ABB ACS880-1604 User manual

—
ABB INDUSTRIAL DRIVES
ACS880-1604 DC/DC converter modules
Hardware manual

ACS880-1604 DC/DC converter
modules
Hardware manual
Table of contents
4. Cabinet construction
6. Electrical installation
8. Start-up
© 2019 ABB Oy. All Rights Reserved. 3AXD50000023642 Rev D
EN
EFFECTIVE: 2019-09-30

Table of contents
1 Introduction to the manual
13Contents of this chapter ..........................................................................
13Applicability ........................................................................................
13Safety instructions ................................................................................
13Target audience ...................................................................................
14Categorization by frame size and option module ............................................
14Use of component designations ................................................................
14Terms and abbreviations .........................................................................
15Related documents ...............................................................................
2 Operation principle and hardware description
17Contents of this chapter ..........................................................................
17Operation principle ................................................................................
18Main circuit diagram ..........................................................................
20Overview diagram of a drive with a DC/DC converter unit ..................................
21Single-line circuit diagram of the DC/DC converter unit .....................................
22Converter module hardware .....................................................................
22Frame R8i layout ..............................................................................
23Connectors X50…X53 ........................................................................
24Frame R8i hardware ..........................................................................
24DC bus connection and capacitor charging ...............................................
25BDCL filter module ................................................................................
26Connectors X30 and X55 ....................................................................
26BCU control unit of frame R8i and multiples ..................................................
27Overview of the control connections of the BCU control unit ...............................
28Converter unit control devices ..................................................................
28DC switch/disconnector ......................................................................
28Charging switch ................................................................................
28Door lights ......................................................................................
28BCU control unit ...............................................................................
28ACX-AP-x control panel ......................................................................
29PC connection .................................................................................
29Fieldbus control ................................................................................
29BAMU voltage/current measurement unit .................................................
29CIO-01 I/O module ............................................................................
30Type designation labels ..........................................................................
30Type designation labels of the DC/DC converter module ...............................
31Type designation label of the BDCL filter module ........................................
31Type designation key .............................................................................
31Type designation of the module .............................................................
32Type designation key of the filter module ..................................................
3 Moving and unpacking the module
33Contents of this chapter ..........................................................................
33Moving and lifting the transport package ......................................................
Table of contents 5

33Unpacking ..........................................................................................
33Lifting the modules ................................................................................
34Moving the modules ..............................................................................
4 Cabinet construction
35Contents of this chapter ..........................................................................
35Limitation of liability ...............................................................................
35Energy storage ....................................................................................
35Cooling and mounting orientations .............................................................
36Cabinet configuration overview .................................................................
36ACS880-1604 configuration in Rittal VX25 and generic enclosure ....................
37Installation examples .............................................................................
381×R8i DDC unit in a 800 mm wide Rittal VX25 enclosure ..................................
38Layout with DC switch/disconnector and charging .......................................
39Layout without DC switch/disconnector and charging ...................................
40Installation stages .............................................................................
41Kits for DDC R8i unit in 800 mm Rittal VX25 enclosure .................................
42Stage 1: Installation of common parts ......................................................
43Stage 2: Module and bottom cable entry installation parts ..............................
44Stage 3: Busbars and quick connectors for connecting DDC module and filter .....
45Stage 4A: DC connection with charging ...................................................
46Stage 4B: DC connection without charging ...............................................
47Stage 5A: DC connection with charging ...................................................
48Stage 5B: DC connection without charging ...............................................
49Stage 6: DDC and energy storage connection ............................................
50Stage 7: Control unit mounting plate .......................................................
51Stage 8: DDC shroud installation ...........................................................
52Stage 9: DDC module and filter installation ...............................................
531×R8i DDC unit in a 800 mm wide generic enclosure .......................................
53Parts to be installed ...........................................................................
54Kits for DDC R8i unit in 800 mm wide generic enclosure ...............................
5 Guidelines for planning electrical installation
55Contents of this chapter ..........................................................................
55Limitation of liability ...............................................................................
55Generic guidelines ................................................................................
56Selecting the energy storage ....................................................................
57Implementing protections for the energy storage ............................................
57General principles .............................................................................
57Selecting the protective circuit breaker of the energy storage ..........................
57Energy storage disconnecting device ......................................................
57Overload protection of the system by the DC/DC converter ............................
57Protecting the energy storage cable ........................................................
57Energy storage discharging device .........................................................
58Implementing an interlocking between the disconnecting devices .....................
58Selecting and routing the energy storage cables ............................................
58Recommended cables ........................................................................
58Typical cable sizes ............................................................................
58Minimizing electromagnetic interference ...................................................
58Maximum cable length ........................................................................
59EMC compliance of the complete installation .............................................
6 Table of contents

