ABB ACS880-1604LC User manual

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



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 ....................................................
60
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 ................................................
79
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

205Connection to a cooling unit ...................................................................
205Connection to an ACS880-1007LC cooling unit .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..
205Connection to a custom cooling unit .....................................................
205General requirements ....................................................................
205Coolant temperature control ...........................................................
206Filling up and bleeding the internal cooling circuit ........................................
206Drive line-ups with an ACS880-1007LC cooling unit .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .
206Drive line-ups with a custom cooling unit ...............................................
207Draining the internal cooling circuit ..........................................................
207Maintenance intervals ...........................................................................
208Technical data .....................................................................................
208Coolant specification ........................................................................
208Coolant type ................................................................................
208Temperature limits ...........................................................................
210Pressure limits .................................................................................
210Coolant flow rate limits ......................................................................
210Cooling circuit materials ....................................................................
13 Technical data
211Contents of this chapter ........................................................................
211Ratings ..............................................................................................
214Derating .........................................................................................
214Surrounding air temperature derating ...............................................
214Altitude derating ..........................................................................
214Type equivalence table ..........................................................................
215Fuses ................................................................................................
215Filter module data ................................................................................
216Losses, cooling data and noise ................................................................
218Dimensions and weights ........................................................................
218Free space requirements .......................................................................
218Tightening torques ...............................................................................
218Electrical connections ........................................................................
218Mechanical connections .....................................................................
219Insulation supports ...........................................................................
219Cable lugs .......................................................................................
219Input power (DC bus) connection .............................................................
219Output power (energy storage) connection ................................................
220Typical power cable sizes .......................................................................
221Control accuracy – Current and voltage control performance data ... .. .. .. .. .. .. .. ..
221Control unit connection data ..................................................................
221Coolant connections .............................................................................
221Protection classes ................................................................................
221Energy efficiency data (ecodesign) ...........................................................
222Ambient conditions ..............................................................................
223Materials ............................................................................................
223Module ...........................................................................................
223Package materials for module products .................................................
223Disposal .........................................................................................
225Auxiliary current consumption .................................................................
225Cooling fans ....................................................................................
225Definitions ......................................................................................
225Applicable standards ............................................................................
Table of contents 11

225Markings ............................................................................................
226Disclaimers .........................................................................................
226Generic disclaimer ............................................................................
226Cyber security disclaimer ...................................................................
14 Dimension drawings
227Contents of this chapter ........................................................................
228R7i DC/DC converter module ..................................................................
229R8i DC/DC converter module ..................................................................
230BDCL filter module for R7i DC/DC converter module .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .
231BDCL filter module for R8i DC/DC converter module . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..
232Quick connector ..................................................................................
233BCU control unit ..................................................................................
234UCU control unit ..................................................................................
235BAMU voltage/current measurement unit ..................................................
236BAMU accessories ................................................................................
236Miniature circuit breaker S804S-UCB10 ..................................................
236Auxiliary contact S800-AUX .................................................................
237Shorting plug S802-LINK50 .................................................................
237Mersen PS272PREMCPS fuse disconnector ..............................................
238CIO-01 I/O module ...............................................................................
239DPMP-01 door mounting kit ....................................................................
240Switchgear and charging components ......................................................
240DC switch-disconnectors ....................................................................
240OT1200U11, OT1600E11 ..................................................................
241Charging switches ............................................................................
241OS100GJ04FP ..............................................................................
242OS160GD04F ...............................................................................
243Charging controller BSFC-12C ..............................................................
244Handles ..........................................................................................
244OHB65J6 .....................................................................................
244OHB150J12P ................................................................................
245Contacts ........................................................................................
245Auxiliary contact OA1G10 ................................................................
245Auxiliary contact OA3G01 ................................................................
246DC fuses ............................................................................................
15 Example circuit diagrams
247Contents of this chapter ........................................................................
247Contents of the example circuit diagrams ..................................................
247ACS880-1604LC DC/DC converter unit 1×R7i, 3AXD10002083731 .. .. .. .. .. .. .. .. ..
248ACS880-1604LC DC/DC converter unit 1×R8i, 3AXD10000878887 ... .. .. .. .. .. .. ..
248ACS880-1604LC DC/DC converter unit 2×R8i, 3AXD10000873230 .................
249DC/DC converter unit, 1×R7i with DC switch/disconnector .............................
249Sheet 001a (Main supply) ....................................................................
250Sheet 001b (Charging circuit) ..............................................................
251Sheet 002a (BDCL main circuit) ............................................................
252Sheet 005a (Module connections) .........................................................
253Sheet 005b (BDCL module connections) .................................................
254Sheet 007a (BAMU voltage measurement) ..............................................
255Sheet 020a (Auxiliary voltage distribution) .............................................
12 Table of contents

