ABB ACS880-1604 Hardware Manual
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ABB ACS880-1604 Hardware Manual

Dc/dc converter modules
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  • Page 1 ABB industrial drives Hardware manual ACS880-1604 DC/DC converter modules...
  • Page 2 You can find manuals and other product documents in PDF format on the Internet. See section Document library on the Internet on the inside of the back cover. For manuals not available in the Document library, contact your local ABB representative.
  • Page 3 Hardware manual ACS880-1604 DC/DC converter modules Table of contents 4. Cabinet construction 6. Electrical installation 8. Start-up  2017 ABB Oy. All Rights Reserved. 3AXD50000023642 Rev B EFFECTIVE: 2017-02-08...

  • Page 5: Table Of Contents

    Table of contents 1. Introduction to the manual Contents of this chapter ..........13 Applicability .
  • Page 6 Cabinet configuration overview ......... . . 40 ACS880-1604 configuration in Rittal TS 8 and generic enclosures ... . . 40 Installation examples .
  • Page 7 6. Electrical installation Contents of this chapter ..........65 Safety and liability .
  • Page 8 Cabinets with ABB air outlet kits ........
  • Page 9 Bottom cable entry ..........130 Control unit mounting plate .
  • Page 10 Optical components ........... 156 Degree of protection .
  • Page 11 Providing feedback on ABB Drives manuals ....... . . 221...

  • Page 13: Introduction To The Manual

    Introduction to the manual Contents of this chapter This chapter gives basic information on the manual. Applicability The manual is applicable to ACS880-1604 DC/DC converter modules for user-defined cabinet installations. Safety instructions Follow all safety instructions delivered with the converter.

  • Page 14: Contents Of The Manual

    You can find all documentation related to ACS880 multidrive modules on the Internet at https://www151.abb.com/spaces/lvacdrivesengineeringsupport/content. For other manuals, see the inside of the front cover. If needed, contact your local ABB representative. Categorization by frame size and option code 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.).

  • Page 15: Terms And Abbreviations

    Introduction to the manual 15 Terms and abbreviations Term/Abbreviation Description BAMU Voltage/current measurement unit Type of a control unit BDCL L-filter. BDCL-14 and BDCL-15 filters are used with DC/DC converters. BDPS Type of the R8i module internal power supply board BFPS Type of a power supply and control board for the cooling fan in frame R8i modules.
  • Page 16 16 Introduction to the manual Term/Abbreviation Description Supply unit Part of the drive system that rectifies the AC supply voltage and outputs a DC voltage.

  • Page 17: Operation Principle And Hardware Description

    Operation principle and hardware description 17 Operation principle and hardware description Contents of this chapter This chapter describes the DC/DC converter operation basics and the hardware of the converter.

  • Page 18: Operation Principle

    We also recommend that you use identical cablings (cable type, cross-sectional area, and length) and have identical load for each module. For other solutions, contact ABB. Typically, the DC/DC converter is used in marine applications for heave compensation, peak load compensation, propulsion supply in harbors, as energy storage instead of an additional generator and so on.

  • Page 19: Main Circuit Diagram

    Operation principle and hardware description 19 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. Main circuit diagram of DC/DC converter without DC switch/disconnector and charging circuit This figure shows a simplified main circuit diagram of a DC/DC converter without a DC...

  • Page 20: Charging Circuit

    20 Operation principle and hardware description Main circuit diagram of DC/DC converter with DC switch/disconnector and charging circuit This figure shows a simplified main circuit diagram of a DC/DC converter with the DC switch/disconnector and charging circuit. Drive DC bus DC switch/disconnector DC/DC converter module Filter module...

  • Page 21: Main Circuit Diagram Of Parallel-Connected Dc/Dc Converter Modules

    Operation principle and hardware description 21 Main circuit diagram of parallel-connected DC/DC converter modules This figure shows a simplified main circuit diagram of parallel-connected DC/DC converter modules with the DC switch/disconnector and charging circuit. Also the energy storage and related cabling and equipment are visible. DC/DC converter cubicles Energy storage cabinet Drive DC bus...

  • Page 22: Overview Diagram Of A Drive With A Dc/Dc Converter Unit

    22 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. For the DC/DC converter configurations, see Type equivalence table on page 151.

  • Page 23: Single-Line Circuit Diagram Of The Dc/Dc Converter Unit

    The connection is the same in both Rittal TS 8 and generic enclosures. The table gives explanations for the numbers and letters of the diagram. It also indicates if customer can order the components from ABB or if the customer needs to acquire them separately.

  • Page 24: Hardware Description

    24 Operation principle and hardware description Hardware description R8i and BDCL filter modules  The R8i DC/DC converter modules and BDCL filter modules run on wheels, and can easily be removed from the cubicle for cable installation or service. The quick connector at the back of the R8i module couples when the module is inserted into the cubicle.

  • Page 25: Layout Drawings

    Operation principle and hardware description 25 Layout drawings  R8i DC/DC converter module This figure shows the layout of the converter module. DC/DC converter module, frame size R8i, front DC/DC converter module, frame size R8i, back Common DC bus connection Handle Fiber optic connectors of the module (wired to the control board) Quick connector (BDCL connection) (The counterpart fastened to the cabinet behind the module.)

  • Page 26: Converter Module Connectors X50

    26 Operation principle and hardware description Converter module connectors X50…X53 Connector X50 Description Not in use 115/230 V AC input for optional heating element (option +C183) Not in use 115/230 V AC input for internal power supply (BDPS) (115 V with option +G304) W 400 V AC (50/60 Hz) supply for optional DOL (direct-on- line) cooling fan (option +C188).

  • Page 27: Bdcl Filter Module

    Operation principle and hardware description 27 BDCL filter module Filter module, front Filter module, back Energy storage connection Converter module connection Terminal block [X55] (DOL fan supply, option +C188) (ready-connected) Handle Wheels Terminal block [X30] (module DOL fan supply, option +C188) Type designation label of the module The unpainted grounding point 10.

  • Page 28: Filter Module Connectors X30 And X55

    These terminals are wired further to connector X55:1 and A55:2 internally by ABB. BDCL module connector X55 This connector is plugged further to connector X55 of the filter cooling fan at the factory by ABB. Not in use Plus code +C188: DOL fan N These terminals are wired further...

