782 ACS880-207LC IGBT supply units hardware manual 3AUA0000131562 ACS880 IGBT supply control program firmware manual 3AXD50000579662 ACS880-307LC...+A018 diode supply units hardware manual 3AUA0000103295 ACS880 diode supply control program firmware manual Inverter unit manuals 3AXD50000196111 ACS880-107LC inverter units hardware manual 3AUA0000085967 ACS880 primary control program firmware manual 3AUA0000098062 ACS880 primary control program quick start-up guide Manuals for application programs (Crane, Winder, etc.) Brake unit and DC/DC converter unit manuals 3AXD50000481491 ACS880-607LC 1-phase brake units hardware manual 3AXD50000020967 ACS880 (3-phase) brake control program firmware manual 3AXD50000431342 ACS880-1607LC DC/DC converter units hardware manual 3AXD50000024671 ACS880 DC/DC converter control program firmware manual Option manuals 3AXD50000129607 ACS880-1007LC liquid cooling unit user's manual 3AXD50000039629 ACS880 +C132 marine type-approved cabinet-built drives supplement 3AUA0000085685 ACS-AP-x assistant control panels user’s manual 3AUA0000094606 Drive composer start-up and maintenance PC tool user’s manual 3AXD50000210268 Converter module lifting device for drive cabinets hardware manual Manuals for I/O extension modules, fieldbus adapters, safety options etc. You can find manuals on the Internet. See abb.com/drives/documents. For manuals not available in the document library, contact your local ABB representative. 12 Operation principle and hardware description 13 2 Operation principle and hardware description Contents of this chapter This chapter contains a description of the diode supply unit. The information is valid for the ACS880-307LC...+A018 diode supply units. Operation principle The core of the diode supply unit is a diode-thyristor bridge. It rectifies three-phase AC current to direct current for the intermediate DC link of the drive. The intermediate DC link supplies the inverters that run the motors. There can be one inverter unit only (single drives) or several inverter units (multidrives) connected to the intermediatecircuit. The DSU modules have inbuilt AC chokes. The AC chokes smoothen the current waveform in the power supply network and voltage in the DC link of the drive. The main difference between the ordinary diode-diode bridge and the controlled diode-thyristor bridge is the controllability. You cannot control the operation of the diodes but you can control the thyristors. By controlling the thyristors, you can limit the AC current of the drive at the power up without additional charging circuit in the supply unit or in inverter units. There are two control modes for the upper leg thyristor firing: the charging mode and the normal mode: • The charging mode is in operation a short period after the power switch on: the supply control program controls the thyristor firing angle gradually towards zero while the intermediate circuit capacitors located in the inverter module(s) get charged. • In the normal mode, the thyristor firing angle is 0 degrees: The thyristors operate as diodes. 14 Operation principle and hardware description ■ Overview diagram of the rectifier bridge U 12 3 Diodes. The diodes connect the AC terminals in cyclic sequence to the lower DC busbar (-). 1 Thyristors. The thyristors connect the AC line terminals in cyclic sequence to the upper DC busbar (+). 2 AC chokes 3 ■ 6- and 12-pulse supply connections The figure below illustrates the difference between 6-pulse and 12-pulse AC supply connections. The 6-pulse connection is standard. If the drive has an even number of supply modules, you can order it as a 12-pulse version (option +A004). The 12-pulse supply connection eliminates the fifth and seventh harmonics, which substantially reduces the harmonic distortion of the line current and the conductedemissions. The 12-pulse connection requires a three-winding transformer, or two separate transformers. There must be phase shift of 30-degrees between the two 6-pulse supply lines, which are connected to different supply modules through electrically separate switching equipment. Operation principle and hardware description 15 A 1 2 3 1 2 3 B 6-pulse connection A 12-pulse connection B Supply transformer 1 Switching equipment 2 Diode supply modules 3 16 Operation principle and hardware description Overview diagram of the drive system The following figure shows an example drive with a diode supply unit and three inverter units. 4 5 5 6 3 M3~ 1 Main circuit breaker [Q1] 2 AC fuses 3 Supply module [T01] (including choke and rectifier) 4 Supply module DC fuses 5 Inverter module DC fuses (with or without DC switches) 6 Inverter module [T11] 7 Motor 8 Auxiliary voltage switch [Q21] (option +G344 or +G451) 9 Auxiliary voltage transformer [T21] (option +G344) 5 8 16 6 9 2 7 MM3~ 3~ Operation principle and hardware description 17 Layout drawings ■ Overview layout drawing of the supply unit This drawing shows an example of a diode supply unit. 1 2 3 5 4 89 11 7 6 1 Auxiliary control cubicle 2 Incoming cubicle 3 Supply module cubicle 4...11 Control devices. See section Supply unit control devices. 10 18 Operation principle and hardware description ■ Auxiliary control cubicle layout1 3 4 257 8 6 1 Control panel [A59] (option +J400, or +J425) 2 Operating switch [S21], emergency stop button [S61], etc. 3 CIO-01 I/O module for cooling fan monitoring [A115.99] 4 BCU control unit [A51] 5 Auxiliary voltage transformers behind the assembly plates ([T21] option +G344, [T115] option +G451, in some deliveries also [T125]) 6 Cooling fan and heat exchanger [G115.99] 7 Inlet manifold with stop and drain valves 8 Outlet manifold with stop and drain valves Operation principle and hardware description 19 ■ Incoming cubicle layout - bottom cable entry 54123 121110987614 13 See Supply unit control devices (page 25). 1...4 Main supply breaker [Q1.x] (option +F255) 5, 9 Auxiliary voltage supply breaker (switch fuse) [Q21] 1, 6 Grounding switch [Q9.x] (option +F259) 4, 7 Not in use. 8 CIO-01 I/O module for cooling fan control [A115.x] 10 Cooling fan and heat exchanger [G115.x] 11 Input power cable terminals L1, L2, L3 12 Inlet manifold with stop and drain valves 13 Outlet manifold with stop and drain valves 14 20 Operation principle and hardware description ■ Supply module cubicle layout – frame 1×D8T Supply module cubicle layout – frame 1×D8T, electrical components 1 2 3 M 45 6789 M DC voltage measuring/testing points 1 Cabinet light ([H310.101)], option +G301) 2 Cabinet fan miniature circuit breaker [F115.101) ] 3 CIO-01 I/O module for distributed I/O bus control [A115.101) ] 4 Cabinet light switch ([S130.101) ], option +G301) 5 Module 1 AC fuses [F3.11...1) ] 6 Module 1 DC fuses [F2.11...1) ] 7 Supply module [T01.1] 8 Cabinet heater ([E95.101) ], option +G300) 9 Cabinet fan [G115.101) ] 1) Latter number is for the first supply module cubicle. The number increases in other cubicles (if any). Supply module cubicle layout – frame 1×D8T, cooling circuit Operation principle and hardware description 21 See Supply module cubicle layout – frame 2×D8T, cooling circuit (page 22). ■ Supply module cubicle layout – frame 2×D8T Supply module cubicle layout – frame 2×D8T, electrical components M 7 9101112456812 3 M M DC voltage measuring/testing points 1 Cabinet light ([H310.101)], option +G301) 2 Cabinet fan miniature circuit breaker [F115.101) ] 3 CIO-01 I/O module for distributed I/O bus control [A115.101) ] 4 Cabinet light switch ([S130.101) ], option +G301) 5 Module 1 AC fuses [F3.1...1) ] 6 Module 1 DC fuses [F2.11...1) ] 7 Supply module 1 [T01.1] 8 Module 2 AC fuses [F3.4 or F3.7...1) ] 9 Module 2 DC fuses [F2.21...1) ] 10 Supply module [T01.2] 11 Cabinet heater ([E95.101) ], option +G300) 22 Operation principle and hardware description Cabinet 12 fan [G115.101) ] 1) Latter number is for the first supply module cubicle. The number increases in other module cubicles (if any). Supply module cubicle layout – frame 2×D8T, cooling circuit 1 5 64 564243 7 1 Heat exchanger 2 Inlet manifold with stop and drain valves 3 Outlet manifold with stop and drain valves 4 Inlet pipes (cold coolant) from main pipe to modules and heat exchanger 5 Output pipes (warm coolant) to main pipe from modules and heat exchanger 6 Supply modules [T01.x] 7 Draining pipes (inlet draining pipe, and outlet draining pipe) 5 7 ■ Supply module layout - frame D8T 4 4 1 3 1 5 6 3 2 1 AC input busbars 2 DC output busbars 3 Lifting eyes 4 Coolant in and out connectors 5 Fiber optic connectors 6 230/115 V supply connection Operation principle and hardware description 23 24 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. 4 7 9 FXX 18 FXX 23FXXX 6 5 10 1Analog and digital I/O extension modules and 7 Control panel. 2fieldbus communication modules can be inserted 3 into slots 1, 2 and 3. 4 Memory unit 8 Fiber optic links to power modules (inverter, supply, brake or converter) 5 Slot 4 for RDCO-0x 9 Ethernet port. Not in use. 6 Terminal blocks. 10 Safety option interface. Only in use for the invert- er units. Operation principle and hardware description 25 Supply unit control devices ■ Overview of door switches and lights This figure shows and example of the door control devices. The devices and their exact locations varies depending on the options selected. The purpose of the devices is explained in the following sections.9 110 11 4126 13 14 15 2 3 5781...3 Not in use in multidrives 4 Operating switch [S21]. OFF: Opens main breaker (Q1.x), disables supply unit. ON (ENABLE/RUN): Enables supply unit, closes main breaker (Q1.x). 5 Emergency stop reset button and indication lamp [S62] (option +G331) 6 Ground (earth) fault indicator light and reset button [S90] (option +Q954) 7 Reserved for application-engineered equipment 8 Emergency stop button [S61] (option +G331) 9 Control panel [A59] (option +J400, or +J412) 10 Auxiliary voltage supply breaker (switch fuse) [Q21] 11 Voltage meter [P5.x] (option +G334) 12 Selector switch for phase voltage meter [S5.x] (option +G334) 13 Phase current meter(s) [P2.x] (option +G335) 14 Grounding switch [Q9.x] (option +F259) 15 Main supply breaker [Q1.x] (option +F255) ■ Main disconnecting device [Q1.x] The supply unit is equipped with a main breaker ([Q1], option +F255) as standard. With this device, you can isolate the main circuit of the drive from the power line. The main breaker is withdrawable: to disconnect the drive, crank the breaker out with a separate loose handle (included in the delivery). For the 12-pulse supply unit and power ratings higher than 3000 A there are two main disconnecting devices ([Q1.1] and [Q1.2]). 26 Operation principle and hardware description WARNING! The main disconnecting device does not isolate the input power terminals, AC voltage meters ([P5.x], option +G334) or the auxiliary circuit from the power line. To isolate auxiliary voltage, use the auxiliary voltage switch [Q21]. To isolate the input power terminals and AC voltage meters, open the main breaker of the supply transformer and lock it to the open position. If the drive is equipped with a main breaker and has a charging circuit: The main circuit breaker does not isolate the charging circuit. Use the charging switch [Q3]. ■ Auxiliary voltage switch [Q21] The supply unit is equipped with an auxiliary voltage switch [Q21] as standard. Using the switch, you can disconnect the auxiliary circuit from the power line. The switch has an operating handle on the cabinet door. ■ Grounding switch [Q9.x] The supply unit can be equipped with an optional grounding switch ([Q9.x], option +F259). Using the switch, you can temporarily ground the main AC busbars of the supply unit during the maintenance work. The switch has an operating handle on the cabinet door. WARNING! The grounding switch does not ground the input power terminals of the drive or the auxiliary (control) voltage circuits. ■ Operating switch [S21] The operating switch [S21] is a standard device. By default, the operating switch controls the unit as follows: • TheENABLE/RUN position energizes digital input DI2of thecontrol unit: Control program receives Run/Enable command and controls the supply unit power up via the control unit I/O interface. The supply unit first charges the drive DC link and then starts normal operation. The main breaker [Q1] closes. • The OFF position de-energizes digital input DI2 of the control unit: Control program does not receive Run/Enable command and it opens the main breaker [Q1]. Supply module stops rectifying. Position ENABLE/RUN (1) Position OFF (0) ENABLE / RUN ENABLE / RUN 0-1 0-1 Operation principle and hardware description 27 ■ Emergency stop button [S61] The emergency stop button [S61] is an optional device (option +G331). Pressing the button activates an emergency stop function of the supply unit. The button locks to open position automatically. You must release the button before you can return to the normal operation. Before the restart, you also need to reset the emergency stop circuit with a separate reset button [S62]. ■ E-stop reset button [S62] and indication lamp [P62] The emergency stop reset button [S62] is automatically installed on the door when the supply unit is equipped with an emergency stop function (for example, options +Q951, +Q952, etc). The button is illuminated, ie it includes an indication lamp [P62]. You can reset the emergency stop circuit with the button. Note: The emergency stop options are described in separate option manuals. ■ Other optional door controls • A voltage meter is an optional device ([P5.x], option +G334). There is a meter on the door and a switch [S5.x] with which you can select which phase voltage value to display. • AnAC phase currentmeter is anoptional device ([P2.x], option +G335). It is alsopossible to have three meters on the door - one for each phase currents (option +3G335). • Tripping button for the supply breaker ([S22], option +Q959) is a push button on the cabinet door for the user-defined use, for example, for tripping the breaker of the supply transformer of the drive. The button is wired to a terminal block at the factory. The user connects the external circuit to be controlled on site. • An