Abb Acs880-1604lc User manual

—

ABB INDUSTRIAL DRIVES

ACS880-1604LC DC/DC converter modules

Hardware manual

ACS880-1604LC DC/DC converter

modules

Hardware manual

Table of contents

4. Cabinet construction

6. Electrical installation

9. Start-up

3AXD50000371631 Rev B

Original instructions

EFFECTIVE: 2023-12-29

Table of contents

1 Introduction to the manual

15Contents of this chapter ........................................................................

15Applicability ........................................................................................

15Safety instructions ...............................................................................

15Target audience ...................................................................................

16Categorization by frame size and option module ... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..

16Use of component designations ..............................................................

16Terms and abbreviations .......................................................................

17Related documents ..............................................................................

2 Operation principle and hardware description

19Contents of this chapter ........................................................................

19Operation principle ..............................................................................

19Main circuit diagram .........................................................................

23Overview diagram of a drive with a DC/DC converter unit .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..

24Single-line circuit diagram of the DC/DC converter unit .................................

25Converter module hardware ...................................................................

25Frame R7i .......................................................................................

25Module layout ..............................................................................

25Coolant connectors .......................................................................

26Installation frame ..........................................................................

26Connectors X50, X52 and X53; Auxiliary voltage selector X59 ... .. .. .. .. .. .. .. ..

27Fiber optic connectors ...................................................................

28LEDs ..........................................................................................

29Frame R8i .......................................................................................

29Module layout ..............................................................................

29Coolant connectors .......................................................................

30Connectors X50…X59 ....................................................................

31Fiber optic connectors ...................................................................

31LEDs ..........................................................................................

32DC bus connection and capacitor charging .............................................

33BDCL filter module ...............................................................................

33BDCL filter module for frame R7i converter module ...................................

34BDCL filter module for frame R8i converter module .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..

34Overheating protection of the filter ......................................................

34Control unit ........................................................................................

35Overview of the control connections of the BCU control unit ... .. .. .. .. .. .. .. .. .. .. .. .

36Overview of the control connections of the UCU control unit ..........................

36Converter unit control devices .................................................................

36DC switch-disconnector .....................................................................

37Charging switch ...............................................................................

37Door lights ......................................................................................

37Control unit .....................................................................................

37Control panel [A59] ...........................................................................

38PC connection .................................................................................

38Fieldbus control ...............................................................................

Table of contents 5

38BAMU voltage/current measurement unit ..............................................

38CIO-01 I/O module ............................................................................

39Type designation labels .........................................................................

39Type designation labels of the DC/DC converter module ............................

40Type designation label of the BDCL filter module .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .

40Type designation key ............................................................................

40Type designation key of the converter module .........................................

41Type designation key of the filter module ...............................................

3 Moving and unpacking the module

43Contents of this chapter ........................................................................

43Moving and unpacking the module ...........................................................

4 Cabinet construction

45Contents of this chapter ........................................................................

45Limitation of liability .............................................................................

45North America .................................................................................

45Energy storage ....................................................................................

45Liquid pipe connector installation instructions ............................................

48Cabinet configuration overview ...............................................................

48Frame R7i without DC switch-disconnector .............................................

49Frame R7i with DC switch-disconnector .................................................

50Frame R8i .......................................................................................

51Installation examples ............................................................................

52R7i DC/DC converter module in Rittal VX25 enclosure .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..

52Layout with DC switch-disconnector and charging .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..

53Layout without DC switch-disconnector and charging .. .. .. .. .. .. .. .. .. .. .. .. .. .

54Pipe routing example .....................................................................

55Installation stages .........................................................................

57Kits for ACS880-1604LC R7i unit in Rittal VX25 cabinets .. .. .. .. .. .. .. .. .. .. .. .. .

58Stage 1: Installation of common parts ................................................

59Stage 2: Side plates kit installation ....................................................

Stage 3: BDCL filter mounting mechanics kit and output busbar kit

installation ..................................................................................

61Stage 4: Cooling components kit and filter to module busbars installation ..

62Stage 5: Heat exchanger and fan mechanics installation .. .. .. .. .. .. .. .. .. .. .. .. .

63Stage 6: BDCL filter installation ........................................................

64Stage 7: Installation frame kit and DC busbar kit installation ... .. .. .. .. .. .. .. ..

65Stage 8A: Busbar kits for fuse only solution (unit without DC switch) ... .. .. .

66Stage 8B: Busbar kits for DC switch solution (unit with DC switch) ... .. .. .. ..

67Stage 9: Module installation ............................................................

68Stage 10: Swing-out frame and shroud kit installation .. .. .. .. .. .. .. .. .. .. .. .. .. .

69Stage 11: Marine kit installation ........................................................