  • Page 29: Overview Of The Control Connections On The Bcu Control Unit

    Operation principle and hardware description 29 Overview of the control connections on the BCU control unit Each converter unit is controlled by a control unit. The control unit is connected by fiber optic cables to each converter module. For details, see chapter Control unit.

  • Page 30: Converter Unit Control Devices

    30 Operation principle and hardware description Converter unit control devices DC switch/disconnector  The DC/DC converter cabinet can be equipped with DC switch/disconnector [Q11.xx]. A converter unit with a DC switch/disconnector must also have a precharge circuit including a charging switch. The DC switch/disconnector allows the isolation of the unit from the DC bus.

  • Page 31: Pc Connection

    Operation principle and hardware description 31 For the instructions on the use of the panel, see ACX-AP-x assistant control panels user's manual (3AUA0000085685 [English]). For the parameter settings and control modes, see ACS880 DC/DC converter control program firmware manual (3AXD50000024671 [English]).

  • Page 32: Type Designation Labels

    32 Operation principle and hardware description Type designation labels Type designation labels of the DC/DC converter module  Each DC/DC converter module has type designation labels attached to it. The type designation stated on the labels contains information on the specifications and configuration of the unit.

  • Page 33: Type Designation Label Of The Bdcl Filter Module

    Operation principle and hardware description 33 Type designation label of the BDCL filter module  Each filter module has a type designation label attached to it. Quote the complete type designation and serial number when contacting technical support on the subject of individual filter modules. An example label is shown below.

  • Page 34: Type Designation Key

    The type designation describes the composition of the module in short. Note that in the type designation label of a R8i DC/DC converter module (ACS880-1604), the type of the module is ACS880-104. The complete designation code is divided in subcodes: •...

  • Page 35: Type Designation Of The Filter Module

    Operation principle and hardware description 35 Type designation of the filter module  The designation code of the BDCL filter is divided in subcodes: • The first 4 letters and two numbers give the type of the filter, for example, BDCL-15-7. •...
  • Page 36 36 Operation principle and hardware description...

  • Page 37: Moving And Unpacking The Module

    Moving and unpacking the module 37 Moving and unpacking the module Contents of this chapter This chapter gives basic information on moving, unpacking and lifting the modules. Moving and lifting the transport package Move the transport package by a pallet truck or lift. Lift the transport package in horizontal position.

  • Page 38: Lifting The Modules

    38 Moving and unpacking the module Lifting the modules Lift the unpacked module only from its lifting holes. BDCL filter R8i DC/DC converter module Moving the modules WARNING! If you ignore the following instructions, injury or death, or damage to the equipment can occur. •...

  • Page 39: Cabinet Construction

    Cabinet construction 39 Cabinet construction Contents of this chapter This chapter instructs in placing the ACS880-1604 DC/DC converter modules and additional equipment into a cabinet. For general instructions, see Cabinet design and construction instructions for ACS880 multidrive modules (3AUA0000107668 [English]).

  • Page 40: Cabinet Configuration Overview

    ACS880-1604 configuration in Rittal TS 8 and generic enclosures  This figure shows the ACS880-1604 DC/DC converter configuration that can be installed in the Rittal TS 8 and generic enclosures. The figure shows the converter with a DC switch/disconnector solution and without the DC switch/disconnector.

  • Page 41: Installation Examples

    You can find the kit-specific assembly drawings, step-by-step instructions and kit information on the Internet. Go to https://sites- apps.abb.com/sites/lvacdrivesengineeringsupport/content. If needed, contact your local ABB representative. The example includes also cabinet assembly drawings that show each stage listed in the table.

  • Page 42: 1×R8I Ddc Unit In A 800 Mm Wide Rittal Ts 8 Enclosure

    42 Cabinet construction 1×R8i DDC unit in a 800 mm wide Rittal TS 8 enclosure  Layout with DC switch/disconnector and charging This figure shows an example of the DC/DC converter unit in the Rittal TS 8 enclosure. The unit includes an R8i DC/DC converter module, a BDCL filter module, bottom cable entries for the energy storage connection, DC switch/disconnector and charging components.

  • Page 43: Layout Without Dc Switch/Disconnector And Charging

    Cabinet construction 43 Layout without DC switch/disconnector and charging This figure shows an example of the DC/DC converter unit in the Rittal TS 8 enclosure without DC switch/disconnector and charging. The unit includes an R8i DC/DC converter module, a BDCL filter module and bottom cable entries for the energy storage connection. Cubicle including: 1.

  • Page 44: Installation Stages

    44 Cabinet construction Installation stages Installation stage Instruction code Kit code Kit ordering code Installation of common parts: • Baying parts • 3AUA0000114535 • PE busbar [PE] • 3AUA0000114475 • Divider panel • 3AUA0000115695 • Common DC Flat-PLS • 3AUA0000115891 A-468-X-001 3AUA0000115906 assembly...

  • Page 45: Kits For Ddc R8I Unit In 800 Mm Rittal Ts 8 Enclosure

    Cabinet construction 45 Kits for DDC R8i unit in 800 mm Rittal TS 8 enclosure...

  • Page 46: Stage 1: Installation Of Common Parts

    46 Cabinet construction Stage 1: Installation of common parts...

  • Page 47: Stage 2: Module And Bottom Cable Entry Installation Parts

    Cabinet construction 47 Stage 2: Module and bottom cable entry installation parts...

  • Page 48: Stage 3: Busbars And Quick Connectors For Connecting Ddc Module And Filter

    48 Cabinet construction Stage 3: Busbars and quick connectors for connecting DDC module and filter...

  • Page 49: Stage 4A: Dc Connection With Charging

    Cabinet construction 49 Stage 4A: DC connection with charging...

  • Page 50: Stage 4B: Dc Connection Without Charging

    50 Cabinet construction Stage 4B: DC connection without charging...

  • Page 51: Stage 5A: Dc Connection With Charging

    Cabinet construction 51 Stage 5A: DC connection with charging...

  • Page 52: Stage 5B: Dc Connection Without Charging

    52 Cabinet construction Stage 5B: DC connection without charging...

  • Page 53: Stage 6: Ddc And Energy Storage Connection

    Cabinet construction 53 Stage 6: DDC and energy storage connection...

  • Page 54: Stage 7: Control Unit Mounting Plate

    54 Cabinet construction Stage 7: Control unit mounting plate...

  • Page 55: Stage 8: Ddc Shroud Installation

    Cabinet construction 55 Stage 8: DDC shroud installation...

