ABB ACS880-1607LC User manual

—
ABB INDUSTRIAL DRIVES
ACS880-1607LC DC/DC converter units
Hardware manual

ACS880-1607LC DC/DC converter
units
Hardware manual
Table of contents
3. Mechanical installation
5. Electrical installation
8. Start-up
3AXD50000431342 Rev C
EN
Original instructions
EFFECTIVE: 2023-12-29

Table of contents
1 Introduction to the manual
11Contents of this chapter ........................................................................
11Applicability ........................................................................................
11Safety instructions ...............................................................................
11Target audience ...................................................................................
12Categorization by frame size and option module ... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..
12Use of component designations ..............................................................
12Terms and abbreviations .......................................................................
13Related documents ..............................................................................
2 Operation principle and hardware description
15Contents of this chapter ........................................................................
15Operation principle ..............................................................................
15Main circuit diagram .........................................................................
19Overview diagram of a drive with a DC/DC converter unit .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..
20Converter unit hardware ........................................................................
20Cabinet layout – Frame R7i converter module ..........................................
22Cabinet layout – Frame R8i converter module ..........................................
24Converter module hardware ...................................................................
24Frame R7i .......................................................................................
24Module layout ..............................................................................
24Coolant connectors .......................................................................
25Connectors X50, X52 and X53; Auxiliary voltage selector X59 ... .. .. .. .. .. .. .. ..
25Fiber optic connectors ...................................................................
26LEDs ..........................................................................................
26Frame R8i .......................................................................................
26Module layout ..............................................................................
27Coolant connectors .......................................................................
27Connectors X50…X59 ....................................................................
27Fiber optic connectors ...................................................................
28LEDs ..........................................................................................
28BDCL filter module ...............................................................................
28BDCL filter module for frame R7i converter module ...................................
29BDCL filter module for frame R8i converter module .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..
29Overheating protection of the filter ......................................................
30Overview of the control connections of the BCU control unit ... .. .. .. .. .. .. .. .. .. .. .. .
31Overview of the control connections of the UCU control unit ..........................
31Converter unit control devices .................................................................
32DC switch-disconnector .....................................................................
32Charging switch ...............................................................................
32Door lights ......................................................................................
33Control panel [A59] ...........................................................................
33PC connection .................................................................................
33Fieldbus control ...............................................................................
34Type designation labels .........................................................................
34Type designation label of the DC/DC converter unit ..................................
Table of contents 5

34Type designation labels of the DC/DC converter module ............................
36Type designation label of the BDCL filter module .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .
36Type designation key ............................................................................
36Type designation key of the converter unit .............................................
37Option codes ...............................................................................
38Type designation key of the converter module .........................................
39Type designation key of the filter module ...............................................
3 Mechanical installation
41Contents of this chapter ........................................................................
41DC/DC converter units ..........................................................................
41Energy storage ....................................................................................
41Internal cooling system .........................................................................
4 Guidelines for planning electrical installation
43Contents of this chapter ........................................................................
43Limitation of liability .............................................................................
43North America .................................................................................
43Generic guidelines ................................................................................
44Selecting the energy storage ..................................................................
45Implementing protections for the energy storage ........................................
45General principles .............................................................................
45Selecting a protective device for the energy storage ... .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..
45Energy storage disconnecting (isolating) device .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..
45Overload protection of the system by the DC/DC converter .. .. .. .. .. .. .. .. .. .. .. ..
45Protecting the energy storage cable ......................................................
45Energy storage discharging device .......................................................
46Implementing earth fault protection .........................................................
46Implementing an interlocking between the disconnecting devices ... .. .. .. .. .. .. .. ..
46Selecting and routing the energy storage cables ..........................................
46Cable selection procedure ..................................................................
46Recommended cables ........................................................................
47Typical cable sizes ............................................................................
47Minimizing electromagnetic interference ...............................................
47Maximum cable length .......................................................................
47EMC compliance of the complete installation .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..
48Parallel connection ...............................................................................
5 Electrical installation
49Contents of this chapter ........................................................................
49Safety ...............................................................................................
49Electrical safety precautions ...................................................................
51Measuring the insulation resistance of the DC cabling .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..
52Connecting the energy storage cable and load disconnected indicator cable .. .. ..
52Use of fasteners in cable lug connections ...............................................
53Connection diagram ..........................................................................
53Connection procedure of the energy storage cables .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .
56Connecting the control cables .................................................................
56Control cable connection procedure ......................................................
57Grounding the outer shields of the control cables 360° at the cabinet entry .
59Routing the control cables inside the cabinet .......................................
6 Table of contents