70Stage 12: Pressure relief vent kit and cabinet cover installation ... .. .. .. .. .. .. .

712×R7i DC/DC converter modules in Rittal VX25 enclosure .. .. .. .. .. .. .. .. .. .. .. .. .. .

71Parallel connection ........................................................................

72R8i DC/DC converter module in Rittal VX25 enclosure ................................

72Layout with DC switch/disconnector and charging .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .

73Layout without DC switch/disconnector and charging .. .. .. .. .. .. .. .. .. .. .. .. .. .

74Pipe routing example .....................................................................

75Installation stages .........................................................................

6 Table of contents

77Kits for ACS880-1604LC R8i unit in Rittal VX25 cabinets ... .. .. .. .. .. .. .. .. .. .. ..

78Stage 1: Installation of common parts ................................................

Stage 2: Side plates, busbars and quick connectors for connecting DDC

module and filter ..........................................................................

80Stage 3: Module installation parts .....................................................

81Stage 4: DDC and energy storage connection .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..

82Stage 5A: DC connection with charging ..............................................

83Stage 5B: DC connection without charging ..........................................

84Stage 6: Cooling components ..........................................................

85Stage 7: DDC module and filter installation ..........................................

86Stage 8: Swing frame and shroud installation .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..

872×R8i DC/DC converter modules in Rittal VX25 enclosure ... .. .. .. .. .. .. .. .. .. .. .. ..

87Parallel connection ........................................................................

88Generic enclosures ............................................................................

5 Guidelines for planning electrical installation

89Contents of this chapter ........................................................................

89Limitation of liability .............................................................................

89North America .................................................................................

89Generic guidelines ................................................................................

90Selecting the energy storage ..................................................................

91Implementing protections for the energy storage ........................................

91General principles .............................................................................

91Selecting a protective device for the energy storage ... .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..

91Energy storage disconnecting (isolating) device .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..

91Overload protection of the system by the DC/DC converter .. .. .. .. .. .. .. .. .. .. .. ..

91Protecting the energy storage cable ......................................................

92Energy storage discharging device .......................................................

92Implementing earth fault protection .........................................................

92Implementing an interlocking between the disconnecting devices ... .. .. .. .. .. .. .. ..

92Selecting and routing the energy storage cables ..........................................

92Cable selection procedure ..................................................................

92Recommended cables ........................................................................

93Typical cable sizes ............................................................................

93Minimizing electromagnetic interference ...............................................

93Maximum cable length .......................................................................

93EMC compliance of the complete installation .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..

94Parallel connection ...............................................................................

6 Electrical installation

95Contents of this chapter ........................................................................

95Safety and liability ................................................................................

95Electrical safety precautions ...................................................................

97General notes ......................................................................................

97Printed circuit boards ........................................................................

97Handling fiber optic cables .................................................................

97Measuring the insulation resistance of the DC cabling .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..

99Connecting the energy storage cable and load disconnected indicator cable .. .. ..

99Use of fasteners in cable lug connections ...............................................

100Connection diagram ..........................................................................

Table of contents 7

101

Connection procedure for power connections inside the DC/DC converter cu-

bicle ..............................................................................................

101Connection procedure of the energy storage cables .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .

104Connecting the BDCL filter .....................................................................

105Internal circuit diagram for the BDCL filter ..............................................

105Installing the charging circuit ..................................................................

106Connecting the external power supply cable for the auxiliary circuit .................

106DC/DC converter module ...................................................................

106BDCL filter module ............................................................................

106Connecting the control cables .................................................................

106Default I/O connection diagram ...........................................................

106Connection procedure .......................................................................

108Installing option modules .......................................................................

109Connecting a PC ..................................................................................

7 The control unit

111Contents of this chapter ........................................................................

111General ..............................................................................................

112BCU layout .........................................................................................

114UCU-22…24 layout ...............................................................................

117Default I/O diagram of the converter control unit (BCU) ................................

119Default I/O diagram of the converter control unit (UCU-22…24) ......................

122Additional information on the connections .................................................

122Power supply for the control unit (XPOW) ...............................................

122The X485 connector (BCU) ..................................................................

122The X485 connector (UCU) ..................................................................

123Safe torque off (XSTO, XSTO OUT) ........................................................

123FSO safety functions module connection (X12, with BCU only) .. .. .. .. .. .. .. .. .. .. .

123SDHC memory card slot .....................................................................

123MicroSDHC memory card slot ..............................................................

124Connector data ...................................................................................

127BCU ground isolation diagram .............................................................

128UCU-22…24 ground isolation diagram ...................................................

8 Installation checklist

129Contents of this chapter ........................................................................

129Checklist ............................................................................................

9 Start-up

133Contents of this chapter ........................................................................

134Start-up procedure ...............................................................................