  • Page 56: Stage 9: Ddc Module And Filter Installation

    56 Cabinet construction Stage 9: DDC module and filter installation...

  • Page 57: 1×R8I Ddc Unit In A 800 Mm Wide Generic Enclosure

    Cabinet construction 57 1×R8i DDC unit in a 800 mm wide generic enclosure  Parts to be installed Parts to be installed Instruction code Kit code Kit ordering code Module installation parts 3AXD50000023218 A-8-8-333 3AXD50000023031 Bottom cable entry 3AXD50000004817 A-468-8-441 3AXD50000004385 Busbars for connecting DDC module 3AXD50000023212...

  • Page 58: Kits For Ddc R8I Unit In 800 Mm Wide Generic Enclosure

    58 Cabinet construction Kits for DDC R8i unit in 800 mm wide generic enclosure...

  • Page 59: Guidelines For Planning Electrical Installation

    ABB does not assume any liability whatsoever for any installation which breaches the local laws and/or other regulations. Furthermore, if the recommendations given by ABB are not followed, the drive may experience problems that the warranty does not cover.

  • Page 60: Selecting The Energy Storage

    60 Guidelines for planning electrical installation Selecting the energy storage WARNING! ABB is not responsible for the customer ‘s energy storage selection or protection of the energy storage. The customer must equip the DC/DC converter with a suitable energy storage system.

  • Page 61: Disconnection Of Energy Storage At The Storage End

    Guidelines for planning electrical installation 61 Disconnection of energy storage at the storage end  The customer must equip the energy storage with a device for disconnecting the storage from the DC/DC converter. The disconnecting device does not belong to the module product offering.

  • Page 62: Selecting And Routing The Energy Storage Cables

    ACS880-1604-0600A-3 3×(3×185+95) 2×(3×240+120) 2×(4×120+70) 1×(4×240+120) ACS880-1604-0900A-3 1080 4×(3×240+120) 4×(3×150+70) 2×(4×240+120) 2×(4×185+95) ACS880-16041200A-3 2×R8i 1440 2×(3×(3×185+95)) 2×(2×(3×240+120)) 4×(4×120+70) 2×(4×240+120) ACS880-1604-1800A-3 2×R8i 2160 2×(4×(3×240+120)) 2×(4×(3×150+70)) 4×(4×240+120) 4×(4×185+95) = 500 V ACS880-1604-0600A-5 3×(3×185+95) 2×(3×240+120) 2×(4×120+70) 1×(4×240+120) ACS880-1604-0900A-5 1080 4×(3×240+120) 4×(3×150+70) 2×(4×240+120) 2×(4×185+95) ACS880-1604-1200A-5 2×R8i 1440 2×(3×(3×185+95)) 2×(2×(3×240+120)) 4×(4×120+70)

  • Page 63: Minimizing Electromagnetic Interference

    The maximum cable length of the energy storage cable(s) is 100 m (328 ft). EMC compliance of the complete installation  Note: ABB has not verified that the EMC requirements are fulfilled with external energy storage and its cabling. The EMC compliance of the complete installation must be considered by the customer.
  • Page 64 64 Guidelines for planning electrical installation...

  • Page 65: Electrical Installation

    Note: The installation must always be designed and made according to applicable local laws and regulations. ABB does not assume any liability whatsoever for any installation which breaches the local laws and/or other regulations.

  • Page 66: Electrical Safety Precautions

    66 Electrical installation Electrical safety precautions  WARNING! Obey these instructions. If you ignore them, injury or death, or damage to the equipment can occur. If you are not a qualified electrician, do not do installation or maintenance work. Go through these steps before you begin any installation or maintenance work.

  • Page 67: General Notes

    Electrical installation 67 General notes Static electricity  WARNING! Circuit boards contain components sensitive to electrostatic discharge (ESD). Wear a grounding wrist band when handling the boards. Do not touch the boards unnecessarily. Optical components  Handle fiber optic cables with care. When unplugging optic cables, always grab the connector, not the cable itself.

  • Page 68: Checking The Insulation Of The Energy Storage Cable

    68 Electrical installation Checking the insulation of the energy storage cable WARNING! Repeat the steps described in section Electrical safety precautions on page 66. The complete safety instructions are given in See Safety instructions for ACS880 multidrive cabinets and modules (3AUA0000102301 [English]).

  • Page 69: Connecting The Power Cables

    Electrical installation 69 Connecting the power cables For connecting parallel-connected DC/DC converter modules, see Main circuit diagram of parallel-connected DC/DC converter modules on page 21. Connection diagram (frame 1×R8i)  DC/DC converter cubicle Energy storage cubicle Charging circuit components (For charging circuit connections, see the example circuit diagrams.) DC/DC converter module (R8i) BDCL filter module Shielded 3-conductor or 4-conductor cable and 360 degree grounding of the cable shield at the cable...

  • Page 70: Connection Procedure For Power Connections Inside The Dc/Dc Converter Cubicle

    70 Electrical installation Connection procedure for power connections inside the DC/DC  converter cubicle For the cable types, see Electrical planning instructions for ACS880 multidrive cabinets and modules (3AUA0000102324 [English]). For the filter connections, see Internal circuit diagram for the BDCL filter on page 74.
  • Page 71 Electrical installation 71 5. Refit any shrouding removed earlier and close the cubicle doors.

  • Page 72: Connection Procedure For Energy Storage Cables

    72 Electrical installation Connection procedure for energy storage cables  For the cable types, see Selecting and routing the energy storage cables on page 62. WARNING! Repeat the steps described in section Electrical safety precautions on page 66. The complete safety instructions are given in Safety instructions for ACS880 multidrive cabinets and modules (3AUA0000102301 [English]).

  • Page 73: Connecting The Bdcl Filter

    Connect the cooling fan power supply [X30:1, X30:2]. For power consumption and voltage, Auxiliary current consumption on page 159. WARNING! Do not disable the module temperature monitoring function. WARNING! Use the BDCL filter only with an ACS880-1604 DC/DC converter module.

  • Page 74: Internal Circuit Diagram For The Bdcl Filter

    74 Electrical installation Internal circuit diagram for the BDCL filter  =-R03 FILTER MODULE BDCL-1x-x OUTPUT CONNECTION =-X30 H07Z-K1.5 -LCLTP =-X55 INVERTER CONNECTION plug-connector =-X55 =-G41 X1:1 X1:2 X1:3 X1:4 DOL FAN +C188...