59Parallel connection ...............................................................................
6 Electrical installation
61Contents of this chapter ..........................................................................
61Safety and liability ................................................................................
61Electrical safety precautions ....................................................................
63General notes .....................................................................................
63Printed circuit boards .........................................................................
63Optical components ...........................................................................
64Checking the insulation of the energy storage cable ........................................
65Connecting the power cables ...................................................................
65Connection diagram (frame 1×R8i) .........................................................
66Connection procedure for power connections inside the DC/DC converter cubicle ..
67Connection procedure of the energy storage cables .....................................
68Connecting the BDCL filter ......................................................................
69Internal circuit diagram for the BDCL filter .................................................
69Installing the charging circuit ....................................................................
70Connecting the external power supply cable for the auxiliary circuit ......................
70R8i DC/DC converter module ...............................................................
70BDCL filter module ............................................................................
70Connecting the control cables ..................................................................
70Default I/O connection diagram .............................................................
70Connection procedure ........................................................................
72Fiber optic connectors of the DC/DC converter module .................................
72Installing optional modules ......................................................................
72Connecting a PC ..................................................................................
7 Installation checklist of the drive
75Contents of this chapter ..........................................................................
75Checklist ...........................................................................................
8 Start-up
77Contents of this chapter ..........................................................................
78Start-up procedure ................................................................................
80Disconnecting the DC/DC converter with DC switch/disconnector ........................
81Reconnecting the DC/DC converter with DC switch/disconnector ........................
9 Maintenance
83Contents of this chapter ..........................................................................
83Maintenance intervals ............................................................................
85Maintenance timers and counters ..............................................................
85Cabinet .............................................................................................
85Cleaning the interior of the cabinet .........................................................
86Cleaning the door air inlets (IP22 and IP42) ..............................................
87Replacing the inlet door filters (IP54) .......................................................
87Cleaning the roof outlet filters (IP54) .......................................................
88Power connections ...............................................................................
88Retightening the power connections .......................................................
88Fans ................................................................................................
88Replacing the cabinet cooling fan ...........................................................
90Replacing the speed-controlled cooling fan of the DC/DC converter module ........
Table of contents 7

91Replacing the direct-on-line fan (option +C188) of the DC/DC converter module ...
93Replacing the circuit board compartment fan .............................................
95Replacing the fan of the BDCL filter ........................................................
96Replacing the roof fan for IP54 cabinet ....................................................
96Cabinets with ABB air outlet kits .........................................................
96Cabinets with other fan types ............................................................
97DC/DC converter module ........................................................................
97Cleaning the module ..........................................................................
98Replacing the R8i DC/DC converter module ..............................................
102BDCL filter module ................................................................................
102Replacing the BDCL filter ....................................................................
106Capacitors .........................................................................................
106Reforming the capacitors .....................................................................
106Control panel ......................................................................................
106Cleaning the control panel ...................................................................
106Replacing the control panel battery .........................................................
106Control unit .........................................................................................
106BCU control unit types ........................................................................
106Replacing the memory unit ..................................................................
107Replacing the BCU control unit battery ....................................................
107LEDs and other status indicators ...........................................................
10 Ordering information
109Contents of this chapter ..........................................................................
109Kit code key ........................................................................................
111DC/DC converter modules .......................................................................
112BDCL filters ........................................................................................
112BDCL filters (+C188) ..........................................................................
113BDCL filters (+C188+G304) .................................................................
114Control panel ......................................................................................
115Control electronics ................................................................................
115Control unit .....................................................................................
115Fiber optic cables ..............................................................................
116Control circuit plug connectors ..............................................................
117Mechanical installation accessories and tools ................................................
117Module installation parts .....................................................................
118Shrouds .........................................................................................
118Ramp ............................................................................................
119Bottom cable entry ............................................................................
119Control unit mounting plate ..................................................................
120Electrical installation accessories ..............................................................
120Busbars and quick connectors for connecting DDC module and filter ................
121Common DC Flat-PLS assembly ...........................................................
121DC connection with DC switch/disconnector and charging .............................
122DC connection without DC switch/disconnector and charging .........................
124Energy storage connection ..................................................................
125DC fuses (DC bus side) ......................................................................
125Output DC fuses (energy storage side) ....................................................
126DC switch/disconnector kits .................................................................
126DC switch/disconnectors (IEC, 230 V, 50 Hz) .........................................
126DC switch/disconnectors (IEC, 240 V, 60 Hz) .........................................
127DC switch/disconnectors (UL/CSA, 110 V, 60 Hz) ....................................
8 Table of contents