electrical on/off push button ([S23], option +G332) on the cabinet door for tripping the supply unit. The button is connected in series with the operating switch. The button trips the Run enable signal and further the main contactor/breaker of the drive. ■ Control panel The control panel is the user interface of the unit. For the cabinet-installed drives, the panel is optional (option +J400 or +J425). With the control panel, you can: • start and stop the unit • view and reset the fault and warning messages, and view the fault history • view actual signals • change parameter settings • change between local and external control. To be able to start and stop the unit by the control panel, you must have the Run enable signal and Start enable signal on (1) on the control board. Normally this means, that you must have the operating switch on the cabinet door in ENABLE/RUN position. The control panel must also be in local control mode. You can select the mode with the Loc/Rem key on the panel. For the instructions on the use of the panel, see ACX-AP-x Assistant control panels user's manual (3AUA0000085685 [English]). ■ PC connection There is a USB connector on the front of the control panel that can be used to connect a PC to the drive. When a PC is connected to the control panel, the control panel keypad is disabled. ■ Fieldbus control You can control the unit through a fieldbus interface if the unit is equipped with an optional fieldbus adapter (for example, option +K454), and when you have configured the control program for the fieldbus control with the parameters. For information on the parameters, see the firmware manual. Note: To be able to switch the main breaker [Q1] and the supply unit on and off (Run enable signal) through the fieldbus, the Run enable command at digital input DI2 must be on (1). That is the case when the operating switch [S21] is switched to the ENABLE/RUN position. Type designation labels Each diode supply module and unit has a type designation label. The type designation stated on the label contains information on the specifications and configuration of the unit. Supply unit 28 Operation principle and hardware description 1 2 3 4 5 7 6 8 1 Type designation 2 Frame size 3 Cooling method 4 Degree of protection 5 UL/CSA data 6 Ratings 7 Valid markings 8 Serial number. The first digit of the serial number refers to the manufacturing plant. The next four digits refer to the unit’s manufacturing year and week, respectively. The remaining digits complete the serial number so that there are no two units with the same number. Supply module Operation principle and hardware description 29 1 23 45 7 6 8 1 Type designation 2 Frame size 3 Cooling method 4 Degree of protection 5 UL/CSA data 6 Ratings 7 Valid markings 8 Serial number. The first digit of the serial number refers to the manufacturing plant. The next four digits refer to the unit’s manufacturing year and week, respectively. The remaining digits complete the serial number so that there are no two units with the same number. 30 Operation principle and hardware description Type designation keys ■ Type designation key of the supply unit The type designation describes the composition of the unit in short. The type designation is visible on the label (sticker) which is attached to the cabinet. The complete designation code is divided in subcodes: • The first 1...18 digits form the basic code. It describes the basic construction of the unit. The fields in the basic code are separated by hyphens. • The option codes follow the basic code. Each option code starts with an identifying letter (common for the whole product series), followed by descriptive digits. The option codes are separated by plus signs. Basic codeCode Description ACS880 Product series 307LC Default configuration: liquid-cooled cabinet-installed diode supply unit, IP42 (UL Type 1), supply frequency 50 Hz, control (auxiliary) voltage 230 V AC, half-controlled diode thyristor bridge, IEC industrial cabinet construction, main switch type: air circuit breaker, degree of protection IP42 (UL type 1), EMC filter (category 3, 2nd Environment), EN/IEC approved components, speed-controlled module cooling fans, DC busbar material copper, cable supply conductors, standard wiring material, power and control cabling through the bottom of the cabinet, ACS-AP-W assistant control panel, ACS880 diode supply control program, coated circuit boards, lead-through-type cable entries, multilingual door device label sticker, complete documentation in English in a USB memory stick. Size xxxxx Refer to the rating table in the technical data. Voltage range 7525...690 V. This is indicated in the type designation label as typical input voltage levels 3~525/600/690 V AC. Option codes Code Description A004 12-pulse supply connection A012 50 Hz supply frequency A013 60 Hz supply frequency A018 Half-controlled diode-thyristor bridge B054 IP42 (UL Type 1) B055 IP54 (UL Type 12) C121 Marine construction C129 UL Listed (evaluated to both U.S. and Canadian safety requirements) C132 Marine type approval. Refer to ACS880 +C132 marine type-approved cabinet-built drives supplement (3AXD50000039629 [English]). C164 Plinth height 100 mm C176 Door hinges on left C179 Plinth height 200 mm C205 Marine product certification issued by DNV GL C206 Marine product certification issued by the American Bureau of Shipping (ABS) C207 Marine product certification issued by Lloyd's Register (LR) Operation principle and hardware description 31 Description Code C209 Marine product certification issued by Bureau Veritas C228 Marine product certification issued by China Classification Society (CCS) C229 Marine product certification issued by Russian Maritime Register of Shipping (RS) E210 EMC/RFI filter for 2nd environment TN (grounded) or IT (ungrounded) system, category C3 F255 Main circuit breaker F259 Grounding (earthing) switch F274 100 kA short-circuit rating G300 Cabinet and module heating elements (external supply) G301 Cabinet lighting G304 Control (auxiliary) voltage 115 V AC G307 Terminals for connecting external control voltage (230 V AC or 115 V AC, eg. UPS) G315 Tin-plated copper DC busbars G316 Cable supply conductors G317 Supply connection by busbars G320 Control (auxiliary) voltage 230 V AC G330 Halogen-free wiring and materials G331 Emergency stop push button on the door (red) G332 Electrical disconnect push button on the door (black, opens main contactor / ACB) G333 kW-meter on door G334 V-meter with selector switch G335 A-meter in one phase G336 Arc monitoring G337 Arc monitoring with current monitoring unit G338 G339 G340 Additional wire markings G341 G342 G343 Corrosion indicator G344 Auxiliary voltage transformer G426 Arc monitoring extension unit H350 Bottom power cable entry H351 Top power cable entry H358 Cable gland plates (3 mm steel, undrilled) H364 Cable gland plates (3 mm aluminum, undrilled) H365 Cable gland plates (6 mm brass, undrilled) H367 Control cable entry through floor of cabinet H368 Control cabling through roof of cabinet J410 Control panel mounting platform K450 Panel bus (control of several units from one control panel) K451 FDNA-01 DeviceNetTM adapter module K454 FPBA-01 PROFIBUS DP adapter module 32 Operation principle and hardware description Description Code FCAN-01 CANopen adapter module K457 FSCA-01 RS-485 (Modbus/RTU) adapter module K458 FCNA-01 ControlNetTM adapter module K462 FECA-01 EtherCat adapter module K469 FEPL-02 EtherPOWERLINK adapter module K470 FENA-21 Ethernet adapter module for EtherNet/IPTM, Modbus TCP and PROFINET IO protocols, 2-port K475 Ethernet switch for PC tool or control network (for max. 6 inverter units) K480 Ethernet switch with optical link for PC tool or control network (for max. 6 inverter units) K483 FEIP-21 Ethernet adapter module for EtherNet/IPTM K490 FMBT-21 Ethernet adapter module for Modbus TCP K491 FPNO-21 Ethernet adapter module for PROFINET IO K492 FIO-11 analog I/O extension module L500 FIO-01 digital I/O extension module L501 FDCO-01 optical DDCS communication adapter module L503 FDCO-02 optical DDCS communication adapter module L508 RDCO-04 optical DDCS communication for BCU-xx (4xTransmitter/Receiver) L509 FAIO-01 analog I/O extension module L525 FDIO-01 digital I/O extension module L526 IEC 61131-3 application programmability N8010 Special color (RAL Classic) P913 Special color (other than RAL Classic) P966 Emergency stop (category 0) with safety relays, by opening the main breaker/contactor Q951 Emergency stop (category 1) with safety relays, by opening the main breaker/contactor Q952 Earth fault monitoring for IT (ungrounded) systems Q954 Supply transformer breaker disconnect push button (red, wired to terminals) on the door Q959 Emergency stop (category 0) with safety relays, by activating the Safe torque off function Q963 Emergency stop (category 1) with safety relays, by activating the Safe torque off function Q964 Emergency stop (configurable for category 0 or 1) with FSO-xx safety functions module, by activating the Safe torque off function Q979 Emergency stop button monitoring Q984 Documentation/manuals in English R700 ■ Type designation key of the diode supply module The type designation describes the composition of the module in short. The complete designation code is divided in subcodes: • The first 1...18 digits form the basic code. It describes the basic construction of the unit. The fields in the basic code are separated by hyphens. • The option codes follow the basic code. Each option code starts with an identifying letter (common for the whole product series), followed by descriptive digits. The option codes are separated by plus signs. Description Code Basic codes Operation principle and hardware description 33 Description Code ACS880 Product series 304LC Construction: Liquid cooled diode supply module, IP00 (UL Open Type), AC-choke, circuit boards with coating, CE approval Size 0780A Refer to the technical data. Voltage range 7525...690 V. This is indicated in the type designation label as typical input voltage levels 3~525/600/690 V AC. Plus codesA018 Half-controlled diode-thyristor bridge (as standard) C132 Marine type approval C209 Marine product certification (only with +C132) P904 Extended warranty 24/30 P909 Extended warranty 36/42 P911 Extended warranty 60/66 34 3Electrical installation 35Electrical installation 11 Contents of this chapter This chapter instructs how to check the insulation of the assembly and how to install the input power cables and control cables. The information is valid for ACS880-307LC...+A018 diode supply units. For more information on cable selection, protections, etc., see ACS880 multidrive cabinets and modules electrical planning instructions (3AUA0000102324 [English]). WARNING! Obey the safety instructions given in ACS880 liquid-cooled multidrive cabinets and modules safety instructions (3AXD50000048633 [English]). If you ignore the safety instructions, injury or death, or damage to the equipment can occur. If you are not a qualified electrical professional, do not do installation or maintenance work. 36 Electrical installation Electrical safety precautions These electrical safety precautions are for all personnel who do work on the drive, motor cable or motor. WARNING! Obey these instructions. If you ignore them, injury or death, or damage to the equipment can occur. If you are not a qualified electrical professional, do not do installation or maintenance work. Go through these steps before you begin any installation or maintenance work. 1. Clearly identify the work location and equipment. 2. Disconnect all possible voltage sources. Make sure that re-connection is not possible. Lock out and tag out. • Open the main disconnecting device of the drive. • Open the charging switch if present. • Open the disconnector of the supply transformer. (The main disconnecting device in the drive cabinet does not disconnect the voltagefrom the AC input power busbars of the drive cabinet.) • Close the grounding switch or switches ([Q9], option +F259) if present. Do not use excessive force as the switch has electromagnetic interlocking. • If the drive is equipped with a DC/DC converter unit (optional): Open the DC switch-disconnector ([Q11], option +F286) of the DC/DC converter. Open the disconnecting device of the energy storage connected to the DC/DC converter unit (outside the drive cabinet). • Open the auxiliary voltage switch-disconnector (if present), and all other possible disconnecting devices that isolate the drive from dangerous voltage sources. • In the liquid cooling unit (if present), open the switch-disconnector of the cooling pumps. • If you have a permanent magnet motor connected to the drive, disconnect the motor from the drive with a safety switch or by other means. • Disconnect all dangerous external voltages from the control circuits. • After you disconnect power from the drive, always wait 5 minutes to let the intermediate circuit capacitors discharge before you continue. 3. Protect any other energized parts in the work location against contact. 4. Take special precautions when close to bare conductors. Electrical installation 375. Measure that the installation is de-energized. If the measurement requires removal or disassembly of shrouding or other cabinet structures, obey thelocal laws and regulations applicable to live working (including – but not limited to – electric shock and arc protection). • Before and after measuring the installation, verify the operation of the voltage tester on a known voltage source. • Make sure that the voltage between the drive input power terminals (L1, L2, L3) and the grounding (PE) busbar is zero. • Make sure that the voltage between the drive output terminals (T1/U, T2/V, T3/W) and the grounding (PE) busbar is zero. • Make sure that the voltage between the drive DC busbars (+ and -) and the grounding (PE) busbar is zero. WARNING! The busbars inside the cabinet of liquid-cooled drives are partially coated. Measurements made through the coating are potentially unreliable, so only measure at uncoated portions. Note that the coating does not constitute a safe or touch-proof insulation.

