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ACS880-107 Series
ABB ACS880-107 Series User Manual
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ABB
INDUSTRIAL
DRIVES
ACS880-107
inverter
units
Hardware
manual
2
Table of Contents
Default Chapter
5
Table of Contents
5
Table of Contents
7
1 Introduction to the Manual
11
Contents of this Chapter
11
Applicability
11
Safety Instructions
11
Target Audience
11
Categorization by Frame Size, Option Code and Item Designation
12
Use of Component Designations
12
Terms and Abbreviations
12
Related Documents
13
2 Hardware Description
15
Contents of this Chapter
15
Overview Diagram of the Drive System
16
Inverter Unit Hardware
17
General
17
Cabinet System
17
Cooling
17
Inverter Module Frame Sizes R1I to R4I
18
General
18
Module Layout Examples
18
Standard Cabinet Layout
19
Layout of Cubicle with Frame R1I
20
C204)
20
Inverter Module Frame Size R5I
22
General
22
Module Layout
22
Standard Cabinet Layout
22
Layout of Cubicle with Frame R5I Modules in Their Own Compartments (Option +C204)
23
Inverter Module Frame Sizes R6I and R7I
25
Module Layout
25
Cabinet Layout
25
Motor Cabling
26
Inverter Module Frame Size R8I and Multiples
27
Cooling Fans
28
Control Electronics
28
Cabinet Layout
28
Motor Cabling
30
Control Interfaces
31
Overview of Control Connections of the ZCU Control Unit
31
Overview of the Control Connections of the BCU Control Unit
32
The Acx-AP-X Control Panel
32
Control by PC Tools
33
Fieldbus Control
33
Other Control Devices
33
DC Switch-Disconnector (Option +F286)
33
Charging Switch (Frame R8I and Multiples Only)
33
Type Designation Labels
34
Inverter Unit Type Designation Label
34
Inverter Module Type Designation Label
34
Type Designation Key
36
Option Codes
36
3 Control Units of the Drive
41
Contents of this Chapter
41
General
41
Layout
42
Layout
43
Default I/O Diagram of the Inverter Control Unit (ZCU-1X)
44
BCU-X2 Layout
46
Default I/O Diagram of the Inverter Control Unit (A41)
48
Additional Information on the Connections
49
External Power Supply for the Control Unit (XPOW)
49
DI6 as a PTC Sensor Input
49
AI1 or AI2 as a Pt100, Pt1000, PTC or KTY84 Sensor Input
50
DIIL Input
50
The XD2D Connector
51
Safe Torque off (XSTO, XSTO OUT)
52
FSO-XX Safety Functions Module Connection (X12)
52
SDHC Memory Card Slot
52
Connector Data
53
BCU-X2 Ground Isolation Diagram
55
ZCU-1X Ground Isolation Diagram
56
4 Electrical Installation
57
Contents of this Chapter
57
Electrical Safety Precautions
57
General Notes
59
Printed Circuit Boards
59
Optical Components
59
Checking the Insulation of the Assembly
59
Measuring the Insulation of the Drive
59
Measuring the Insulation of the Motor and Motor Cable
59
Connecting the Motor Cable - Frame Sizes R1I to R5I
61
Diagram
61
Motor Cable Connection Procedure
61
Connecting the Motor Cable - Frame Sizes R6I and R7I
62
Diagram
62
Motor Cable Connection Procedure
63
Connecting the Motor Cables - Frame Size R8I and Multiples Without Common Motor Terminal Cubicle or Sine Output Filter
65
Motor Connection Diagram (Without Option +H366)
65
Motor Connection Diagram (with Option +H366)
66
Procedure
67
Removing the Inverter Module(S)
67
Removing the Fan Carriage of an Inverter Module
71
Connecting the Motor Cables
73
Re-Installing the Fan Carriage of an Inverter Module
76
Re-Inserting the Inverter Modules into the Cubicle
76
Connecting the Motor Cables - Frame Size R8I and Multiples with Common Motor Terminal Cubicle
78
Output Busbars
78
Connection Diagram
78
Procedure
78
Installing Optional Modules on the Control Unit
80
Installing an FSO-XX Safety Functions Module (Frame Sizes R1I
80
Installing an FSO-XX Safety Functions Module (Frame Sizes R8I and Multiples)
81
Installation of I/O Extension, Fieldbus Adapter and Pulse Encoder Interface Modules
83
Connecting the Control Cables
85
Connecting a PC
87
Panel Bus (Control of Several Units from One Control Panel)
87
5 Installation Checklist of the Drive
91
Contents of this Chapter
91
Checklist
91
6 Start-Up
93
Contents of this Chapter
93
Start-Up Procedure
93
7 Maintenance
97
Contents of this Chapter
97
Maintenance Intervals
97