127Charging kits ...................................................................................
127IEC ...........................................................................................
129UL ............................................................................................
129Charging resistors .............................................................................
129IEC / UL .....................................................................................
130Cabinet ventilation kits ...........................................................................
130Air inlet kits 800 mm cabinet .................................................................
131Air outlet kits 800 mm cabinet ...............................................................
132Cooling fans ....................................................................................
132Roof fans ....................................................................................
132Internal cabinet fan ........................................................................
133Miscellaneous .....................................................................................
133BAMU voltage/current measurement unit .................................................
11 Technical data
135Contents of this chapter ..........................................................................
135Ratings .............................................................................................
136Definitions ......................................................................................
137Derating ............................................................................................
137Ambient temperature derating ...............................................................
137Altitude derating ...............................................................................
139Type equivalence table ..........................................................................
139Fuses ...............................................................................................
139Fuses on BFPS board ........................................................................
139Fuses and fuse bases for BAMU unit ......................................................
139Filter module data .................................................................................
140Charging component ratings ....................................................................
140Dimensions and weights .........................................................................
140R8i DC/DC converter module ...............................................................
140BDCL filter module ............................................................................
140Free space requirements ........................................................................
141Allowable mounting orientations ................................................................
141Losses, cooling data and noise .................................................................
142Tightening torques ................................................................................
142Electrical connections ........................................................................
142Mechanical connections ......................................................................
142Insulation supports ............................................................................
142Cable lugs ......................................................................................
142Input power (DC bus) connection ..............................................................
143Output power (energy storage) connection ...................................................
143Control accuracy – Current and voltage control performance data .......................
143Control unit connection data ....................................................................
143Optical components ..............................................................................
144Protection classes ................................................................................
145Ambient conditions ...............................................................................
146Materials ...........................................................................................
146Auxiliary current consumption ...................................................................
147Cooling fans ....................................................................................
147Applicable standards .............................................................................
147Markings ...........................................................................................
147Disclaimers ........................................................................................
147Generic disclaimer ............................................................................
Table of contents 9

147Cybersecurity disclaimer .....................................................................
12 Control units of the drive
149Contents of this chapter ..........................................................................
149General .............................................................................................
150BCU-x2 control unit layout and connections ..................................................
152Default I/O diagram of the converter control unit .............................................
153External power supply for the control unit (XPOW) ..........................................
153The XD2D connector .............................................................................
154Safe torque off (XSTO, XSTO OUT) ...........................................................
154FSO-xx safety functions module connection (X12) ..........................................
154SDHC memory card slot .........................................................................
155Connector data ....................................................................................
157BCU-x2 ground isolation diagram ...........................................................
13 Dimension drawings
159Contents of this chapter ..........................................................................
160R8i DC/DC converter module ...................................................................
162Quick connectors of the DC/DC converter module ..........................................
163Quick connectors .................................................................................
164BDCL filter module ................................................................................
165DPMP-01 door mounting kit .....................................................................
166BCU control unit ...................................................................................
167BAMU voltage/current measurement unit .....................................................
168BAMU fuse holders and fuses ..................................................................
168PS272PREMCPS fuse disconnector and PS27 terminal cover ........................
168Fuse, 27 × 60 mm .............................................................................
169Ramp ...............................................................................................
171Internal cabinet fan ...............................................................................
171W2E 143-AA09-01, W2E 143-AA15-01 ....................................................
172Switchgear and charging components .........................................................
172DC switch/disconnectors .....................................................................
172OT1600E11 (IEC), OT1200U11 (UL) ...................................................
173Charging switches .............................................................................
173OS160GD04F (IEC) .......................................................................
174OS100GJ04FP (UL/CSA) ................................................................
175Charging controller ............................................................................
176Resistors ........................................................................................
176ZRF 30X165 ................................................................................
176Handles .........................................................................................
176OHB65J6 ....................................................................................
177Contacts ........................................................................................
177Auxiliary contact OA3G01, OA1G10 ....................................................
178DC fuses ...........................................................................................
14 Example circuit diagrams
179Contents of this chapter ..........................................................................
179Component designations used in the diagrams ..............................................
179DC/DC converter 1×R8i and 2×R8i without DC switch/disconnector ..................
179DC/DC converter 1×R8i and 2×R8i with DC switch/disconnector ......................
10 Table of contents