6. If the drive is not equipped with a grounding switch, install temporary grounding as required by the local regulations. 11 7. Ask the person in control of the electrical installation work for a permit to work. General notes ■ Static electricity

WARNING! Use a grounding wristband when you handle printed circuit boards. Do not touch the boards unnecessarily. The boards contain components sensitive to electrostatic discharge. ■ Optical components WARNING! Obey these instructions. If you ignore them, damage to the equipment can occur. • Handle the fiber optic cables with care. • When you unplug the fiber optic cables, always hold the connector, not the cable itself. • Do not touch the ends of the fibers with bare hands as the ends are extremely sensitive to dirt. • Do not bend the fiber optic cables too tightly. The minimum allowed bend radius is 35 mm (1.4 in). 38 Electrical installation Measuring the insulation ■ Measuring the insulation of the drive WARNING! Do not do any voltage withstand or insulation resistance tests on any part of the drive as testing can damage the drive. Every drive has been tested for insulation between the main circuit and the chassis at the factory. Also, there are voltage-limiting circuits inside the drive which cut down the testing voltage automatically. ■ Measuring the insulation of the input power cable Before you connect the input power cable to the drive, measure its insulation according to local regulations. Connecting the input power cables ■ Connection diagram – 6-pulse supply unit This is a connection diagram for the 6-pulse supply unit. See also the delivery specific circuit diagrams. 1 2 L1 1 Fuses or other protection means for the short-circuit protection of the cable. 2Grounding of the cable shield at the cable entry (360 degrees grounding). Additional information: • See the technical data for the dimensions of the cable entries, and the dimensions and tightening torques of the terminals. • Use a separate PE conductor in addition if the conductivity of the shields does not meet the requirement for the PE conductor. • See ACS880 multidrive cabinets and modules electrical planning instructions [3AUA0000102324 (English)] for the cable selection instructions. ■ Connection diagram – 12-pulse supply unit (option +A004) This is a connection diagram for the 12-pulse supply unit (option +A004). See also the delivery specific circuit diagrams. L2L3PE Electrical installation 391 2 11 1L1 1L2 1L3 PE 2L1 2L2 2L3 PE 1 Fuses or other protection means for the short-circuit protection of the cable. 2 Grounding of the cable shield at the cable entry (360 degrees grounding). Additional information: • See the technical data for the dimensions of the cable entries, and the dimensions and tightening torques of the terminals. • If the conductivity of the shields does not meet the requirement for the PE conductor, use a separate PE conductor in addition. • See ACS880 multidrive cabinets and modules electrical planning instructions (3AUA0000102324 [English]) for the cable selection instructions. ■ Connection procedure – bottom cable entry See the technical data for the dimensions of the cable entries, and the dimensions and tightening torques of the terminals. WARNING! Apply grease to stripped aluminum conductors beforeattaching them to non-coated aluminum cable lugs. Obey the grease manufacturer’s instructions. Aluminum-aluminum contact can cause oxidation in the contact surfaces. 1. Disconnect the drive from the AC power line and make sure it is safe to start the work. See section Electrical safety precautions (page 36). 2. Open the door of the incoming cubicle. 3. Remove the shrouding covering the input terminals. 4. Peel off 3 to 5 cm of the outer insulation of the cables above the lead-through plate for 360° high-frequency grounding. 5. Prepare the ends of the cables. 6. Remove the rubber grommet from the cable entry plate for the cable to be connected. Cut adequate hole into the rubber grommet. Slide the grommet onto the cable. Slide the cable through the cable entry and attach the grommets to the holes. 7. Fasten the conductive sleeve of the cable entry to the cable shield with cable ties. 8. Tie up the unused conductive sleeves with cable ties. 9. Connect the twisted shield of the cable to the PE busbar of the cabinet. Tighten the screw to the torque given in the technical data. 10. Connect the phase conductors of the input cable to the L1, L2 and L3 terminals. Tighten the screws to the torque given in the technical data. 40 Electrical installation 11. Reinstall the shrouding removed earlier. 12. Close the door. 3 PE PE