  • Page 75: Installing The Charging Circuit

    The cabinet builder must install and connect the charging circuit. For connections, see chapter Example circuit diagrams. Consult ABB for more information on the components and wirings needed. Activate and tune the charging function in the control program. For information on tuning the parameters, see ACS880 DC/DC converter control program firmware manual (3AXD50000024671 [English]).

  • Page 76: Connecting The Control Cables

    76 Electrical installation Connecting the control cables Default I/O connection diagram  See chapter Control unit on page 161. Connection procedure  Note: The instructions below are based on an example cabinet construction. They are not applicable to all possible solutions but only clarify the principles. The following procedure instructs how to connect the control cables of a DC/DC converter unit.

  • Page 77: Fiber Optic Connectors Of The Dc/Dc Converter Module

    Electrical installation 77 6. Strip the cable ends and conductors. When connecting to the drive I/O, also remove the shield along with the outer sheathing, and use electrical tape or shrink tubing to contain the strands. Elsewhere, twist the outer shield strands into a bundle, crimp a lug onto it and connect it to the nearest chassis grounding point.

  • Page 78: Installing Optional Modules

    78 Electrical installation Installing optional modules WARNING! Repeat the steps described in section Electrical safety precautions on page 66. The complete safety instructions are given in Safety instructions for ACS880 multidrive cabinets and modules (3AUA0000102301 [English]). Ignoring the instructions can cause physical injury or death, or damage to the equipment.

  • Page 79: Connecting A Pc

    Electrical installation 79 Connecting a PC A PC (with eg. the Drive composer PC tool) can be connected to the DC/DC converter unit as follows: 1. Connect an ACS-AP-x control panel to the control unit either by using an Ethernet (eg. CAT5E) networking cable, or by inserting the panel into the panel holder (if present).
  • Page 80 80 Electrical installation...

  • Page 81: Installation Checklist

    Installation checklist 81 Installation checklist Contents of this chapter This chapter contains an installation checklist which you must complete before you start up the converter. Warnings WARNING! Obey the safety instructions for the drive. See Safety instructions for ACS880 multidrive cabinets and modules (3AUA0000102301 [English]). If you ignore the safety instructions, injury or death, or damage to the equipment can occur.

  • Page 82: Checklist

    82 Installation checklist Checklist Do the steps in section Electrical safety precautions on page before you start the work. Check the mechanical and electrical installation of the drive before start-up. Go through the checklist together with another person. Make sure that … The ambient operating conditions meet the specifications given in Ambient conditions on page 157.

  • Page 83: Start-Up

    Contents of this chapter This chapter describes the start-up procedure of the converter unit. The information is valid for the example DC/DC converter unit with ACS880-1604 DC/DC converter modules. The underlined tasks are needed for certain cases only. The default device designations (if any) are given in square brackets, for example, DC switch/disconnector [Q11].

  • Page 84: Start-Up Procedure

    Note: If the drive has been stored over one year: Reform the electrolytic DC capacitors in the DC bus of the drive. See the separate reforming instructions (available in the Internet or from your local ABB representative). Make sure that the DC/DC converter is equipped with a control panel, or preferably, you have a PC with the Drive composer tool connected to the DC/DC converter control unit [A41].

  • Page 85: Setting The Parameters

    If your converter unit consists of more than one module: • Set parameter 195.12 Parallel connection rating id accordingly. For setting this parameter, you need a service level pass code. To obtain the pass code, contact your ABB representative. For the settings, see the table below: ACS880-1604-…...

  • Page 86: Testing The Dc/Dc Converter Operation

    Close the energy storage contactor (customer-installed device). Testing the DC/DC converter operation Contact your local ABB representative for testing instructions. Make sure that the DC/DC converter module and filter module cooling fan rotates freely in the right direction. A paper sheet set on the intake (door) gratings stays. The fans run noiselessly.

  • Page 87: Disconnecting The Dc/Dc Converter With Dc Switch/Disconnector

    Start-up 87 Disconnecting the DC/DC converter with DC switch/disconnector Tasks Safety WARNING! Only qualified electricians are allowed to carry out the work described in this chapter. Read the complete safety instructions in Safety instructions for ACS880 multidrive cabinets and modules (3AUA0000102301 [English]). Ignoring the instructions can cause physical injury or death, or damage to the equipment.

  • Page 88: Reconnecting The Dc/Dc Converter With Dc Switch/Disconnector

    88 Start-up Reconnecting the DC/DC converter with DC switch/disconnector Tasks Safety WARNING! Only qualified electricians are allowed to carry out the work described in this chapter. Read the complete safety instructions in Safety instructions for ACS880 multidrive cabinets and modules (3AUA0000102301 [English]). Ignoring the instructions can cause physical injury or death, or damage to the equipment.

  • Page 89: Maintenance

    Contents of this chapter This chapter instructs how to maintain the DC/DC converter modules and how to interpret their fault indications. The information is valid for ACS880-1604 DC/DC converter modules and example cabinet installations of the modules. Note: The instructions do not cover all possible cabinet constructions.

  • Page 90: Maintenance Intervals

    R Replacement Maintenance and component replacement intervals are based on the assumption that the equipment is operated within the specified ratings and ambient conditions. ABB recommends annual drive inspections to ensure the highest reliability and optimum performance. Note: Long term operation near the specified maximum ratings or ambient conditions may require shorter maintenance intervals for certain components.

  • Page 91: Maintenance Timers And Counters

    Maintenance 91 Maintenance timers and counters The control program has maintenance timers and counters that can be configured to generate a warning when a pre-defined limit is reached. Each timer/counter can be set to monitor any parameter. This feature is especially useful as a service reminder. For more information, see the firmware manual.

  • Page 92: Cleaning The Door Air Inlets (Ip42)

    92 Maintenance Cleaning the door air inlets (IP42)  WARNING! Use a vacuum cleaner with an antistatic hose and nozzle, and wear a grounding wristband. Using a normal vacuum cleaner creates static discharges which can damage circuit boards. Check the dustiness of the air inlet meshes. If the dust cannot be removed by vacuum cleaning from outside through the grating holes with a small nozzle, proceed as follows: 1.

  • Page 93: Cleaning The Door Air Inlets (Ip54)

    Maintenance 93 Cleaning the door air inlets (IP54)  1. Recommendation: De-energize the fans by switching off the DC/DC converter unit. Obey the instructions in section Electrical safety precautions on page 66. 2. Remove the fasteners at the top of the grating. 3.