180DDC 1×R8i without DC switch/disconnector ..................................................
180DC main circuit (sheet 001) ..................................................................
181Module connections (sheet 005) ............................................................
182Auxiliary voltage distribution (sheet 020) ..................................................
183Control unit (sheet 040) ......................................................................
184BAMU measurement unit (sheet 041) ......................................................
185DDC 1×R8i with DC switch/disconnector .....................................................
185DC main circuit, charging circuit (sheet 001) ..............................................
186Module connections (sheet 005) ............................................................
187Auxiliary voltage distribution (sheet 020) ..................................................
188Control unit (sheet 040) ......................................................................
189BAMU measurement unit (sheet 041) ......................................................
190DDC 2×R8i without DC switch/disconnector ..................................................
190DC main circuit (sheet 001) ..................................................................
191DC main circuit (sheet 002) ..................................................................
192Module connections (sheet 005) ............................................................
193Module connections (sheet 006) ............................................................
194Auxiliary voltage distribution (sheet 020) ..................................................
195Auxiliary voltage distribution (sheet 021) ..................................................
196Control unit (sheet 040) ......................................................................
197BAMU measurement unit (sheet 041) ......................................................
198DDC 2×R8i with DC switch/disconnector .....................................................
198DC main circuit, charging circuit (sheet 001) ..............................................
199DC main circuit, charging circuit (sheet 002) ..............................................
200Module connections (sheet 005) ............................................................
201Module connections (sheet 006) ............................................................
202Auxiliary voltage distribution (sheet 020) ..................................................
203Auxiliary voltage distribution (sheet 021) ..................................................
204Control unit (sheet 040) ......................................................................
205BAMU measurement unit (sheet 041) ......................................................
Further information
Table of contents 11

12

Introduction to the manual
Contents of this chapter
This chapter gives basic information on the manual.
Applicability
The manual is applicable to ACS880-1604 DC/DC converter modules for user-defined
cabinet installations.
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 multidrive cabinets and
modules safety instructions (3AUA0000102301 [English]).
•Read the software-function-specific warnings and 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 service 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
Introduction to the manual 13

The manual is written for readers worldwide. Both SI and imperial units are shown.
Categorization by frame size and option module
Some descriptions, instructions and technical data which concern only certain module or
frame sizes are marked with the size identifier (such as "2×R8i", etc.). The marking derives
from the quantity and basic construction of the converter modules that form the converter
unit. For example, frame size "2×R8i" indicates that the converter unit consists of two frame
size R8i converter modules connected in parallel.
The frame size is marked on the type designation labels. The frame size of each drive
module is also shown in the rating tables.
The instructions and technical data which concern only certain optional selections are marked
with option codes (such as +E205). The options included in the drive can be identified from
the option codes visible 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
DescriptionTerm
Auxiliary measurement unitBAMU
Type of control unitBCU
Series of L-filters, for example BDCL-14-5BDCL
Module internal power supply boardBDPS
Control and power supply board for speed-controlled cooling fanBFPS
Circuit board in which the control program runsControl board
Control board built in a housing (often rail-mountable)Control unit
One section of a cabinet-installed drive. A cubicle is typically behind a door of its own.Cubicle
Charges or discharges an external energy storage (such as a battery or capacitor
bank) from or into the DC bus
DC/DC converter
Converter power electronics, related components and DC capacitors enclosed in a
metal frame or enclosure. Intended for cabinet installation.
DC/DC converter mod-
ule
DC/DC converter module(s) under control of one control board, and related componentsDC/DC converter unit
DC/DC converter unitDDC
Digital inputDI
Direct-on-lineDOL
Frequency converter for controlling AC motorsDrive
Electromagnetic compatibilityEMC
Device that stores electrical energy, for example, a battery or a super capacitor.Energy storage
Rittal Flat-PLS, a busbar system for standard, commercially available flat busbarsFlat-PLS
Physical size of the drive or power moduleFrame, frame size
Insulated gate bipolar transistorIGBT
Inverter unitINU
Converts direct current and voltage to alternating current and voltage.Inverter
Inverter module(s) under control of one control board, and related components. One
inverter unit typically controls one motor.
Inverter unit
Drive for controlling several motors which are typically coupled to the same machinery.
Includes one supply unit, and one or several inverter units.
Multidrive
14 Introduction to the manual