10 9 7 6 8 Electrical installation 4111

42 Electrical installation Connectingthe externalpower supply cable for theauxiliary circuit (option +G307) WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. If you are not a qualified electrical professional, do not do installation or maintenance work. For the connection diagram, see the delivery-specific circuit diagrams. For the auxiliary circuit current consumption, see the delivery-specific technical documentation. Wiring the functional safety options The wiring instructions for the functional safety options such as +Q951, +Q952, etc are in separate option manuals. Connecting the control cables See the chapter on control units for the default I/O connections. Note that the default I/O connections can be affected by some options. See the circuit diagrams delivered with the drive for the actual wiring. ■ Control cable connection procedure WARNING! Obey the safety instructions given in ACS880 liquid-cooled multidrive cabinets and modules safety instructions (3AXD50000048633 [English]). If you ignore the safety instructions, injury or death, or damage to the equipment can occur. If you are not a qualified electrical professional, do not do installation or maintenance work. 1. Stop the drive (if running) and do the steps in section Electrical safety precautions (page 36) before you start the work. 2. Run the control cables into the cabinet as described in section Grounding the outer shields of the control cables at the cabinet entry below. 3. Route the control cables as described in section Routing the control cables inside the cabinet. 4. Connect the control cables as described in section Connecting control cabling. Grounding the outer shields of the control cables at the cabinet entry Ground the outer shields of all control cables 360 degrees at the EMI conductive cushions as follows (example constructions are shown below, the actual hardware may vary): 1. Loosen the tightening screws of the EMI conductive cushions and pull the cushions apart. 2. Cut adequate holes to the rubber grommets in the entry plate and put the cables through the grommets and the cushions. Electrical installation 433. Strip off the cable plastic sheath above the entry plate just enough to ensure proper connection of the bare shield and the EMI conductive cushions. 4. Tighten the two tightening screws so that the EMI conductive cushions press tightly round the bare shield. 4 3 1 2 Note 1: Keep the shields continuous as close to the connection terminals as possible. Secure the cables mechanically at the entry strain relief. Note 2: If the outer surface of the shield is non-conductive: • Cut the shield at the midpoint of the bare part. Be careful not to cut the conductors or 11 the grounding wire (if present). • Turn the shield inside out to expose its conductive surface. • Cover the turned shield and the stripped cable with copper foil to keep the shielding continuous. A B C 12 32 4 5 A Stripped cable B Conductive surface of the shield exposed C Stripped part covered with copper foil 1 Cable shield 2 Copper foil 3 Shielded twisted pair 4 Grounding wire Note for top entry of cables: When each cable has its own rubber grommet, sufficient IP and EMC protection can be achieved. However, if there is more than one cable per grommet, plan the installation beforehand as follows: 1. Make a list of the cables coming to the cabinet. 2. Sort the cables going to the left into one group and the cables going to the right into another group to avoid unnecessary crossing of cables inside the cabinet. 3. Sort the cables in each group according to size. 4. Group the cables for each grommet as follows ensuring that each cable has a proper contact to the cushions on both sides. Cable diameter in mm Max. number of cables per grommet ≤ 13 4 ≤ 17 3 < 25 2 ≥ 25 1 5. Arrange conductive conductive the cushions. bunches cushions. according to size from thickest to the thinnest between the EMI 6. If more than one cable go through a grommet, seal the grommet by applying Loctite 5221 inside the grommet. Routing the control cables inside the cabinet Use the existing trunking in the cabinet wherever possible. Use sleeving if cables are laid against sharp edges. When running cables to or from a swing-out frame, leave enough slack at the hinge to allow the frame to open fully. Connecting control cabling Connect the conductors to the appropriate terminals. Refer to the wiring diagrams delivered with the drive. Connect the inner twisted pair shields and all separate grounding wires to the grounding clamps closest to the terminals. The drawing below represents the grounding of the control cabling when connecting to a terminal block inside the cabinet. The grounding is done in the same way when connecting directly to a component such as the control unit. Notes: 44 Electrical installation Electrical installation 45• Do not ground the outer shield of the cable here since it is grounded at the cable entry. • Keep any signal wire pairs twisted as close to the terminals as possible. Twisting the wire with its return wire reduces disturbances caused by inductive coupling. 11 At the other end of the cable, leave the shields unconnected or ground them indirectly via a high-frequency capacitor with a few nanofarads, eg. 3.3 nF / 630 V. The shield can also be grounded directly at both ends if they are in the same ground line with no significant voltage drop between the end points. 46 Electrical installation Connecting a PC WARNING! Do not connect the PC directly to the control panel connector of the control unit as this can cause damage. A PC (with eg, the Drive composer PC tool) can be connected as follows: 1. Connect an ACx-AP-x control panel to the unit either • by inserting the control panel into the panel holder or platform, or • by using an Ethernet (eg, Cat 5e) networking cable. 2. Remove the USB connector cover on the front of the control panel. 3. Connect an USB cable (Type A to Type Mini-B) between the USB connector on the control panel (3a) and a free USB port on the PC (3b). 4. The panel will display an indication whenever the connection is active. 5. See the documentation of the PC tool for setup instructions.

4 ? USB connected Stop Loc/Rem Start ? Stop Loc/Rem Start 3b 2 2 3a 3a

The control unit 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.4The control unit 47

∎48 The control unit BCU-x2 layout Description I/O I/O terminals (see following diagram) SLOT 1 I/O extension, encoder interface or fieldbus adapter module connection. (This is the sole location for an FDPI-02 diagnostics and panel interface.) SLOT 2 I/O extension, encoder interface or fieldbus adapter module connection SLOT 3 I/O extension, encoder interface, fieldbus adapter or FSO-xx safety functions module connection SLOT 4 RDCO-0x DDCS communication option module connection X205 Memory unit connection BATTERY Holder for real-time clock battery (BR2032) AI1 Mode selector for analog input AI1 (I = current, U = voltage) AI2 Mode selector for analog input AI2 (I = current, U = voltage) D2D TERM Termination switch for drive-to-drive link (D2D) DICOM= Ground selection. Determines whether DIOGND DICOM is separated from DIOGND (ie. the common reference for the digital inputs floats). See the ground isolation diagram. 7-segment display Multicharacter indications are displayed as repeated se- quences of characters (“U” is indicated briefly before “o”.) Control program running Control program startup in progress (Flashing) Firmware cannot be started. Memory unit missing or corrupted Firmware download from PC to control unit in progress At power-up, the display may show short indications of eg. “1”, “2”, “b” or “U”. These are normal indications immediately after power-up. If the display ends up showing any other value than those described, it in- dicates a hardware failure.

