ABB DCS880 series User manual

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ABB INDUSTRIAL DRIVES
DCS880 drives
H4T (Tosa) manual

DCS880 Drive Manuals
General
Publication number
EN
DE
IT
ES
FR
PL
ZH
RU
DCS880 Quick guide
3ADW000545
EN
DE
IT
ES
FR
Safety instructions all languages
3ADW000481
EN
DE
IT
ES
FR
PL
ZH
RU
DCS880 Manual set
DCS880
Manual set
EN
DCS880 Units
DCS880 Flyer
3ADW000475
EN
DE
IT
ES
FR
ZH
RU
DCS880 Technical catalog
3ADW000465
EN
DE
IT
ES
FR
PL
ZH
RU
DCS880 Hardware manual
3ADW000462
EN
DE
IT
ES
FR
PL
RU
DCS880 Firmware manual
3ADW000474
EN
DE
IT
ES
FR
PL
RU
DCS880 Service manual
3ADW000488
EN
DCS880 Hardparallel manual (on request only)
3ADW000530
EN
DCS880 12-pulse manual
3ADW000533
EN
DCS880 Current measurement aid (SDCS-CMA-2) manual
3ADW000745
EN
ACS-AP-x assistant control panels user’s manual
3AUA0000085685
EN
DCS Thyristor power converter – Technical guide
3ADW000163
EN
DCS External DC voltage measurement H1 … H5
3ADW000601
EN
Functional safety
Supplement for functional safety
3ADW000452
EN
IT
ES
FR
PL
RU
Functional safety for enclosed converter
+Q957 Prevention of unexpected Start Up
3ADW000504
EN
+Q951 Emergency stop, category 0 with MC opening
3ADW000505
EN
+Q952 Emergency stop, category 1 with MC opening
3ADW000506
EN
+Q963 Emergency stop, category 0 without MC opening
3ADW000507
EN
+Q964 Emergency stop, category 1 without MC opening
3ADW000508
EN
Enclosed converter
DCS880-A Catalog
3ADW000531
EN
DCS880-A Installation manual
3ADW000627
EN
DCS800-A +S880 Enclosed converters, flyer
3ADW000523
EN
Rebuild and upgrade systems
DCS880-R Rebuild manual
3ADW000599
EN
DCS880-U Upgrade manual
3ADW000719
EN
Door mounting kits
DPMP-01 mounting platform for ACS-AP control panel
3AUA0000100140
EN
DPMP-02 mounting platform for ACS-AP control panel
3AUA0000136205
EN
Serial communication
FCAN-01 CANopen adapter module
3AFE68615500
EN
DE
FDNA-01 DeviceNet™ adapter module
3AFE68573360
EN
FECA-01 EtherCAT adapter module
3AUA0000068940
EN
DE
ES
FENA-11/-21 Ethernet adapter module
3AUA0000093568
EN
ZH
FEPL-02 Ethernet POWERLINK adapter module
3AUA0000123527
EN
DE
FPBA-01 PROFIBUS DP adapter module
3AFE68573271
EN
DE
PL
ZH
FSCA-01 RS-485 adapter module
3AUA0000109533
EN
ZH
FDCO-01/02 DDCS communication modules
3AUA0000114058
EN
FSPS-21 PROFIsafe safety functions module
3AXD50000158638
EN
FSO-21 Safety functions module
3AXD50000015614
EN
Tool and maintenance manuals and guides
Drive Composer PC tool
3AUA0000094606
EN
Drive application programming (IEC61131-3) manual
3AUA0000127808
EN
Adaptive programming, Application guide
3AXD50000028574
EN
NETA-21 remote monitoring tool
3AUA0000096939
EN
NETA-21 remote monitoring tool guide
3AUA0000096881
EN
DDCS branching unit NDBU-95 user’s manual
3BFE64285513
EN
Extension modules
FIO-11 Analog extension module
3AFE68784930
EN
DE
IT
FIO-01 Digital extension module
3AFE68784921
EN
DE
IT
FAIO-01 Analog extension module
3AUA0000124968
EN
DE
FDIO-01 Digital extension module
3AUA0000124966
EN
FEN-01 TTL encoder interface
3AFE68784603
EN
DE
IT
ZH
FEN-31 HTL encoder interface
3AUA0000031044
EN
ZH
FSE-31 pulse encoder interface module user’s manual 3AXD50000016597 EN
FEA-03 F series extension adapter
3AUA0000115811
EN
Ethernet tool network for ACS880 drives appl. guide
3AUA0000125635
EN
Status 04.2022 DCS880 Manuals list en s.docx