10 Maintenance

137Contents of this chapter ........................................................................

137Maintenance intervals ...........................................................................

137Description of symbols ......................................................................

138Recommended maintenance intervals after start-up .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .

139Maintenance timers and counters ............................................................

139Disconnecting the DC/DC converter .........................................................

139Disconnecting the DC/DC converter from the energy storage ... .. .. .. .. .. .. .. .. ..

8 Table of contents

140

Disconnecting the DC/DC converter from the drive system with the DC switch-

disconnector ...................................................................................

140Connecting the DC/DC converter .............................................................

140Fans .................................................................................................

141Frame R7i – internal module fan replacement .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..

142Frame R8i fan replacement .................................................................

143R7i converter module ............................................................................

143Removing the module ........................................................................

145Installing the module .........................................................................

146R8i converter module ............................................................................

146Replacing an R8i converter module .......................................................

146Assembling the service platform .......................................................

147Removing the module ....................................................................

150Reinstalling the module ..................................................................

151Capacitors .........................................................................................

151Reforming the capacitors ...................................................................

151Control panel ......................................................................................

151Control unit ........................................................................................

151BCU control unit types .......................................................................

151UCU control unit types .......................................................................

151Replacing the memory unit (BCU) .........................................................

152Replacing the memory unit (UCU-22…24) ...............................................

153Replacing the BCU control unit battery ..................................................

154Replacing the real-time clock battery (UCU-22…24) .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..

155Replacing the microSDHC memory card (UCU-22…24) ...............................

155LEDs and other status indicators .............................................................

156Control panel and panel platform/holder LEDs .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..

156Converter module LEDs ......................................................................

11 Ordering information

157Contents of this chapter ........................................................................

157Kit code key ........................................................................................

159Frame R7i and multiples .........................................................................

159DC/DC converter modules ..................................................................

160BDCL filters .....................................................................................

162Control panel ...................................................................................

163Control electronics ...........................................................................

163Control unit (UCU) .........................................................................

163Fiber optic cables ..........................................................................

164Control circuit plug connectors ........................................................

164Options ......................................................................................

165Mechanical installation accessories .......................................................

165Module installation parts ................................................................

167Swing-out frame (for Rittal VX25 enclosures) .......................................

168Shrouds ......................................................................................

168Heat exchanger mechanics kit ..........................................................

169Bottom cable entry ........................................................................

170Marine kit ....................................................................................

170Pressure relief vent kit ....................................................................

171Electrical installation accessories .........................................................

171

Busbars and quick connectors for connecting DC/DC converter module and

filter ..........................................................................................

Table of contents 9

172Common DC Flat-PLS assembly ........................................................

172DC connection with DC switch-disconnector and charging ......................

174DC connection without DC switch-disconnector and charging .. .. .. .. .. .. .. .. .

175Energy storage connection ..............................................................

176Input DC fuses .............................................................................

177Output DC fuses ...........................................................................

178Parallel connection busbar kit ..........................................................

178Cooling system parts ........................................................................

178Coolant distribution manifold kits ....................................................

179Piping ........................................................................................

180Heat exchanger ............................................................................

180Cooling fan ..................................................................................

181Frame R8i and multiples ........................................................................

181DC/DC converter modules ..................................................................

182BDCL filters .....................................................................................

183Control panel ...................................................................................

184Control electronics ...........................................................................

184Control unit (BCU) .........................................................................

184Fiber optic cables ..........................................................................

185Control circuit plug connectors ........................................................

185Options ......................................................................................

185Mechanical installation accessories .......................................................

185Module installation parts ................................................................

188Swing-out frame (for Rittal VX25 enclosures) .......................................

189Shrouds ......................................................................................

190Bottom cable entry ........................................................................

191Marine kit ....................................................................................

191Pressure relief vent kit ....................................................................

192Electrical installation accessories .........................................................

192

Busbars and quick connectors for connecting DC/DC converter module and

filter ..........................................................................................

193Common DC Flat-PLS assembly ........................................................

193DC connection with DC switch-disconnector and charging ......................

195DC connection without DC switch-disconnector and charging .. .. .. .. .. .. .. .. .

196Energy storage connection ..............................................................

197Input DC fuses .............................................................................

198Output DC fuses ...........................................................................

198Parallel connection busbar kit ..........................................................

199Cooling system parts ........................................................................

199Coolant distribution manifold kits ....................................................

200Piping ........................................................................................

200Heat exchanger ............................................................................

200Cooling fan ..................................................................................

201Miscellaneous .....................................................................................

201BAMU voltage/current measurement unit ..............................................

201CIO-01 I/O module ............................................................................

12 Internal cooling circuit

203Contents of this chapter ........................................................................

203Applicability ........................................................................................

203Internal cooling system .........................................................................

10 Table of contents

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