XRO3 XD24 XPOW XRO2 XDIO XAO XRO1 XDI XAI X485 XD2D XSTO XSTO OUT Description XAI Analog inputs XAO Analog outputs XDI Digital inputs, Digital input interlock (DIIL) XDIO Digital input/outputs XD2D Drive-to-drive link XD24 +24 V output (for digital inputs) XETH Ethernet port – Not in use XPOW External power input XRO1 Relay output RO1 XRO2 Relay output RO2 XRO3 Relay output RO3 XSTO Safe torque off connection (input signals) XSTO OUT Safe torque off connection (to inverter mod- ules) X12 (On the opposite side) Connection for FSO- xx safety functions module (optional) X13 Control panel / PC connection X485 Not in use V1T/V1R, Fiber optic connection to modules 1 and 2 V2T/V2R (VxT = transmitter, VxR = receiver) V3T/V3R Fiber optic connection to modules 3...7 (BCU- ...12/22 only) V7T/V7R (VxT = transmitter, VxR = receiver) V8T/V8R Fiber optic connection to modules 8...12 ...(BCU-22 only) V12T/V12R (VxT = transmitter, VxR = receiver) SD CARD Data logger memory card for inverter module communication BATT OK Real-time clock battery voltage is higher than 2.8 V. If the LED is off when the control unit is powered, replace the battery. FAULT The control program has generated a fault. See the firmware manual of the supply/invert- er unit. PWR OK Internal voltage supply is OK WRITE Writing to memory card in progress. Do not remove the memory card. The control unit 49

50 The control unit 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. Under normal circumstances, the factory-made wiring should not be changed. The wire size accepted by all screw terminals (for both stranded and solid wire) is 0.5 ... 2.5 mm2 (24...12 AWG). The torque is 0.5 N·m (5 lbf·in). Terminal Description XD2D Drive-to-drive link 11 B 23Not in use by default 4 2 A 3 BGND 4 Shield D2D.TERM Drive-to-drive link termination switch1) X485 RS485 connection 55 B 67Cooling fan monitoring (CIO module) 8 6 A 7 BGND 8 Shield XRO1, XRO2, XRO3 Relay outputs 11 NC Norm. closed XRO1: Running2) (Energized = running) 250 V AC / 30 V DC, 2 A 111213212223313233 12 COM Common 13 NO Norm. open 21 NC Norm. closed XRO2: Fault (-1)2) (Energized = no fault) 22 COM Common 250 V AC / 30 V DC, 2 A Note: If drive is equipped with a liquid cool- ing unit, the relay output controls the cooling unit start signal. Then the selection Fault(- 23 NO Norm. open 1) may also be changed to Started by bit 12 of parameter 195.12. See ACS880 diode supply control program firmware manual (3AUA0000103295 [English]). 31 NC Norm. closed XRO3: MCB ctrl3) (Energized = closes 32 COM Common main contactor/breaker) 250 V AC / 33 NO Norm. open 30 V DC, 2 A XSTO, XSTO OUT Safe torque off4) 1 OUT 123XSTO: Factory connection. Both circuits must be closed for the drive to start (IN1 and IN2 must be connected to OUT). 4 56782 SGND 3 IN1 4 IN2 5 IN1 6 SGND 7 IN2 XSTO OUT: Not in use. 8 SGND XDI Digital inputs

The control unit 51 Description Terminal 1 DI1 Temp fault2) (0 = overtemperature) 1234 5672 DI2 Run enable2) (1 = run enable) 3 DI3 MCB feedback3) (0 = main contactor/breaker open) 4 DI4 Auxiliary circuit breaker fault2) 5 DI5 Not in use by default. Can be used for eg. earth fault monitoring. 6 DI6 Reset2) (0 -> 1 = fault reset) 7 DIIL Not in use by default. Can be used for eg. emergency stop. XDIO Digital input/outputs 11 DIO1 Not in use by default 234 2 DIO2 Not in use by default 3 DIOGND Digital input/output ground 4 DIOGND Digital input/output ground XD24 Auxiliary voltage output 51 +24VD +24 V DC 200 mA5) 678 2 DICOM Digital input ground 3 +24VD +24 V DC 200 mA5) 4 DIOGND Digital input/output ground DICOM=DIOGND Ground selection switch6) XAI Analog inputs, reference voltage output 11 +VREF 10 V DC, RL 1...10 kohm 234 5672 -VREF -10 V DC, RL 1...10 kohm 3 AGND Ground 4 AI1+ 5 AI1- Not in use by default. 0(2)...10 V, Rin > 200 kohm7) 6 AI2+ 7 AI2- Not in use by default. 0(4)...20 mA, Rin = 100 ohm8) AI1 AI1 current/voltage selection switch AI2 AI2 current/voltage selection switch XAO Analog outputs 11 AO1 2Zero (no signal indicated)2) 0...20 mA, RL < 500 ohm 34 2 AGND 3 4 AO2 AGND Zero (not signal indicated)2) 0...20 mA, RL < 500 ohm XPOW External power input 11 +24VI 2324 V DC, 2.05 A 4 2 GND 3 +24VI 4 GND X12 Not in use in supply units X13 Control panel connection

52 The control unit Description Terminal X205 Memory unit connection 1) Must be set to ON when the supply unit is the first or last unit on the drive-to-drive (D2D) link. On intermediate units, set termination to OFF. 2) Default use of the signal in the control program. The use can be changed by a parameter. See also the delivery-specific circuit diagrams. 3) Use of the signal in the control program (fixed). See also the delivery-specific circuit diagrams. 4) This input only acts as a true Safe torque off input in inverter units. In other applications (such as a supply or brake unit), de-energizing the IN1 and/or IN2 terminal will stop the unit but not constitute a true safety function. 5) Total load capacity of these outputs is 4.8 W (200 mA at 24 V) minus the power taken by DIO1 and DIO2. 6) Determines whether DICOM is separated from DIOGND (ie, common reference for digital inputs floats). ON: DICOM connected to DIOGND. OFF: DICOM and DIOGND separate. 7) Current setting requires [0(4)...20 reboot mA, Rof in control = 100 ohm] unit. or voltage [0(2)...10 V, Rin > 200 kohm] input selected by switch AI1. Change of 8) Current setting requires [0(4)...20 reboot mA, Rof in control = 100 ohm] unit. or voltage [0(2)...10 V, Rin > 200 kohm] input selected by switch AI2. Change of External power supply for the control unit (XPOW) The control unit is powered from a 24 V DC, 2 A supply through terminal block XPOW. With a type BCU control unit, a second supply can be connected to the same terminal block for redundancy. Using an external supply is recommended if • the control unit needs to be kept operational during input power breaks, for example, because of continuous fieldbus communication • immediate restart is needed after a power break (that is, no control unit power-up delay is allowed). The X485 connector The X485 provides a connection for optional CIO-01 I/O module. The following diagram shows the wiring for the CIO module. BCU CIO CIO X485 BA BGND SHIELD X485 BAGND SHIELD X485 BAGND SHIELD