3
Table of contents
3ADW000803R0101 DCS880 H4T (Tosa) manual en a
Table of contents
DCS880 Drive Manuals..................................................................................................................................................2
Safety instructions 4
What this chapter contains..........................................................................................................................................4
To which products this chapter applies ....................................................................................................................4
Usage of warnings and notes......................................................................................................................................4
Installation and maintenance work ............................................................................................................................4
Grounding ...................................................................................................................................................................5
Printed circuit boards and fiber optic cables.......................................................................................................5
Mechanical installation .................................................................................................................................................6
Operation.........................................................................................................................................................................6
Introduction to this manual 8
H4T....................................................................................................................................................................................8
Application ......................................................................................................................................................................8
Related documents........................................................................................................................................................8
Terms and abbreviations..............................................................................................................................................9
Cybersecurity disclaimer ............................................................................................................................................ 11
H4T hardware 12
Type code ...................................................................................................................................................................... 12
Type code units size H4T........................................................................................................................................ 13
Main circuit and control..............................................................................................................................................14
Armature converter DCS880 H4T .........................................................................................................................14
Converters size H4T configuration ......................................................................................................................15
Mains power connection ........................................................................................................................................16
Cooling fans ..................................................................................................................................................................16
Fan assignment for DCS880..................................................................................................................................16
Fan cable sizes and tightening torque connected at the fan terminals .......................................................16
Cross-sectional areas - Tightening torques .......................................................................................................16
Current ratings - IEC non regenerative converters (S01)................................................................................. 17
2-Q units size H4T.................................................................................................................................................... 17
Circuit diagram ........................................................................................................................................................18
Galvanic isolation - T90, A92, F11, F90 .................................................................................................................19
Size H4T .................................................................................................................................................................... 20
Fuses and fuse holders IEC for converter size H4T........................................................................................... 21
H4T firmware 22
H4T service 23
Current ratings .............................................................................................................................................................23
Fault Tracing Thyristors 24
Units size H4T...........................................................................................................................................................24
Blown fuses...............................................................................................................................................................24
Exchange thyristors size H4T 25
Remove faulty thyristor modules .........................................................................................................................25
Install new thyristor modules................................................................................................................................32
Commissioning 33

4
Safety instructions
3ADW000803R0101 DCS880 H4T (Tosa) manual en a
Safety instructions
What this chapter contains
This chapter contains the safety instructions you must follow when installing, operating and servicing
the drive/unit.
If ignored, physical injury or death may follow, or damage may occur to the drive/unit, the motor/load or
driven equipment. Read the safety instructions before you work on the unit.
To which products this chapter applies
The information is valid for the whole range of the product line DCS880, the converter modules DCS880-
S0x size H1 … H8, field exciter units DCF80x, Rebuild Kit DCS880-R00, etc.
Usage of warnings and notes
There are two types of safety instructions throughout this manual: warnings and notes.
Warnings caution you about conditions which can result in serious injury or death and/or damage to the
equipment, and advice on how to avoid the danger.
Notes draw attention to a particular condition or fact or give information on a subject.
The warning symbols are used as follows:
Dangerous voltage warning warns of high voltage which can cause physical injury or death
and/or damage to the equipment.
General danger warning warns about conditions, other than those caused by electricity,
which can result in physical injury or death and/or damage to the equipment.
Electrostatic sensitive devices warning
warns of electrostatic discharge which can
damage the equipment.
Installation and maintenance work
These warnings are intended for all who work on the drive/unit, motor/load cable or motor/load.
Ignoring the instructions can cause physical injury or death and/or damage to the equipment.
WARNING
−Only qualified electricians are allowed to install and maintain the drive/unit!
−Never work on the drive/unit, motor/load cable or motor/load when mains power is
applied.
−Always ensure by measuring with a multimeter (impedance at least 1 MΩ) that:
−1. Voltage between drive/unit input phases U1, V1 and W1 and the frame is close
to 0 V.
−2. Voltage between terminals C+ and D- and the frame is close to 0 V.
−Do not work on the control cables when power is applied to the drive/unit or to the
external control circuits. Externally supplied control circuits may cause dangerous
voltages inside the drive/unit even when the mains
power on the drive/unit is switched
off.
−Do not make any insulation resistance or voltage withstand tests on the drive/unit or
drive modules.
−Isolate the motor/load cables from the drive/unit when testing the insulation
resistance or voltage withstand of the cables or the motor/load.
−When reconnecting the motor/load cable, always check that the C+ and D- cables are
connected with the proper terminal.