59Connecting control cabling .............................................................
60Installing option modules .......................................................................
61Connecting a PC ..................................................................................
6 The control unit
63Contents of this chapter ........................................................................
63General ..............................................................................................
64BCU layout .........................................................................................
66UCU-22…24 layout ...............................................................................
69Default I/O diagram of the converter control unit (BCU) ................................
71Default I/O diagram of the converter control unit (UCU-22…24) ......................
74Additional information on the connections .................................................
74Power supply for the control unit (XPOW) ...............................................
74The X485 connector (BCU) ..................................................................
74The X485 connector (UCU) ..................................................................
75Safe torque off (XSTO, XSTO OUT) ........................................................
75FSO safety functions module connection (X12, with BCU only) .. .. .. .. .. .. .. .. .. .. .
75SDHC memory card slot .....................................................................
75MicroSDHC memory card slot ..............................................................
76Connector data ...................................................................................
79BCU ground isolation diagram .............................................................
80UCU-22…24 ground isolation diagram ...................................................
7 Installation checklist
81Contents of this chapter ........................................................................
81Checklist ............................................................................................
8 Start-up
83Contents of this chapter ........................................................................
84Start-up procedure ...............................................................................
9 Maintenance
87Contents of this chapter ........................................................................
87Maintenance intervals ...........................................................................
87Description of symbols ......................................................................
87Recommended maintenance intervals after start-up .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .
89Maintenance timers and counters ............................................................
89Disconnecting the DC/DC converter .........................................................
89Disconnecting the DC/DC converter from the energy storage ... .. .. .. .. .. .. .. .. ..
90
Disconnecting the DC/DC converter from the drive system with the DC switch-
disconnector ...................................................................................
90Connecting the DC/DC converter .............................................................
90Liquid pipe connector installation instructions ............................................
93Fuses ................................................................................................
93Checking and replacing the fuses – frame R7i ..........................................
93Replacing a converter fuse ..............................................................
94Replacing an output fuse ................................................................
96Checking and replacing the fuses – frame R8i ..........................................
97Fans .................................................................................................
98Frame R7i cabinet fan replacement .......................................................
99Frame R7i – internal module fan replacement ..........................................
Table of contents 7

100Frame R8i fan replacement .................................................................
101R7i converter module ............................................................................
102Removing the module ........................................................................
103Installing the module .........................................................................
104R8i converter module ............................................................................
104Replacing an R8i converter module .......................................................
104Assembling the service platform .......................................................
105Removing the module ....................................................................
108Reinstalling the module ..................................................................
108Capacitors .........................................................................................
109Reforming the capacitors ...................................................................
109Control panel ......................................................................................
109Control unit ........................................................................................
109BCU control unit types .......................................................................
109UCU control unit types .......................................................................
109Replacing the memory unit (BCU) .........................................................
110Replacing the memory unit (UCU-22…24) ...............................................
111Replacing the BCU control unit battery ..................................................
111Replacing the real-time clock battery (UCU-22…24) .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..
112Replacing the microSDHC memory card (UCU-22…24) ...............................
113LEDs and other status indicators .............................................................
113Control panel and panel platform/holder LEDs .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..
113Converter module LEDs ......................................................................
114Converter unit LEDs ..........................................................................
10 Internal cooling circuit
115Contents of this chapter ........................................................................
115Applicability ........................................................................................
115Internal cooling system .........................................................................
117Connection to a cooling unit ...................................................................
117Connection to an ACS880-1007LC cooling unit .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..
117Connection to a custom cooling unit .....................................................
117General requirements ....................................................................
117Coolant temperature control ...........................................................
118Filling up and bleeding the internal cooling circuit ........................................
118Drive line-ups with an ACS880-1007LC cooling unit .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .
118Drive line-ups with a custom cooling unit ...............................................
119Draining the internal cooling circuit ..........................................................
119Maintenance intervals ...........................................................................
120Technical data .....................................................................................
120Coolant specification ........................................................................
120Coolant type ................................................................................
120Temperature limits ...........................................................................
122Pressure limits .................................................................................
122Coolant flow rate limits ......................................................................
122Cooling circuit materials ....................................................................
11 Technical data
123Contents of this chapter ........................................................................
8 Table of contents