The control unit 53 Safe torque off (XSTO, XSTO OUT) Note: The XSTO input only acts as a true Safe torque off input on the inverter control unit. De-energizing the IN1 and/or IN2 terminals of other units (supply, DC/DC converter, or brake unit) will stop the unit but not constitute a true safety function. FSO-xx safety functions module connection (X12) See the user manual of the FSO-xx module. Note that the FSO-xx safety functions module is not in use in supply, DC/DC converter or brake units. SDHC memory card slot 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. 54 The control unit Connector data Power supply (XPOW) Connector pitch 5 mm, wire size 2.5 mm2 24 V (±10%) DC, 2 A External power input. Two supplies can be connected for redundancy. Relay outputs RO1...RO3 Connector pitch 5 mm, wire size 2.5 mm2 (XRO1...XRO3) 250 V AC / 30 V DC, 2 A Protected by varistors +24 V output (XD24:2 and XD24:4) Connector pitch 5 mm, wire size 2.5 mm2 Total load capacity of these outputs is 4.8 W (200 mA / 24 V) minus the power taken by DIO1 and DIO2. Digital inputs DI1...DI6 (XDI:1...XDI:6) Connector pitch 5 mm, wire size 2.5 mm2 24 V logic levels: “0” < 5 V, “1” > 15 V Rin: 2.0 kohm Input type: NPN/PNP (DI1...DI5), NPN (DI6) Hardware filtering: 0.04 ms, digital filtering up to 8 ms DI6 (XDI:6) can alternatively be used as an input for a PTC sensor. “0” > 4 kohm, “1” < 1.5 kohm. Imax: 15 mA (DI1...DI5), 5 mA (DI6) Start interlock input DIIL (XDI:7) Connector pitch 5 mm, wire size 2.5 mm2 24 V logic levels: “0” < 5 V, “1” > 15 V Rin: 2.0 kohm Input type: NPN/PNP Hardware filtering: 0.04 ms, digital filtering up to 8 ms Digital inputs/outputs DIO1 and DIO2 Connector pitch 5 mm, wire size 2.5 mm2 (XDIO:1 and XDIO:2) Input/output mode selection by paramet- As inputs: 24 V tering: 1 ms. logic levels: “0” < 5 V, “1” > 15 V. Rin: 2.0 kohm. Fil- ers. As outputs: Total output current from +24VD is limited to 200 mA DIO1 can be configured as a frequency input (0...16 kHz with hardware filtering +24VD of 4 microseconds) for 24 V level square wave signal (sinusoidal or other wave form cannot be used). DIO2 can be con- figured as a 24 V level square wave fre- DIOx quency output. See the firmware manual, parameter group 111/11. RL DIOGND Reference voltage for analog inputs Connector pitch 5 mm, wire size 2.5 mm2 +VREF and -VREF (XAI:1 and XAI:2) 10 V ±1% and –10 V ±1%, Rload 1...10 kohm Maximum output current: 10 mA Analog inputs AI1 and AI2 Connector pitch 5 mm, wire size 2.5 mm2 (XAI:4 ... XAI:7). Current/voltage input mode selection by switches Current input: –20...20 mA, Rin = 100 ohm Voltage input: –10...10 V, Rin > 200 kohm Differential inputs, common mode range ±30 V Sampling interval per channel: 0.25 ms Hardware filtering: 0.25 ms, adjustable digital filtering up to 8 ms Resolution: 11 bit + sign bit Inaccuracy: 1% of full scale range The control unit 55 Connector pitch 5 mm, wire size 2.5 mm2 Analog outputs AO1 and AO2 (XAO) 0...20 mA, Rload < 500 ohm Frequency range: 0...500 Hz Resolution: 11 bit + sign bit Inaccuracy: 2% of full scale range Connector pitch 5 mm, wire size 2.5 mm2 XD2D connector Physical layer: RS-485 Transmission rate: 8 Mbit/s Cable type: Shielded twisted-pair cable with a twisted pair for data and a wire or another pair for signal ground (nominal impedance 100 ... 165 ohm, for example Belden 9842) Maximum length of link: 50 m (164 ft) Termination by switch Connector pitch 5 mm, wire size 2.5 mm2 RS-485 connection (X485) Physical layer: RS-485 Connector pitch 5 mm, wire size 2.5 mm2 Safe torque off connection (XSTO) Input voltage range: -3...30 V DC Logic levels: “0” < 5 V, “1” > 17 V. Note: For the unit to start, both connections must be “1”. This applies to all control units (including drive, inverter, supply, brake, DC/DC converter etc. control units), but true Safe torque off functionality is only achieved through the XSTO connector of the drive/inverter control unit. EMC (immunity) according to IEC 61326-3-1 Connector pitch 5 mm, wire size 2.5 mm2 Safe torque off output (XSTO OUT) To STO connector of inverter module. Connector: RJ-45 Control panel connection (X13) Cable length < 3 m Connector: RJ-45 Ethernet connection (XETH) This connection is not supported by the firmware. Memory card type: SDHC SDHC memory card slot (SD CARD) Maximum memory size: 4 GB The terminals of the control unit fulfill the Protective Extra Low Voltage (PELV) requirements. The PELV re- quirements of a relay output are not fulfilled if a voltage higher than 48 V is connected to the relay output. 56 The control unit ■ BCU-x2 ground isolation diagram

XPOW +24VI 1 GND 2 +24VI 3 GND 4XAI +VREF 1 -VREF 2 AGND 3 AI1+ 4 AI1- 5 AI2+ 6 AI2- 7XAO AO1 1 AGND 2 AO2 3 AGND 4 XD2D B 1 A 2 BGND 3 SHIELD 4 XRO1, XRO2, XRO3 NC 11 COM 12 NO 13 NC 21 COM 22 NO 23 NC 31 COM 32 NO 33 XD24 +24VD 5 DICOM 6 +24VD 7 DIOGND 8XDIO DIO1 1 DIO2 2 DIOGND 3 DIOGND 4XDI DI1 1 DI2 2 DI3 3 DI4 4 DI5 5 DI6 6 DIIL 7 XSTO OUT 1 SGND 2 IN1 3 IN2 4 XSTO OUT IN1 5 SGND 6 IN2 7 SGND 8 ** *

*Ground selector (DICOM=DIOGND) settings DICOM=DIOGND: ON All digital inputs share a common ground (DICOM connected to DIOGND). This is the default setting. DICOM=DIOGND: OFF Ground of digital inputs DI1...DI5 and DIIL (DICOM) is isolated from DIO signal ground (DIOGND). Isolation voltage 50 V. **Common mode voltage between each AI input and AGND is +30 V 5Installation checklist 57 Installation checklist 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. WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. If you are not a qualified electrical professional, do not do installation or maintenance work. WARNING! Stop the drive and do the steps in section Electrical safety precautions (page 36) before you start the work. Make sure that ... The ambient operating conditions meet the drive ambient conditions specification, and enclosure rating (IP code or UL enclosure type). The supply voltage matches the nominal input voltage of the drive. See the type designation label. The insulation resistance of the input power cable, motor cable and motor is measured according to local regulations and the manuals of the drive. The drive cabinet is attached to the floor, and if necessary due to vibration etc, also by its top to the wall or roof. The drive module is fastened properly to the cabinet. 58 Installation checklist Make sure that ... If the drive is connected to a network other than a symmetrically grounded TN-S system: You have done all the required modifications (for example, you may need to disconnect the EMC filter or ground- to-phase varistor). See the electrical installation instructions in the supply unit manual. Appropriate DC fuses are installed. There is an adequately sized protective earth (ground) conductor(s) between the drive and the switchboard, the conductor is connected to correct terminal, and the terminal is tightened to the correct torque. Proper grounding has also been measured according to the regulations. If the drive is equipped with a DC/DC converter unit: There is an adequately sized protective earth (ground) conductor between the energy storage and the DC/DC converter, the conductor has been connected to appropriate terminal, and the terminal has been tightened to the proper torque. Proper grounding has also been measured according to the regulations. If the drive is equipped with a DC/DC converter unit: The energy storage cable has been connected to the correct terminals of the DC/DC converter and energy storage, and the terminals have been tightened to the proper torque. If the drive is equipped with a DC/DC converter unit: The energy storage has been equipped with fuses for protecting energy storage cable in a cable short-circuit situation. If the drive is equipped with a DC/DC converter unit: The energy storage has been equipped with a disconnecting device. The input power cable is connected to the correct terminals, the phase order is correct, and the terminals are tightened to the correct torque. There is an adequately sized protective earth (ground) conductor between the motor and the drive, and the conductor is connected to the correct terminal, and the terminal is tightened to the correct torque. Proper grounding has also been measured according to the regulations. The motor cable is connected to the correct terminals, the phase order is correct, and the terminals are tightened to the correct torque. The motor cable is routed away from other cables. No power factor compensation capacitors are connected to the motor cable. If an external brake resistor is connected to the drive: There is an adequately sized protective earth (ground) conductor between the brake resistor and the drive, and the conductor is connected to the correct terminal, and the terminals are tightened to the correct torque. Proper grounding has also been measured according to the regulations. If an external brake resistor is connected to the drive: The brake resistor is connected to the correct terminals, and the terminals are tightened to the correct torque. If an external brake resistor is connected to the drive: The brake resistor cable is routed away from other cables. The control cables are connected to the correct terminals, and the terminals are tightened to the correct torque. The voltage setting of the auxiliary voltage transformers (if any) is correct. See the electrical installation instructions. If a drive bypass connection will be used: The direct-on-line contactor of the motor and the drive output contactor are either mechanically and/or electrically interlocked, that is, they cannot be closed at the same time. A thermal overload device must be used for protection when bypassing the drive. Refer to local codes and regulations. There are no tools, foreign objects or dust from drilling inside the drive. Cover(s) of the motor connection box are in place. Cabinet shrouds are in place and doors are closed. The motor and the driven equipment are ready for power-up. The coolant connections between cubicles (if any) and to the cooling circuit are tight. If the drive is equipped with a cooling unit: Refer to the cooling unit documentation for specific tasks.

Start-up 5912 6 Start-up Contents of this chapter This chapter contains start-up instructions of the diode supply unit.