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Safety instructions
3ADW000803R0101 DCS880 H4T (Tosa) manual en a
Notes:
−The motor/load cable terminals on the drive/unit are at a dangerously high voltage
when the mains power is on, regardless of whether the motor/load is running or not.
−Depending on the external wiring, dangerous voltages (115 V, 220 V or 230 V) may be
present on the relay outputs of the drive/unit system (e.g. XRO1 … XRO3).
−DCS880 with enclosure extension: Before working on the drive/unit, isolate the whole
drive/unit system from the supply.
Grounding
These instructions are intended for all who are responsible for the grounding of the drive/unit. Incorrect
grounding can cause physical injury, death and/or equipment malfunction and increase electromagnetic
interference.
WARNING
−Ground the drive/unit, motor/load and adjoining equipment to ensure personnel safety
in all circumstances, and to reduce electromagnetic emission and pick-up.
−Make sure that grounding conductors are adequately sized and marked as required by
safety regulations.
−In a multiple-drive/unit installation, connect each drive/unit separately to protective
earth (PE ).
−Minimize EMC emission and make a 360° high frequency grounding (e.g. conductive
sleeves) of screened cable entries at the cabinet lead-through plate.
−Do not install a drive/unit equipped with an EMC filter to an ungr
ounded power system or
a high resistance-grounded (> 30 Ω) power system.
Notes:
−Power cable shields are suitable as equipment grounding conductors only when
adequately sized to meet safety regulations.
−As the normal leakage current of the drive/unit is higher than 3.5 mAAC or 10 mADC a fixed
protective earth connection is required.
−This product can cause a DC current in the protective earthing conductor. Where a
residual current-operated protective (RCD) or monitoring (RCM) device is used for
protection in case of direct or indirect contact, only an RCD or RCM of Type B is allowed
on the supply side of this product.
Printed circuit boards and fiber optic cables
These instructions are intended for all who handle the circuit boards and fiber optic cables. Ignoring the
following instructions can cause damage to the equipment.
WARNING
−The printed circuit boards contain components sensitive to electrostatic discharge.
Wear a grounding wrist band when handling the boards. Do not touch the boards
unnecessarily.
−Use grounding strip:
−
ABB order no.: 3ADV050035P0001
WARNING
−Handle the fiber optic cables with care.
−When unplugging optic cables, always grab the connector, not the cable itself.