  • Page 94: Power Connections

    94 Maintenance Power connections Retightening the power connections  WARNING! Only qualified electricians are allowed to do this work. Read the complete safety instructions given in Safety instructions for ACS880 multidrive cabinets and modules (3AUA0000102301 [English]) before you service the drive. If you ignore them, injury or death, or damage to the equipment can occur.

  • Page 95: Fans

    Fans The lifespan of the cooling fan depends on the running time of the fan, ambient temperature and dust concentration. Replacement fans are available from ABB. Do not use other than ABB specified spare parts. Replacing the cabinet cooling fan ...

  • Page 96: Replacing The Speed-Controlled Cooling Fan Of The Dc/Dc Converter Module

    96 Maintenance Replacing the speed-controlled cooling fan of the DC/DC converter  module If the module is equipped with a direct-on-line cooling fan (option +C188), see page 98. WARNING! Only qualified electricians are allowed to do this work. Read the complete safety instructions given in Safety instructions for ACS880 multidrive cabinets and modules (3AUA0000102301 [English]) before you service the drive.
  • Page 97 Maintenance 97...

  • Page 98: Replacing The Direct-On-Line Fan (Option +C188) Of The Dc/Dc Converter Module

    98 Maintenance Replacing the direct-on-line fan (option +C188) of the DC/DC  converter module If the module is equipped with a standard speed-controlled cooling fan, see page 96. WARNING! Only qualified electricians are allowed to do this work. Read the complete safety instructions given in Safety instructions for ACS880 multidrive cabinets and modules (3AUA0000102301 [English]) before you service the drive.
  • Page 99 Maintenance 99...

  • Page 100: Replacing The Circuit Board Compartment Fan

    100 Maintenance Replacing the circuit board compartment fan  The DC/DC converter module is equipped with a fan blowing air through the circuit board compartment. The fan is accessible from the front of the module. WARNING! Only qualified electricians are allowed to do this work. Read the complete safety instructions given in Safety instructions for ACS880 multidrive cabinets and modules (3AUA0000102301 [English]) before you service the drive.
  • Page 101 Maintenance 101 6. Remove the four nuts which hold the fan. 7. Remove the fan from the fan holder. 8. Put the new fan onto the threaded studs on the fan holder with the airflow direction arrow pointing towards the fan holder. 9.
  • Page 102 102 Maintenance 12. Install and tighten the two screws.

  • Page 103: Replacing The Fan Of The Bdcl Filter

    Maintenance 103 Replacing the fan of the BDCL filter  WARNING! Only qualified electricians are allowed to do this work. Read the complete safety instructions given in Safety instructions for ACS880 multidrive cabinets and modules (3AUA0000102301 [English]) before you service the drive. If you ignore them, injury or death, or damage to the equipment can occur.

  • Page 104: Replacing The Roof Fan For Ip54 Cabinet

    104 Maintenance Replacing the roof fan for IP54 cabinet  Cabinets with ABB air outlet kits WARNING! Only qualified electricians are allowed to do this work. Read the complete safety instructions given in Safety instructions for ACS880 multidrive cabinets and modules (3AUA0000102301 [English]) before you service the drive.

  • Page 105: Dc/Dc Converter Module

    Maintenance 105 DC/DC converter module Cleaning the module  The R8i module heatsink fins pick up dust from the cooling air. Modules run into overtemperature warnings and faults if the heatsink is not clean. When necessary, clean the heatsink as follows. WARNING! Only qualified electricians are allowed to do this work.

  • Page 106: Replacing The R8I Dc/Dc Converter Module

    106 Maintenance Replacing the R8i DC/DC converter module  WARNING! Repeat the steps described in section Electrical safety precautions on page 66. The complete safety instructions are given in Safety instructions for ACS880 multidrive cabinets and modules (3AUA0000102301 [English]). If you ignore them, injury or death, or damage to the equipment can occur.
  • Page 107 Maintenance 107 Lift the module by the upper part only Mind your fingers! Keep fingers Support the top and using the lifting holes at the top! away from the edges of the front bottom of the module flange of the module and beware while replacing! of the sharp edges when moving the module!
  • Page 108 108 Maintenance...
  • Page 109 Maintenance 109...

  • Page 110: Bdcl Filter

    110 Maintenance BDCL filter Replacing the BDCL filter  WARNING! Repeat the steps described in section Electrical safety precautions on page 66. The complete safety instructions are given in Safety instructions for ACS880 multidrive cabinets and modules (3AUA0000102301 [English]). If you ignore them, injury or death, or damage to the equipment can occur.
  • Page 111 Maintenance 111 Lift the module by the upper part only Mind your fingers! Keep fingers Support the top and using the lifting holes at the top! away from the edges of the front bottom of the module flange of the module and beware while replacing! of the sharp edges when moving the module!
  • Page 112 112 Maintenance...
  • Page 113 Maintenance 113...

  • Page 114: Capacitors

    Capacitor failure is usually followed by damage to the unit and an input fuse failure, or a fault trip. Contact ABB if capacitor failure is suspected. Replacements are available from ABB. Do not use other than ABB-specified spare parts. Contact an ABB service representative for spare parts and repair services.

  • Page 115: Control Panel

    Maintenance 115 Control panel Replacing the control panel battery  1. Turn the lid on the back of the panel counter-clockwise until the lid opens. 2. Replace the battery with a new CR2032 battery. 3. Put the lid back and tighten it by turning it clockwise. 4.

  • Page 116: Control Unit

    116 Maintenance Control unit BCU control unit types  There are three variants of the BCU control unit used in ACS880 drives: BCU-02, BCU-12 and BCU-22. These have a different number of converter module connections (2, 7 and 12 respectively) but are otherwise identical. The three BCU types are interchangeable as long as the number of connections is sufficient.

  • Page 117: Control Unit Battery

    Maintenance 117 Control unit battery  Replace the real-time clock battery if the BATT OK LED is not illuminated when the control unit is powered. For information on the LED, see Layout and connections on page 164. 1. Undo the fastening screw and remove the battery 2.

  • Page 118: Leds And Other Status Indicators

    118 Maintenance LEDs and other status indicators This section instructs how to interpret the status indications of the ACS880-1604 DC/DC converter. Warnings and faults reported by the control program are displayed on the control panel on the cabinet door. For further information, see the firmware manual.