The underlined tasks are necessary only for certain cases. The symbols in brackets, for example [Q1], refer to the item designations used in the circuit diagrams. If a task is valid only for a certain option device or feature, the option code is given in brackets, for example, (option +F259). Note: The instructions do not cover all possible supply unit configurations. Always refer to the delivery-specific circuit diagrams when proceeding with the start-up. This default start-up procedure is valid for a supply unit equipped with a main breaker ([Q1], option +F255) and an external auxiliary voltage supply (option +G307). Note: For the functional safety options, the start-up instructions are given in separate option manuals. Reserve the necessary option manuals at hand before the supply unit start-up. Obey their start-up instructions. WARNING! Obey the safety instructions during the start-up procedure. See ACS880 liquid-cooled multidrive cabinets and modules safety instructions (3AXD50000048633 [English]). If you ignore the safety instructions, injury or death, or damage to the equipment can occur. If you are not a qualified electrical professional, do not do installation or maintenance work. 60 Start-up Start-up procedure ■ Basic checks with no voltage connected Action Disconnect the drive from the AC power line and make sure it is safe to start the work. See section Electrical safety precautions (page 36). Set the current trip limits of the main breaker. The trip limits have been preset to generic values by the breaker manufacturer. The generic limits do not correspond the protection requirements of the applic- ation. General rule Make sure that the selectivity condition is fulfilled, that is the breaker trips at the lower current than the protection device of the supplying network, and that the limit is high enough to cause unnecessary trips during the intermediate DC circuit load peak at start. Long term current limit Rule of thumb: Set to the rated AC current of the drive. Peak current limit Rule of thumb: Set to a value 3...4 times the rated AC current of the drive. Make sure that the mechanical and electrical installation of the drive is completed. See Installation checklist (page 57). Check the settings of breakers/switches in the auxiliary circuits. Make sure that the voltage settings of the auxiliary voltage transformers (option +G344) are according to the actual power line voltage. See the delivery-specific circuit diagrams. Transformer [T21] is selected by option +G344; [T101] and [T111] are present if required by the options specified by the customer. ■ Starting and checking the cooling system Action Fill up and bleed the internal cooling circuit. Start the cooling unit up. See Internal cooling cir- cuit (page 79). Check the cooling system for leaks. Make sure that cooling circuit joints at the shipping split joining cubicles are tight and that all drain valves have been closed. Make sure that the coolant can flow freely in all cubicles. Install all shrouds (if removed) and close the cabinet doors. ■ Connecting voltage to input terminals and auxiliary Action Remove the temporary grounding system (if installed). Drive with voltage meters (option +G334): Close the circuit breaker for the voltage meters [F5]. Close the circuit breakers supplying the auxiliary circuits [F20, F22.x]. Drive with an external control voltage supply (option +G307): Close the circuit breaker of the external control voltage supply. Start-up 61Action Make sure that it is safe to connect voltage: • nobody is working on the unit or circuits that are wired from outside into the cabinets • covers of the motor terminal boxes are on • cabinet doors are closed • the disconnecting device [Q1] is open. Drive with the earthing/grounding switch [Q9] (option +F259): Open the earthing/grounding switch. Close the auxiliary voltage switch [Q21]. ■ Setting the supply unit parameters Action If the supply unit includes one supply module: • Check the correct voltage ranges by parameter 195.01 Supply voltage. • Reboot the control unit by parameter 196.08 Control board boot. If the supply unit includes more than one supply module: Make sure that the value of parameter 195.31 Parallel connection rating id corresponds to the actual number of parallel-connected diode supply modules: • Select the correct voltage range with parameter 195.30 Parallel type filter. • 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. If you need more information on the use of the control panel, see ACX-AP-x assistant control panels user's manual (3AUA0000085685 [English]). 12 ■ Powering up the drive Action Close the disconnecting device of the supply unit. Drive with main breaker [Q1] (option +F255): Unlock the withdrawn breaker, and crank it in. WARNING! Never use the start button of the air circuit breaker to close it. Start button bypasses normal start-up procedure and may damage the module. Make sure that the control panel [A59] is in the remote mode (Loc/Rem key of the panel). Switch the Run enable and Start signals at digital input DI2 on (1) to start the operation of the supply unit. Turn the operating switch [S21] on the cabinet door to ENABLE/RUN (1) position. Run enable starts the supply unit power up sequence. After the program has stepped through it (ap- proximately 3 seconds), the drive DC link is charged, the main breaker is closed and the supply unit is in operation and ready to the supply inverters. Turn the operating switch [S21] to on (1) position to activate the Run enable signal and to close the main breaker [Q1].