6
Safety instructions
3ADW000803R0101 DCS880 H4T (Tosa) manual en a
−Do not touch the ends of the fibers with bare hands as the fiber is extremely sensitive
to dirt.
−The minimum allowed bend radius is 35 mm (1.38 in.).
Mechanical installation
These notes are intended for all who install the drive/unit. Handle the unit carefully to avoid damage and
injury.
WARNING
−DCS880 sizes H4 ... H8:
−The drive/unit is heavy. Lift the drive/unit by lifting lugs only.
−The drive’s/unit’s center of gravity is high. Do not tilt the drive/unit. The
drive/unit will overturn from a tilt of about 6 degrees. An overturning drive/unit
can cause physical injury.
−Do not lift the drive/unit by the front cover.
−Place drives/units H4 … H6 only on their back.
−Make sure that dust from drilling does not enter the drive/unit when installing.
Electrically conductive dust inside the drive/unit may cause damage or lead to
malfunction.
−Ensure sufficient cooling.
−Do not fasten the drive/unit by riveting or welding.
Operation
These warnings are intended for all who plan the operation of the drive/unit or operate the drive/unit.
Ignoring the instructions can cause physical injury or death and/or damage to the equipment.
WARNING
−Before adjusting the drive/unit and putting it into service, make sure that the
motor/load and all driven equipment are suitable for operation throughout the
speed/voltage range provided by the drive/unit. The drive can be adjusted to operate
the motor at speeds above and below the base speed.
−Do not control the motor/load with the disconnecting device (disconnecting mains);
instead, use the control panel keys and
, or commands via the I/O board of the
drive/unit.
−Mains connection:
You can use a disconnect switch (with fuses) to disconnect the electrical components
of the drive/unit from the mains for installation and maintenance work. The type of
disconnect switch used must be as per EN 60947-3, Class B, so as to comply with EU
regulations, or a circuit-breaker type which switches off the load circuit by means of an
auxiliary contact causing the breaker's main contacts to open. The mains disconnect
must be locked in its "OPEN" position during any installation and maintenance work.
−EMERGENCY STOP buttons must be installed at each control desk and at all other
control panels requiring an emergency stop function. Pressing the STOP button on the
control panel of the drive/unit will neither cause an emergency stop of the motor/load,
nor will the drive/unit be disconnected from any dangerous potential.
−To avoid unintentional operating states, or to shut the unit down in case of any
imminent danger according to the standards in the safety instructions it is not
sufficient to merely shut down the drive/unit via signals "RUN", "drive/unit OFF" or
"Emergency Stop" respectively "control panel" or "PC tool".
−Intended use:
The operating instructions cannot take into consideration every possible case of
configuration, operation or maintenance. Thus, they mainly give such advice only,

7
Safety instructions
3ADW000803R0101 DCS880 H4T (Tosa) manual en a
which is required by qualified personnel for normal operation of the machines and
devices in industrial installations.
If in special cases the electrical machines and devices are intended for use in non-
industrial installations - which may require stricter safety regulations (e.g. protection
against contact by children or similar) - these additional safety measures for the
installation must be provided by the customer during assembly.
Note:
−When the control location is not set to Local (Local not shown in the status row of the
display), the stop key on the control panel will not stop the drive/unit. To stop the
drive/unit using the control panel, press the Loc/Rem key and then the stop key .

8
Introduction to this manual
3ADW000803R0101 DCS880 H4T (Tosa) manual en a
Introduction to this manual
This manual contains all additional information needed for DCS880 units size H4T using the higher mains
voltage and DC voltage setup.
H4T
To increase the mains voltage and DC voltage of some DCS880 2-Q units size H4 the SDCS-PIN-H01 has
been substituted by an SDCS-POW-H01 together with an SDCS-PIN-H51 and an SDCS-PIN-H41.
This creates DCS880 2-Q units size H4T.
Application
H4T units are mainly used for non-motoric applications.
Related documents
A list of related manuals is shown on the inside of the front cover under DCS880 Drive Manuals.