DescriptionTerm
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.
Parameter
Programmable logic controllerPLC
Supply module(s) under control of one control board, and related components.Supply unit
Enclosure system by Rittal (www.rittal.com)VX25
Related documents
CodeManual
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3AUA0000102301
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Introduction to the manual 15

CodeManual
3AXD50000010531
Installation frames for ACS880 multidrive modules hardware manual
Manuals and quick guides for I/O extension modules, fieldbus adapters, safety functions modules, etc.
See www.abb.com/drives/documents for all manuals on the Internet.
You can find all documentation related to the multidrive modules on the Internet at
https://sites-apps.abb.com/sites/lvacdrivesengineeringsupport/content.
16 Introduction to the manual

Operation principle and hardware
description
Contents of this chapter
This chapter describes the DC/DC converter operation basics and the hardware of the
converter.
Operation principle
The DC/DC converter unit (DDC) transfers energy from a common DC bus of a drive into
an external energy storage and discharges energy back to the DC bus. The energy storage
can be, for example, a battery or super capacitor. The energy storage media does not belong
to the DC/DC module product offering.
The DC/DC converter unit has a single converter module or parallel converter modules
under the command of one control unit. Parallel DC/DC converter modules must have a
common energy storage. Each parallel module must have the output cabling of its own. We
also recommend that you use identical cablings (cable type, cross-sectional area, and
length) and have identical load for each module. For other solutions, contact ABB.
Typically, the DC/DC converter is used in marine applications for heave compensation,
peak load compensation, propulsion supply in harbors, energy storing instead of an additional
generator and so on. The DC/DC converter can also be used in automotive applications
such as electric car charging systems and also in several other applications where energy
storing and reuse is needed.
2
Operation principle and hardware description 17

￭Main circuit diagram
The DC/DC converter module must be equipped with external DC fuses. You can equip the
converter with a DC switch/disconnector, if quick isolation of the module from the DC bus
is required.
This figure shows a simplified main circuit diagram of a DC/DC converter without a DC
switch/disconnector and charging circuit.
+
_
U2
V2
W2
U2
V2
W2
ES+1
ES+
ES-
ES+2
ES+3
L+
L-
123
4
Drive DC bus1
DC/DC converter module2
Filter module3
Energy storage4
This figure shows a simplified main circuit diagram of a DC/DC converter with the DC
switch/disconnector and charging circuit.
L+
L-
+
_
U2
V2
W2
U2
V2
W2
ES+1
ES
ES
ES+2
ES+3
1
2
34
5
6
Drive DC bus1
DC switch/disconnector2
DC/DC converter module3
Filter module4
Energy storage5
Charging components6
18 Operation principle and hardware description

This figure shows a simplified main circuit diagram of parallel-connected DC/DC converter
modules with the DC switch/disconnector and charging circuit. Also the energy storage and
related cabling and equipment are visible.
12
3
4
56
7
8
8
9
10 11
7
6
4
3
5
DC/DC converter cubicles1
Energy storage cabinet2
Drive DC bus3
DC switch/disconnector4
Charging components5
DC/DC converter module6
Filter module7
Cabling between DC/DC converter unit and energy storage8
Energy storage disconnecting device9
Energy storage protective circuit breaker10
Energy storage11
Operation principle and hardware description 19

Overview diagram of a drive with a DC/DC converter unit
This diagram shows a possible application of a converter unit in an example system. The
DC/DC converter unit includes a DC/DC converter module and a filter module.
t°
1
2
36
6
4
58
9
10
11
7
AC supply1
Input (AC) fuses2
Supply module3
DC bus (-,+)4
Inverter DC fuses (with or without a DC switch/disconnector)5
Inverter modules6
Motors7
DC fuses (DC bus side, with or without a DC switch/disconnector)8
DC/DC converter unit (converter and filter module)9
Output DC fuses10
Customer-defined energy storage with disconnecting and protection devices11
20 Operation principle and hardware description