123Ratings ..............................................................................................
125Derating .........................................................................................
125Surrounding air temperature derating ...............................................
126Altitude derating ..........................................................................
126Type equivalence table ..........................................................................
127Fuses ................................................................................................
127DC fuses .........................................................................................
128BAMU unit fuses ...............................................................................
128Filter module data ................................................................................
128Dimensions and weights ........................................................................
129Free space requirements .......................................................................
129Free space requirements ....................................................................
129Losses, cooling data and noise ................................................................
131Tightening torques ...............................................................................
131Electrical connections ........................................................................
132Mechanical connections .....................................................................
132Insulation supports ...........................................................................
132Cable lugs .......................................................................................
132Input power (DC bus) connection .............................................................
132Output power (energy storage) connection ................................................
133Typical power cable sizes .......................................................................
134Control accuracy – Current and voltage control performance data ... .. .. .. .. .. .. .. ..
134Coolant connections .............................................................................
134Protection classes ................................................................................
134Energy efficiency data (ecodesign) ...........................................................
135Ambient conditions ..............................................................................
136Colors ...............................................................................................
136Materials ............................................................................................
136Drive .............................................................................................
136Packaging of drive ............................................................................
136Packaging of options ........................................................................
137Manuals .........................................................................................
137Disposal ............................................................................................
137Applicable standards ............................................................................
137Markings ............................................................................................
138Disclaimers .........................................................................................
138Generic disclaimer ............................................................................
138Cyber security disclaimer ...................................................................
12 Dimension drawings
139Contents of this chapter ........................................................................
140DC/DC converter unit with 1×R7i converter module ......................................
142DC/DC converter unit with 1×R8i converter module ......................................
144Location and size of energy storage connection terminals – Frame R7i ..............
145Location and size of energy storage connection terminals – Frame R8i ... .. .. .. .. ..
Further information
Table of contents 9

10

Introduction to the manual
Contents of this chapter
This chapter gives basic information on the manual.
Applicability
The manual is applicable to ACS880-1607LC DC/DC converter units that form a part
of an ACS880 multidrives system.
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 11

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
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
Device that stores electrical energy, for example, a battery or a super capacitor.Energy storage
Physical size of the drive or power moduleFrame, frame size
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
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
Drive for controlling one motorSingle drive
12 Introduction to the manual

DescriptionTerm
Supply module(s) under control of one control unit, and related components.Supply unit
Type of control unitUCU
Uninterruptible power supplyUPS
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 cabinets
Introduction to the manual 13

14

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 converter unit delivery.
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 has output DC fuses and DC fuses on the drive DC bus side. A
DC switch-disconnector is available as option +F286.
2
Operation principle and hardware description 15

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
16 Operation principle and hardware description

This figure shows a simplified main circuit diagram of a DC/DC converter with the DC
switch-disconnector (option +F286) and charging circuit.
1 2
3
4
5
6
789
10 11
DC/DC converter cubicle1
Energy storage cabinet2
Drive DC bus3
DC switch-disconnector (option +F286)4
Charging components (with option +F286)5
DC/DC converter module6
Filter module7
Cabling between DC/DC converter unit and energy storage8
Energy storage disconnecting device9
Energy storage protective circuit breaker10
Energy storage11
Operation principle and hardware description 17

This figure shows a simplified main circuit diagram of parallel-connected DC/DC
converter modules with the DC switch-disconnector (option +F286) and charging
circuit. Also the energy storage and related cabling and equipment are visible.
1 2
3
3
4
4
5
5
6
6
7
7
8
8
9
10 11
12
DC/DC converter cubicles1
Energy storage cabinet2
Drive DC bus3
DC switch-disconnector (option +F286)4
Charging components (with option +F286)5
DC/DC converter module6
Filter module7
Cabling between DC/DC converter unit and energy storage8
Energy storage disconnecting device9
Energy storage protective circuit breaker10
Energy storage11
Bridging busbar12
18 Operation principle and hardware description

Overview diagram of a drive with a DC/DC converter unit
This diagram shows a possible application of a converter unit in an example system.
The DC/DC converter unit includes a DC/DC converter module and a filter module.
t°
1
2
36
6
4
58
9
10
11
7
AC supply1
Input (AC) fuses2
Supply module3
DC bus (-,+)4
Inverter DC fuses (with or without a DC switch-disconnector, option +F286)5
Inverter modules6
Motors7
DC fuses (DC bus side, with or without a DC switch-disconnector, option +F286)8
DC/DC converter unit (converter and filter module)9
Output DC fuses10
Customer-defined energy storage with disconnecting and protection devices11
Operation principle and hardware description 19

Converter unit hardware
￭Cabinet layout – Frame R7i converter module
This figure shows an example converter unit cubicle.
A B C
1
2
3
5
4
6
7
8
9
15
12
13
10 16
17
14 18
16
17
11
DescriptionItem desig-
nation
Sym-
bol
Door closed-A
Door open-B
Door open and shrouds removed-C
DC switch-disconnector handle (with option +F286)Q11.11
Charging switch handle (with option +F286)Q10.12
Control panelA493
Door lights:P11.14
• Charging OK [P11.1] (green)
• DC/DC converter disconnected [P12.1] (white)
• Load disconnected [P13.1] (white).
P12.1
P13.1
Input DC fuses (DC bus side)F11.115
F11.12
Charging switch shaft (with option +F286)Q10.16
20 Operation principle and hardware description