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Introduction to this manual
3ADW000803R0101 DCS880 H4T (Tosa) manual en a
Terms and abbreviations
Term/Abbreviation
Definition
AC 800M
Type of programmable controller manufactured by ABB.
ACS-AP-I
Types of control panel used with DCS880 drives and DCT880 units.
ACS-AP-W
Adaptive Program
(AP)
Adaptive Program of the drive/unit. See Adaptive programming, Application
guide (3AXD50000028574)
AI
Analog input; interface for analog input signals.
AO
Analog output; interface for analog output signals.
Application program
Program written by the Automation Builder. See Drive (IEC61131-3) application
programming manual (3AUA0000127808).
Automation Builder
Tool to write application programs. See Drive (IEC61131-3) application
programming manual (3AUA0000127808).
Control unit Contains the electronics and I/O connections of the drive/unit. The control unit is
connected to the power unit.
D2D
Drive-to-Drive or Device-to-Device; communication link between drives/units.
DCS880
A product family of ABB drives.
DCSLink
Communication between the armature converter and the field exciters or 12-pulse
communication.
DDCS
Distributed drives communication system. A protocol used in communication
between ABB equipment.
DI
Digital input; interface for digital input signals.
DIO
Digital input/output; interface that can be used as a digital input or output.
DO
Digital output; interface for digital output signals.
Drive
Converter to control DC motors/loads.
DriveBus A communication link used by, for example, ABB controllers. DCS880 drives/units
can be connected to the DriveBus link of the controller.
DriveAP
Adaptive Programming of the drive/unit. See Adaptive programming, Application
guide (3AXD50000028574).
Drive Composer
PC tool for commissioning and maintenance of ABB drives/units.
EFB
Embedded fieldbus.
FAIO-01
Optional analog I/O extension module.
FBA
Fieldbus adapter.
FCAN-01
Optional CANopen adapter.
FCNA-01
Optional ControlNet adapter.
FDCO-0x
Optional DDCS communication module.
FDIO-01
Optional digital I/O extension module.
FDNA-01
Optional DeviceNet adapter.
FEA-03
Optional I/O extension module.
FECA-01
Optional EtherCAT® adapter.
FEN-01
Optional TTL encoder interface module.
FEN-11
Optional absolute encoder interface module.
FEN-21
Optional resolver interface module.
FEN-31
Optional HTL encoder interface module.
FENA-11
Optional Ethernet/IP, Modbus/TCP and PROFINET IO adapter.

10
Introduction to this manual
3ADW000803R0101 DCS880 H4T (Tosa) manual en a
Term/Abbreviation
Definition
FENA-21
Optional dual-port Ethernet/IP, Modbus/TCP and PROFINET IO adapter.
FEPL-02
Optional POWERLINK adapter.
FIO-01
Optional digital I/O extension module.
FIO-11
Optional analog I/O extension module.
FPBA-01
Optional PROFIBUS DP adapter.
FPTC-01
Optional thermistor protection module.
FPTC-02 Optional ATEX-certified thermistor protection module for potentially explosive
atmospheres.
FSCA-01
Optional Modbus/RTU adapter.
FSO-21
Optional safety functions module.
FSPS-21
Optional PROFIsafe safety functions module.
HTL
High-threshold logic.
I/O
Input/Output.
ModuleBus
A communication link used by, for example, ABB controllers. DCS880 drives/units
can be connected to the optical ModuleBus link of the controller.
Network control
With fieldbus protocols based on the Common Industrial Protocol (CIPTM), such as
DeviceNet and Ethernet/IP, denotes the control of the drive/unit using the Net
Ctrl and Net Ref objects of the ODVA AC/DC Drive Profile. For more information,
see www.odva.org, and the following manuals:
−FDNA-01 DeviceNet adapter module User’s manual (3AFE68573360).
−FENA-11/-21 Ethernet adapter module User’s manual (3AUA0000093568).
Off3 (emergency
stop)
Function in Drive:
Off3 (emergency stop) with configurable deceleration time according to cat. 1.
OPL Optical power link. Protocol used in communication between the control unit and
the power unit.
Parameter
User-adjustable operation instruction to the drive/unit.
PID controller
Proportional-integral-derivative controller. The speed control is based on a PID
algorithm.
PLC
Programmable logic controller.
Power unit
Contains the power electronics and power connections of the drive/unit. The
control unit is connected to the power unit.
PTC
Positive temperature coefficient.
PU
See power unit.
RFG
Ramp function generator.
RO
Relay output; interface for a digital output signal. Implemented with a relay.
Signal Value measured or calculated by the drive/unit. It can also contain status
information. Most signals are read-only, but some (especially counter-type
signals) can be reset.
SS1
Safe stop 1.
SSI
Synchronous serial interface.
STO
Safe torque off.
TTL
Transistor-transistor logic.
UPS
Uninterruptible power supply: Power supply equipment with battery to maintain
output voltage during power failure.