256Sheet 021a (Auxiliary voltage distribution) ..............................................
257Sheet 022a (24 V DC distribution) .........................................................
258Sheet 026a (Cabinet fans) ...................................................................
259Sheet 040a (Control unit) ...................................................................
260Sheet 040b (Control unit) ...................................................................
261Sheet 040c (Control unit) ...................................................................
262Sheet 040d (Control unit) ...................................................................
263Sheet 040e (Signal lamps) ..................................................................
264Sheet 041a (Option cards) ..................................................................
265DC/DC converter unit, 1×R8i with DC switch/disconnector .. .. .. .. .. .. .. .. .. .. .. .. .. ..
265Sheet 001a (Main supply) ....................................................................
266Sheet 001b (Charging circuit) ..............................................................
267Sheet 002a (BDCL main circuit) ............................................................
268Sheet 005a (Module connections) .........................................................
269Sheet 005b (BDCL module connections) .................................................
270Sheet 007a (BAMU voltage measurement) ..............................................
271Sheet 020a (Auxiliary voltage distribution) .............................................
272Sheet 021a (Auxiliary voltage distribution) ..............................................
273Sheet 022a (24 V DC distribution) .........................................................
274Sheet 026a (Cabinet fans) ...................................................................
275Sheet 040a (Control board) .................................................................
276Sheet 040b (Control board) ................................................................
277Sheet 040c (Control board) .................................................................
278Sheet 040d (Signal lamps) ..................................................................
279DC/DC converter unit, 2×R8i with DC switch/disconnector .. .. .. .. .. .. .. .. .. .. .. .. .. ..
279Sheet 001a (Main circuit, 1st cubicle) .....................................................
280Sheet 001b (Charging control, 1st cubicle) ..............................................
281Sheet 001c (Main circuit, 2nd cubicle) ....................................................
282Sheet 001d (Charging control, 2nd cubicle) .............................................
283Sheet 002a (BDCL main circuit, 1st cubicle) .............................................
284Sheet 002b (BDCL main circuit, 2nd cubicle) ............................................
285Sheet 005a (Module connections, 1st cubicle) ..........................................
286Sheet 005b (BDCL module connections, 1st cubicle) . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .
287Sheet 007a (BAMU voltage measurement, 1st cubicle) ... .. .. .. .. .. .. .. .. .. .. .. .. .. ..
288Sheet 020a (Auxiliary voltage distribution, 1st cubicle) .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..
289Sheet 021a (Auxiliary voltage distribution, 1st cubicle) ...............................
290Sheet 022a (Auxiliary voltage distribution, 1st cubicle) .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .
291Sheet 026a (Cabinet fan & CIO, 1st cubicle) .............................................
292Sheet 026b (Cabinet fan, 2nd cubicle) ....................................................
293Sheet 040a (Control board, 1st cubicle) ..................................................
294Sheet 040b (Control board, 1st cubicle) .................................................
295Sheet 040c (Control board, 1st cubicle) ..................................................
296Sheet 040d (Signal lamps, 1st cubicle) ...................................................
Further information
Table of contents 13

14

Introduction to the manual
Contents of this chapter
This chapter gives basic information on the manual.
Applicability
The manual is applicable to ACS880-1604LC DC/DC converter modules for user-defined
cabinet installations.
Safety instructions
Obey all safety instructions of 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 multidrives cabinets and modules safety instructions
(3AXD50000048633 [English]).
• Read the warnings of the software function before you take the function in use
or change its default parameter settings. Read the warnings of the parameter
before you change its default setting. Refer to the firmware manual.
Target audience
This manual is intended for people who plan the installation, install, commission 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 you work on the drive. You are expected to know the
fundamentals of electricity, wiring, electrical components and electrical schematic
symbols.
1
Introduction to the manual 15

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 component designation in brackets (for
example, [Q20]). This will help you 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
I/O module for controlling cooling fansCIO
The part in which the control program runs.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 capa-
citor 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 module
DC/DC converter module(s) under control of one control unit, and related
components
DC/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
busbars
Flat-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 unit, and related components.
One inverter unit typically controls one motor.
Inverter unit
Liquid cooling unitLCU
16 Introduction to the manual

DescriptionTerm
Drive for controlling several motors which are typically coupled to the same
machinery. Includes one supply unit, and one or several inverter units.
Multidrive
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. For example, variable, constant, or signal.
Parameter
Programmable logic controllerPLC
Supply module(s) under control of one control unit, and related components.Supply unit
Type of control unitUCU
Adapter for installing F-series option modules onto the UCU control unit.USCA-02
Related documents
You can find manuals on the Internet. See below for the relevant code/link. For more
documentation, go to www.abb.com/drives/documents.
Manuals for ACS880 multidrives modules
Introduction to the manual 17

18

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 is not
included in 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. ABB also recommends 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.
■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.
2
Operation principle and hardware description 19

This figure shows a simplified main circuit diagram of a DC/DC converter without a
DC switch-disconnector or charging circuit.
1 2
34
567
8 9
DC/DC converter cubicle1
Energy storage cabinet2
Drive DC bus3
DC/DC converter module4
Filter module5
Cabling between DC/DC converter unit and energy storage6
Energy storage disconnecting device7
Energy storage protective circuit breaker8
Energy storage9
20 Operation principle and hardware description
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