Maintenance Timers and Counters
98
Cabinet
99
Cleaning the Interior of the Cabinet
99
Cleaning the Door Air Inlets (IP22 and IP42)
99
Replacing the Inlet Door Filters (IP54)
100
Replacing the Outlet (Roof) Filters (IP54)
100
Cleaning the Heatsink
100
Cooling Fans
101
Module Cooling Fans
102
Replacing the R1I and R2I Module Cooling Fan
102
Replacing the R3I and R4I Module Cooling Fan
103
Replacing the R5I Module Main Cooling Fan (Without Option +C204)
103
Replacing the R5I Module Main Cooling Fan (with Option +C204)
104
Replacing the R5I Module Auxiliary Cooling Fan
105
Replacing the R6I and R7I Module Cooling Fan
107
Replacing R8I Module Cooling Fan (Speed-Controlled Version)
108
Replacing R8I Module Cooling Fan (Direct-On-Line Version)
109
Replacing the Circuit Board Compartment Fan
111
Cabinet Cooling Fans
112
Replacing R1I
112
Replacing the Control Cubicle Fan (Frame R8I and Multiples)
113
Inverter Modules
114
Replacing R1I
114
Replacing R5I Inverter Module (Without Option +C204)
115
Replacing R5I Inverter Module (with Option +C204, Modules in Their Own Compartments)
115
Replacing R6I and R7I Inverter Modules
116
Replacing R8I Inverter Modules
119
Removing the Inverter Module(S)
119
Re-Inserting the Inverter Modules into the Cubicle
122
Activating the Reduced Run of the Inverter Unit
123
Replacing DC Fuses (Frame R8I and Multiples)
125
Capacitors
127
Reforming the Capacitors
127
Control Units
127
Replacing the Memory Unit
127
Replacing the ZCU-14 Control Unit Battery
128
Replacing the BCU Control Unit Battery
129
Control Panel
129
Cleaning the Control Panel
129
Replacing the Control Panel Battery
129
8 Technical Data
131
Contents of this Chapter
131
Ratings
131
Definitions
134
Derating
135
Surrounding Air Temperature Derating
135
Altitude Derating
135
Inverter Modules Used, DC Fuses, DC Capacitances
136
Noise and Cooling Characteristics
139
Sine Output Filter Data
142
Input Power (DC) Connection
144
Motor (AC) Connection
144
Typical Power Cable Sizes
147
Control Connections
148
Efficiency
149
Protection Classes
149
Optical Components
149
Ambient Conditions
149
Cooling
150
Cabinet Finish
151
Packaging
151
Disposal
151
Standards
151
Markings
151
Tightening Torques
152
Electrical Connections
152
Mechanical Connections
152
Insulation Supports
152
Cable Lugs
152
Disclaimers
152
Generic Disclaimer
152
Cybersecurity Disclaimer
153
9 Circuit Diagrams
155
10 Dimensions and Weights
157
Contents of this Chapter
157
Frames R1I
157
Weights
157
Frames R6I and R7I
158
Dimension Drawing, 400 MM Wide Cubicle
159
Frame R8I and Multiples
160
Dimension Drawing, R8I (Without +C128 or +H353), Bottom Cable Exit
161
Dimension Drawing, R8I (Without +C128 or +H353), Top Cable Exit
162
Dimension Drawing, 2×R8I (Without +C128 or +H353), Bottom Cable Exit
163
Dimension Drawing, 2×R8I (Without +C128 or +H353), Top Cable Exit
164
Dimension Drawing, 3×R8I (Without +C128 or +H353), Bottom Cable Exit
165
Dimension Drawing, 3×R8I (Without +C128 or +H353), Top Cable Exit
166
Dimension Drawing, Drive Control Unit (DCU) (300 MM)
167
Location and Size of Output Terminals
168
Units Without Common Motor Terminal Cubicle
168
Units with Common Motor Terminal Cubicle (+H359)
176
11 The Safe Torque off Function
183
Contents of this Chapter
183
Description
183
Compliance with the European Machinery Directive
184
Wiring
185
Activation Switch
185
Cable Types and Lengths
185
Grounding of Protective Shields
185
Dual-Channel Connection with Internal Power Supply
186
Frames R1I
186
Frame R8I and Multiples
187
Single-Channel Connection of Activation Switch
188
Multiple Drives
189
Internal Power Supply
189
External Power Supply
190
Operation Principle
191
Start-Up Including Acceptance Test
192
Competence
192
Acceptance Test Reports
192
Acceptance Test Procedure
192
Use
194
Maintenance
195
Competence
195
Fault Tracing
196
Safety Data
197
Abbreviations
198
TÜV Certificate
199
Further Information
201
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ABB ACS880-107 Series Specifications
General
Brand
ABB
Model
ACS880-107 Series
Category
Industrial Electrical
Language
English
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