  • Page 119: Ordering Information

    Ordering information 119 Ordering information Contents of this chapter This chapter lists the types and ordering codes of the ACS880-1604 DC/DC converter unit components. The data is valid for ACS880-1604 DC/DC converter modules and related accessories. You can find the kit-specific assembly drawings, step-by-step instructions and detailed kit information on the Internet.

  • Page 120: Kit Code

    120 Ordering information Kit code The format of the kit code is A-w-s-xxx, for example, A-6-8-110 where: • A = air-cooled • w = cabinet width • x (cabinet width divided by 100) = xxx mm • 4 = 400 mm •...

  • Page 121: Dc/Dc Converter Modules

    DC/DC converter unit Modules used Ordering code Type Frame size Contents (for options, see below) = 400 V • DC/DC converter module(s) (frame R8i) with ACS880-104-0640A-3+E205 ACS880-1604-0600A-3 speed-controlled cooling ACS880-104-0900A-3+E205 ACS880-1604-0900A-3 fan(s) 2×R8i ACS880-104-0640A-3+E205 ACS880-1604-1200A-3 2×R8i ACS880-104-0900A-3+E205 ACS880-1604-1800A-3 = 500 V...

  • Page 122: Bdcl Filters

    122 Ordering information BDCL filters BDCL filters (+C188)  The BDCL filters must be ordered separately. DC/DC converter L-filter Frame unit type ACS880- size Type Ordering code Contents 1604-... = 400 V 3AUA0000173022 • +C188: Direct-on- 0600A-3 ACS880-BDCL-14-5+C188 line (DOL) cooling ACS880-BDCL-15-5+C188 3AUA0000173021 0900A-3...

  • Page 123: Bdcl Filters (+C188+G304)

    Ordering information 123 BDCL filters (+C188+G304)  The BDCL filters must be ordered separately. DC/DC converter L-filter Frame unit type ACS880- size Type Ordering code Contents 1604-... = 400 V ACS880-BDCL-14- • +C188: Direct-on- 0600A-3 3AUA0000180031 5+C188+G304 line (DOL) cooling ACS880-BDCL-15- 0900A-3 3AUA0000180030...

  • Page 124: Control Panel

    124 Ordering information Control panel The control panel is not included with the DC/DC converter module but must be ordered separately. One control panel is required for the commissioning of an ACS880 drive system, even if the Drive composer PC tool is used. The control panel can be flush mounted on the cabinet door with the help of a door mounting kit.
  • Page 125 Ordering information 125 • EMC shield • control panel mounting platform • grounding wire • Ethernet cable (3 m). DPMP-01 mounting platform for ACS-AP control panel installation guide [3AUA0000100140 (English)].

  • Page 126: Control Electronics

    • memory unit with DC/DC converter control program. You must connect the control unit to each DC/DC converter module with a pair of fiber optic cables. You can order them from ABB. See section Fiber optic cables on page 127.

  • Page 127: Fiber Optic Cables

    The fiber optic cables are needed between the control unit and the DC/DC converter R8i module. You need one kit per each module. Select a kit with suitable length. The following kits, each consisting of a pair of plastic fiber optic cables, are available from ABB: Type Data...

  • Page 128: Mechanical Installation Accessories And Tools

    128 Ordering information Mechanical installation accessories and tools Module installation parts  Module installation parts include, for example, top and bottom supports for the DC/DC converter and BDCL filter modules. Note: The designs presented in this manual for Rittal TS 8 enclosures employ the Rittal Flat-PLS busbar system.

  • Page 129: Shrouds

    Ordering information 129 Shrouds  Shrouds are used for IP20 touch protection with the cabinet doors open. Enclosure Ordering code Kit code Illustration 1 per cubicle Rittal TS 8 3AXD50000045955 A-8-8-361 Instruction code: 3AXD50000045956 Ramp  The ramp is used for installing and replacing the R8i and BDCL filter modules in the Rittal TS 8 enclosure.

  • Page 130: Bottom Cable Entry

    130 Ordering information Bottom cable entry  This kit, to be installed on the bottom plate of the enclosure, contains four cable entries for energy storage cables with grommets, wire meshing for 360° grounding, and a strain relief bracket. Enclosure Ordering code Kit code Illustration...

  • Page 131: Electrical Installation Accessories

    Ordering information 131 Electrical installation accessories Busbars and quick connectors for connecting DDC module and  filter Busbars provide connection from the DC/DC converter module to the BDCL filter. For the dimension drawing of the quick connector, see section 170M6545, 170M6549 page 189.

  • Page 132: Common Dc Flat-Pls Assembly

    132 Ordering information Enclosure Ordering code Kit code Illustration 1 per module Rittal TS 8 and (1 for DDC 3AUA0000119227 A-468-8-100 generic and 1 for filter module) Instruction code: 3AUA0000118667 Common DC Flat-PLS assembly  The brackets in this kit act as a mounting base for the busbar supports of the Rittal Flat- PLS DC bus and ensure its correct placement and alignment inside the cabinet line-up.

  • Page 133: Dc Connection With Dc Switch/Disconnector And Charging

    Ordering information 133 DC connection with DC switch/disconnector and charging  These parts provide the mounting base for the charging components and connect the converter module to the DC bus. Enclosure Ordering code Kit code Illustration Rittal TS 8 with DC switch- disconnector 3AXD50000044815...

  • Page 134: Dc Connection Without Dc Switch/Disconnector And Charging

    134 Ordering information Enclosure Ordering code Kit code Illustration Rittal TS 8 and generic with DC 1 kit per switch- 3AXD50000044551 A-468-8-247 disconnector module and charging Instruction code: 3AXD50000043411 Rittal TS 8 and generic with DC 1 kit per switch- 3AXD50000044553 A-468-8-248 disconnector...
  • Page 135 Ordering information 135 Enclosure Ordering code Kit code Illustration Generic without DC switch- 3AXD50000023032 A-8-8-268 disconnector and charging Instruction code: 3AXD50000023291 Rittal TS 8 without DC switch- 3AXD50000004411 A-46-8-206 disconnector and charging Instruction code: 3AXD50000005729 Rittal TS 8 and generic without 1 kit per DC switch- 3AXD50000023340...