62 Start-up ■ Safety function validation Action Validate the operation of safety functions (for example, emergency stop). WARNING! The safety functions are not safe before they are validated according to the instructions. See the function-specific manual for the validation tasks. Safety functions are optional. See the function-specific manual for the validation tasks. ■ On-load checks Action Make sure that the cooling operates properly (no overtemperature related warnings or faults). Switching the supply unit off 1. Stop the motors connected to inverter units. See the inverter unit hardware and firmware manuals. 2. Turn the operating switch [S21] to the OFF (0) position to deactivate the Run enable signal and to switch off the main disconnecting device (main breaker [Q1]). ENABLE / RUN 0-1 Disconnecting and temporary grounding the drive See Electrical safety precautions (page 36). 7Maintenance 63 Maintenance Contents of this chapter This chapter instructs how to maintain the diode supply unit and how to interpret its fault indications. The information is valid for ACS880-307LC...+A018 diode supply units. WARNING! Obey the safety instructions given in ACS880 liquid-cooled multidrive cabinets and modules safety instructions (3AXD50000048633 [English]). If you ignore the safety instructions, injury or death, or damage to the equipment can occur. If you are not a qualified electrical professional, do not do installation or maintenance work. Maintenance intervals The table below shows the maintenance tasks which can be done by the end user. The complete maintenance schedule is available on the Internet ( abb.com/drivesservices). For more information, consult your local ABB Service representative ( abb.com/searchchannels). 64 Maintenance Years from start-up Component ... 12 11 10 9 8 7 6 5 4 3 2 1 Coolant R R Coolant draining and refill P P P P P P Checking coolant quantity P P P P P P P P P P P P P Checking coolant antifreeze con- centration I I I I I I External circuit of main heat ex- changer (temperature, flow, pres- sure) Cabinet fans and fan control board R Cooling fans 230 V AC 50/60 Hz R CIO-module for fan control (230 V AC) R R R Cooling fans 115 V AC 50/60 Hz R I/R CIO-module for fan control (115 V AC)1) Batteries R Control panel battery R R Control unit battery Control unit R BCU Control unit Connections and environment P P P P P P P P P P P P P Quality of supply voltage Inspections I I I I I I I I I I I I I Tightness of terminals I I I I I I I I I I I I I Ambient conditions (dustiness, moisture, corrosion, temperature) I I I I I I I I I I I I I Cooling liquid pipe connections Spare parts I I I I I I I I I I I I I Spare part stock Other I I I I I I I I I I I I I ABB-SACE Air circuit breaker maintenance I I I I I I I I I I I I I ABB Contactors maintenance 1) Replace CIO-module or reset fan counters, see CIO-01 I/O module for distributed I/O bus control user's manual (3AXD50000126880 [English]) Symbols Inspection (visual inspection and maintenance action if needed) I Performance of on/off-site work (commissioning, tests, measurements or other work) P Replacement RMaintenance and component replacement intervals are based on the assumption that the equipment is operatedwithin the specified ratings and ambient conditions. ABB recommends annual drive inspections to ensure the highest reliability and optimum performance. Maintenance 65 Note: Long term operation near the specified maximum ratings or ambient conditions may require shorter maintenanceintervals for certaincomponents. Consult your local ABB Service representative for additional maintenance recommendations. Maintenance timers and counters The control program has maintenance timers andcounters thatcanbe configuredto generate a warning when a pre-defined limit is reached. Each timer/counter can be set to monitor any parameter. This feature is especially useful as a service reminder. For more information, see the firmware manual. Internal liquid-cooling system For instructions on coolant replacement and checking the liquid-cooling system, see chapter Internal cooling circuit. Power connections ■ Retightening the power connections WARNING! Obey the safety instructions given in ACS880 liquid-cooled multidrive cabinets and modules safety instructions (3AXD50000048633 [English]). If you ignore the safety instructions, injury or death, or damage to the equipment can occur. If you are not a qualified electrical professional, do not do installation or maintenance work. 1. Stop the drive and do the steps in section Electrical safety precautions (page 36) before you start the work. 2. Examine the tightness of the cable connections. Use the tightening torques given in the technical data. Fans The lifespan of the cooling fans of the drive depends on the running time, ambient temperature and dust concentration. See the firmware manual for the actual signal which indicates the running time of the cooling fan. 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 fan in the 600 mm wide incoming cubicle WARNING! Read the safety instructions given in Safety instructions for ACS880 liquid-cooled multidrive cabinets and modules (3AXD50000048633 [English]). If you ignore them, injury or death, or damage to the equipment can occur. 66 Maintenance WARNING! Wear protective gloves and long sleeves. Some parts have sharp edges. 1. Repeat the steps described in section Electrical safety precautions (page 36) before you start the work. 2. Remove the shrouding in front of the fan (if any). 3. Disconnect the fan wiring. Remove the CIO module. 4. Remove the two screws and slide the fan unit out. 5. Remove the four screws to detach the fan from the fan unit. 6. Remove the eight screws surrounding the fan unit. 7. Install a new fan in reverse order. 45 6 Maintenance 67 ■ Replacing the cooling fan of a D8T supply module WARNING! Use the required personal protective equipment. Wear protective gloves and long sleeves. Some parts have sharp edges. 1. Repeat the steps described in section Electrical safety precautions (page 36). 2. Remove any shrouding in front of the cooling fan. 3. Remove the support bracket of the fan. 4. Disconnect the fan wiring. 5. Undo the two retaining screws. 6. Pull the fan outwards to separate it from the heat exchanger housing. 7. Install new fan in reverse order. Align the guide pins at the rear of the fan cowling with the slots in the bottom guide, then reinstall the retaining screws. 3 7 5 4 68 Maintenance Fuses ■ Checking and replacing the AC fuses WARNING! Obey the safety instructions given in ACS880 liquid-cooled multidrive cabinets and modules safety instructions (3AXD50000048633 [English]). If you ignore the safety instructions, injury or death, or damage to the equipment can occur. If you are not a qualified electrical professional, do not do installation or maintenance work. WARNING! Use the required personal protective equipment. Wear protective gloves and long sleeves. Some parts have sharp edges. 1. Stop the motors connected to the drive. 2. Repeat the steps described in section Electrical safety precautions (page 36). 3. Open the cubicle door. 4. Remove any shrouding in front of the fuses. 5. 2×D8T: For replacing lower module AC fuses, remove the DC fuse assemblies: • Remove the screws, nuts and washers (8 pcs) from the top and bottom of the DC fuses. Write down the correct order of the washers. • Remove the screws and nuts from the L-shaped busbars. • Remove the DC fuses and the L-shaped busbars. 6. Remove the screw, nut and washer in the middle. 7. Remove the screws (3 pcs, 1 per each phase) from the L-shaped busbars above the fuses. 8. Remove the screws that attach the L-shape busbars below the fuses to the module AC busbars. There is one screw and busbar for each AC phase (3 pcs). Pull out the fuse assemblies with the L-shaped busbars (above and below) attached. 9. Remove the screws, nuts and washers that attach the old fuses to the busbars, remove the old fuses and attach the new fuses in reverse order. Make sure to keep the washers in the original order. See section Tightening torques (page 98). 10. Install the fuse assemblies and busbars in reverse order. See section Tightening torques (page 98). Maintenance 69 6 7 9 8 5 4 ■ Checking and replacing the DC fuses WARNING! Obey the safety instructions given in ACS880 liquid-cooled multidrive cabinets and modules safety instructions (3AXD50000048633 [English]). If you ignore the safety instructions, injury or death, or damage to the equipment can occur. If you are not a qualified electrical professional, do not do installation or maintenance work. WARNING! Use the required personal protective equipment. Wear protective gloves and long sleeves. Some parts have sharp edges. 1. Stop the motors connected to the drive. 2. Repeat the steps described in section Electrical safety precautions (page 36). 3. Open the cubicle door. 4. Remove any shrouding in front of the DC fuses. 5. Remove the screws, nuts and washers from the old fuses. Write down the correct order of the washers. Pull the fuses out. 6. Install the new fuses in reverse order. Make sure that the washers are in the correct order. If necessary, loosen the bolts of the L-shape busbars somewhat. Retighten, after the fuses are attached. See section Tightening torques (page 98). 70 Maintenance 5 4 Supply module ■ Replacing the D8T supply module WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. If you are not a qualified electrical professional, do not do installation or maintenance work. Maintenance 71 WARNING! Use the required personal protective equipment. Wear protective gloves and long sleeves. Some parts have sharp edges. Keep the module in its package until you install it. After unpacking, protect the module from dust, debris and moisture. Lift/lower a heavy module with a lifting device. Use the designated lifting points. See the dimension drawings. There is a lifting device available from ABB (order code 3AXD50000047447). Make sure that the drive cabinet is attached to the floor to prevent it from toppling over. The cabinet has a high center of gravity. Whenyou pull out heavy components or power modules, there is a risk of overturning. 1. Stop the motors connected to the drive. 2. Repeat the steps described in section Electrical safety precautions (page 36). 3. Open the cubicle door. 4. Close the inlet and outlet valve. 5. Lead the drain hoses into a suitable container. If necessary, extend the hoses. Open the inlet and outlet drain valves. This will drain all modules in the cubicle. 6. After the cubicle has drained, disconnect the piping from the module. 7. 2×D8T module: If lower module needs to be replaced, remove the cooling fan (see the fan replacement instructions). 8. Remove any shrouding above the module. 9. Remove the DC fuses above the module. See section Checking and replacing the DC fuses (page 69). 10. Disconnect the plug connector and fiber optic connectors in front of the module. 11. Remove the L-shaped busbars (3 pcs above the module). 12. Remove the module fastening screws (4 pcs). 13. Install the module lifting device to the cabinet. See Converter module lifting device for drive cabinets hardware manual (3AXD50000210268 [English]). 14. Attach one lifting hook to the front lifting eye of the module and pull the module out 10 centimeters. Keep the lifting chain tight. 15. Attach the second lifting hook to the rear lifting eye, and pull the module completely out of the cabinet. Keep the weight constantly on the lifting device. 72 Maintenance 16. Lower the module on a pallet. Keep the lifting chain attached to the module and attach the module safely to the pallet. 17. Remove the lifting chains from the old module and move the pallet out of the way. 18. Install the new module: a. Attach the lifting hooks to the module, lift the module and place it on the module guide plate. Keep the weight on the lifting device. b. Push the module into cabinet. c. Fasten the module fastening screws. d. Remove the lifting chains. e. Reinstall the DC busbars and fuses above the module. f. Connect the plug connector and fiber optic connectors. g. Reconnect the coolant pipes to the module. h. Fill up the cooling system. i. Reinstall all shrouds removed earlier. j. Remove the lifting device. 8 9 11 12 12 10 6 Maintenance 73 74 Maintenance 14 15 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. ■ Replacing the control panel battery For instructions on how to replace the control panel battery, see ACx-AP-x assistant control panels user’s manual (3AUA0000085685 [English]). Maintenance 75 Control unit ■ Replacing the memory unit After replacing a control unit, you can keep the existing parameter settings by transferring the memory unit from the defective control unit to the new control unit. WARNING! Do not remove or insert the memory unit when the control unit is powered. 1. Stop the drive and do the steps in section Electrical safety precautions (page 36) before you start the work. 2. Make sure that the control unit is not powered. 3. Remove the fastening screw and pull the memory unit out. 4. Install a memory unit in reverse order. ■ 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 36) before you start the work. 2. Undo the fastening screw and remove the battery. 3. Replace the battery with a new BR2032 battery. 76 Maintenance 4. Dispose of the old battery according to local disposal rules or applicable laws. 5. Set the real-time clock. LEDs and other status indicators This section instructs how to interpret the status indications of the diode supply unit. Warnings and faults reported by the control program are displayed on the control panel on the cabinet door. For further information, see the firmware manual. ■ Control panel and panel platform/holder LEDs The ACS-AP-... control panel has a status LED. The control panel mounting platform or holder has two status LEDs. For their indications, see the following table. Location LED 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. Blinking red There is a fault that requires the stopping and restarting of the drive/converter/inverter. Blinking blue (ACS- The Bluetooth interface is enabled, in discoverable mode, and AP-W only) ready for pairing. Flickering blue Data is being transferred through the Bluetooth interface of the (ACS-AP-W only) control panel. Control panel Red There is an active fault in the unit. mounting platform or holder (with the control panel removed) Green Power supply for the control unit is OK. Maintenance 77 ■ Control unit LEDs LED Color Indication BATT OK Green Battery voltage of the real-time clock is OK (higher than 2.8 V). When the LED is not lit, • battery voltage is below 2.8 V, • the battery is missing, or • the control unit is not powered. PWR OK Green Internal voltage OK FAULT Red The control program indicates that the equipment is faulty. See the appropriate firmware manual. WRITE Yellow Writing to SD card in progress. 78 8Internal cooling circuit 79 Internal cooling circuit Contents of this chapter The cooling system of a liquid-cooled drive consists of two circuits: the internal cooling circuit and the external cooling circuit. The internal cooling circuit covers the heat-generating electrical components of the drive and transfers the heat to the cooling unit. In the cooling unit, the heat is transferred to the external cooling circuit which is usually part of a larger external cooling system. This chapter deals with the internal cooling circuit. Applicability The information in this chapter is applicable to cabinet-built ACS880 liquid-cooled drives. Except where otherwise indicated, the information is also applicable to drives built out of ACS880 liquid-cooled multidrive modules. Internal cooling system Each cubicle has an inlet and an outlet manifold, fitted with a stop valve and a drain valve. The stop valves can be closed to isolate all modules in the cubicle from the main cooling circuit. In cabinet line-ups built by ABB, valves are color-coded: • Blue – Open during operation • Red – Closed during operation The following diagram shows the coolant pipe connections in a drive system consisting of a supply unit and an inverter unit. 80 Internal cooling circuit 2 2 A/L A/L A/L 1 HS HS HS HSA/L A/La db c a b d c 3 1 Supply modules. The drawing shows the configuration of a diode supply unit, ie. there is a common air-to-liquid exchanger in the cubicle. With an IGBT supply unit, each module has a dedicated air-to- liquid exchanger as shown for item 2. 2 Inverter modules 3 To/From cooling unit A/L Air-to-liquid heat exchanger HS Heat sink a Inlet valve b Inlet-side drain valve c Outlet valve d Outlet-side drain valve The coolant used with ACS880 liquid-cooled drive systems is Antifrogen® L 25% or 50% mixture. See Coolant specification (page 84).


FREE ENGLISH PDF

OPERATING INSTRUCTIONS

USER GUIDE - USER MANUAL

OWNER GUIDE - OWNER MANUAL

REFERENCE GUIDE - REFERENCE MANUAL

INSTRUCTION GUIDE - INSTRUCTION MANUAL

Leave a Reply