  • Page 136: Energy Storage Connection

    136 Ordering information Energy storage connection  These parts provide the DDC and energy storage connection. Enclosure Ordering code Kit code Illustration 1 kit per Rittal TS 8 3AXD50000021808 A-8-8-243 cubicle Instruction code: 3AXD50000023567 1 kit per Generic 3AXD50000023008 A-8-8-244 cubicle Instruction code: 3AXD50000023217...

  • Page 137: Dc Fuses (Dc Bus Side)

    DC fuses on the DC bus side protect the module and drive DC bus against short circuits. For dimension drawings, see section DC fuses on page 188. Fuse (IEC and UL) Frame ACS880-1604-… size Size Type Data Ordering code = 400 V...

  • Page 138: Dc Switch/Disconnector Kits

    138 Ordering information DC switch/disconnector kits  You can equip the DC/DC converter with DC switch/disconnector if quick isolation of the module from the DC bus is required. DC switch/disconnectors (IEC, 230 V, 50 Hz) DC switch/disconnector ACS880- Frame size Ordering code 1604- Type...

  • Page 139: Dc Switch/Disconnectors (Ul/Csa, 110 V, 60 Hz)

    Ordering information 139 DC switch/disconnectors (UL/CSA, 110 V, 60 Hz) DC switch/disconnector ACS880- Frame size Ordering code 1604- Type Data = 400 V 0600A-3 1200 A, 600 V, ICW = 0900A-3 SWITCH KIT 50 kA,1 s, ICM = 3AXD50000009540 OT1200U11 UL 2×R8i 1200A-3 110 kA...

  • Page 140: Charging Kits

    140 Ordering information Charging kits  Charging kits (IEC) ACS880-1604- Frame size Ordering code = 400 V 0600A-3 0900A-3 Charging kit 1 for DDC (500 V) * 3AXD50000022423 2×R8i 1200A-3 2×R8i 1800A-3 = 500 V 0600A-5 0900A-5 Charging kit 1 for DDC (500 V)* 3AXD50000022423 2×R8i...

  • Page 141: Charging Kits (Ul)

    Ordering information 141 Charging kits (UL) ACS880-1604- Frame size Ordering code = 400 V 0600A-3 0900A-3 Charging kit 1 UL for DDC (500 V)* 3AXD50000022425 2×R8i 1200A-3 2×R8i 1800A-3 = 500 V 0600A-5 0900A-5 Charging kit 1 UL for DDC (500 V)* 3AXD50000022425 2×R8i...

  • Page 142: Cabinet Ventilation Kits

    142 Ordering information Cabinet ventilation kits Air inlet kits  Enclosure / Degree of Ordering code Kit code Illustration protection 800 mm / IP20 3AUA0000117005 A-8-X-023 Instruction code: 3AUA0000116887 800 mm / IP42 3AUA0000117009 A-8-X-026 Instruction code: 3AUA0000116875 800 mm / IP54 3AXD50000009186 A-8-X-029 Instruction code 3AXD50000010001...

  • Page 143: Air Outlet Kits

    Ordering information 143 Air outlet kits  The IP54 kits require a cooling fan that must be ordered separately. Enclosure / Degree of Ordering code Kit code Illustration protection 800 mm / IP20 3AUA0000125203 A-4-X-042 Instruction code: 3AXD50000001983 800 mm / IP42 3AUA0000114968 A-4-X-040 Instruction code: 3AUA0000115292...
  • Page 144 144 Ordering information Enclosure / Degree of Ordering code Kit code Illustration protection 3AXD50000010362 A-4-X-067 800 mm / IP54 / UL Instruction code: 3AXD50000010284 Note: Fan to be ordered separately...

  • Page 145: Cooling Fans

    Ordering information 145 Cooling fans  Roof fans One or two cooling fans are to be installed inside the air outlet compartment to ensure sufficient cooling of the cabinet. IEC/UL Component Enclosure / Degree of Ordering code protection Name Data RB4C-355/170 3AXD50000006934 Capacitor...

  • Page 146: Miscellaneous

    146 Ordering information Miscellaneous BAMU voltage/current measurement unit  BAMU voltage/current measurement unit is not included with the DC/DC converter module but must be ordered separately. If you use BAMU to measure the energy storage voltage, the converter measures its output voltage (and thus also the energy storage voltage) automatically.

  • Page 147: Technical Data

    Technical data 147 Technical data Contents of this chapter This chapter contains technical data for ACS880-1604 DC/DC converter modules.

  • Page 148: Ratings

    148 Technical data Ratings No-overload use Module type ACS880- contmax contmax Frame input output output 1604-… A (DC) A (DC) A (DC) = 400 V 0600A-3 12000 0900A-3 1350 12000 1200A-3 2×R8i 1200 1200 1800 24000 1800A-3 2×R8i 1800 1800 1229 2700 24000...

  • Page 149: Definitions

    Technical data 149 Definitions  Supply voltage range. For U , see Input power (DC bus) connection on page 155. For U , see Output power (energy storage) connection on page 155. Nominal ratings DC input current Continuous output current (RMS) Maximum continuous active power contmax Nominal apparent power...

  • Page 150: Derating

    150 Technical data Derating  Temperature derating In the temperature range +40…50 °C (+104…122 °F), the rated output current is derated by 1% for every added 1 °C (1.8 °F). The output current can be calculated by multiplying the current given in the rating table by the derating factor (k): 1.00 0.90 0.80...

  • Page 151: Type Equivalence Table

    2×R8i BDCL-15-7 3AXD00000601909 Cabinet-installed units available from ABB DC/DC converter unit types available from ABB as modules R8i converter modules used.The quantity of the modules is shown in the Frame column. BDCL filter quantity and type. See also BDCL filters on page 122.

  • Page 152: Dimensions And Weights

    152 Technical data Dimensions and weights R8i DC/DC converter module  The dimensions of a DC/DC converter module are: • height 1397.0 mm (55.0 in) • width 240.0 mm (9.45 in) • depth 583.0 mm (22.95 in) • weight 125.0 kg (275.6 lb). For the dimensional drawing, see R8i DC/DC converter module on page 170.

  • Page 153: Allowable Mounting Orientations

    For the BDCL-1x-x filter, the allowable mounting orientations are upright position and on the left-hand-side (viewed from the front). Losses, cooling data and noise Module type Air flow Noise Efficiency loss Frame ACS880-1604-… /min = 400 V 0640A-3 2200 1295 98.3 0900A-3 2200 1295 98.3...

  • Page 154: Tightening Torques

    154 Technical data Tightening torques Unless a tightening torque is specified in the text, the following torques can be used. Cable lugs  Size Max. torque Note 15 N·m (11 lbf·ft) Strength class 8.8 32 N·m (23.5 lbf·ft) Strength class 8.8 50 N·m (37 lbf·ft) Strength class 8.8 Electrical connections...

  • Page 155: Input Power (Dc Bus) Connection

    Technical data 155 Input power (DC bus) connection ACS880-104-xxxxx-3 = DC voltage corresponding AC input voltages Voltage (U 380…415 V. This is indicated in the type designation label as typical input voltage level 566 V DC. ACS880-104-xxxxx-5 = DC voltage corresponding AC input voltages 380…500 V.

  • Page 156: Control Accuracy - Current And Voltage Control Performance Data

    Maximum long-term tensile load: 1 N • Flexing: Max. 1000 cycles ABB drive products in general utilize 5 and 10 MBd (megabaud) optical components from Avago Technologies’ Versatile Link range. Note that the optical component type is not directly related to the actual communication speed.

  • Page 157: Ambient Conditions

    IEC 60068-2-6:2007, 57…150 Hz: 1 g 57…150 Hz: 1 g 9…200 Hz: 10 m/s EN 60068-2-6:2008 Environmental testing Part Tested in ABB multidrive (32.8 ft/s 2: Tests –Test Fc: Vibration cabinet (ACS880-x07) (sinusoidal) according to: Max. 1 mm (0.04 in.) (5 …...

  • Page 158: Materials

    C1-x) and printed circuit boards can be land filled. They are classified as hazardous waste within the EU. They must be removed and handled according to local regulations. For further information on environmental aspects and more detailed recycling instructions, please contact your local ABB distributor.

  • Page 159: Auxiliary Current Consumption

    Technical data 159 Auxiliary current consumption cont start cont Device V DC V AC R8i module internal electronics 230+15%/-20% 50/60 0.45 • Option +G304 (115 V auxiliary voltage 115+15%/-20% 50/60 0.90 supply) Control unit BCU-x2 24+10% 1.50 3.00 R8i module option +C188 (DOL fan) 1.90 3.80 0.60...

  • Page 160: Disclaimer

    ABB Ltd and its affiliates are not liable for damages and/or losses related to such security breaches, any unauthorized access, interference, intrusion, leakage and/or...

  • Page 161: Control Unit

    Control unit 161 Control unit Contents of this chapter This chapter • describes the connections of the BCU control unit • contains the specifications of the inputs and outputs of the control units. General The ACS880 drive utilizes BCU-x2 control units. The BCU control unit is built in a metal housing.

  • Page 162: Default I/O Connection Diagram

    162 Control unit Default I/O connection diagram XD2D Drive-to-drive link Drive-to-drive link (not in use by default) BGND Shield X485 RS485 connection Not in use (not in use by default) BGND Shield XRO1…XRO3 Relay outputs XRO1: Not in use 250 V AC / 30 V DC / 2 A XRO2: Fault(-1) (Energized = no fault) 250 V AC / 30 V DC / 2 A...

  • Page 163: External Power Supply For The Control Unit (Xpow)

    The BCU-x2 has an on-board data logger that collects real-time data from the converter to help fault tracing and analysis. The data is stored onto the SDHC memory card inserted into the SD CARD slot and can be analyzed by the ABB service personnel...

  • Page 164: Layout And Connections

    164 Control unit Layout and connections Description I/O terminals (Default I/O connection diagram) SLOT 1 I/O extension or fieldbus adapter module connection. (This is the sole location for an FDPI-02 diagnostics and panel interface.) SLOT 2 I/O extension or fieldbus adapter module connection SLOT 3 I/O extension, fieldbus adapter or FSO-xx...
  • Page 165 Control unit 165 Description Analog inputs Analog outputs Digital inputs, Digital input interlock (DIIL) XRO3 XDIO Digital input/outputs XD24 XPOW XD2D Drive-to-drive link XD24 +24 V output (for digital inputs) XRO2 XETH Ethernet port (eg. for PC communication) XDIO XPOW External power input XRO1 Relay output RO1...

  • Page 166: Control Unit Connector Data

    166 Control unit Control unit connector data Power supply Connector pitch 5 mm, wire size 2.5 mm (XPOW) 24 V (±10%) DC, 2 A External power supply in. Two supplies can be connected to BCU for redundancy. Relay outputs RO1…RO3 Connector pitch 5 mm, wire size 2.5 mm (XRO1…XRO3) 250 V AC / 30 V DC, 2 A...
  • Page 167 Control unit 167 Analog outputs AO1 and AO2 Connector pitch 5 mm, wire size 2.5 mm (XAO) 0…20 mA, R < 500 ohm load Frequency range: 0…500 Hz Resolution: 11 bit + sign bit Inaccuracy: 2% of full scale range Drive-to-drive link Connector pitch 5 mm, wire size 2.5 mm (XD2D)

  • Page 168: Ground Isolation Diagram

    168 Control unit Ground isolation diagram XPOW +24VI +24VI +VREF -VREF AGND AI1+ Common mode voltage between AI1- each AI input and AGND is AI2+ AI2- +30 V AGND AGND XD2D BGND SHIELD XRO1, XRO2, XRO3 XD24 +24VD DICOM +24VD DIOGND XDIO DIO1...

  • Page 169: Dimension Drawings

    Dimension drawings 169 Dimension drawings Contents of this chapter This chapter shows dimensions of the ACS880-1604 DC/DC converter modules and accessories.

  • Page 170: R8I Dc/Dc Converter Module

    170 Dimension drawings R8i DC/DC converter module...
  • Page 171 Dimension drawings 171...

  • Page 172: Quick Connectors Of The Dc/Dc Converter Module

    172 Dimension drawings Quick connectors of the DC/DC converter module...

  • Page 173: Quick Connectors

    Dimension drawings 173 Quick connector Dimensions in mm 1 mm = 0.0394 in...

  • Page 174: Bdcl Filter Module

    174 Dimension drawings BDCL filter module...

  • Page 175: Acs-Ap-X Control Panel With Door Mounting Kit

    Dimension drawings 175 ACS-AP-x control panel with door mounting kit Cutting in the cabinet door: 109 mm × 223 mm (4.29 in. × 8.78 in.) Plate thickness: 1.5…2.5 mm (0.059…0.098 in.)

  • Page 176: Bcu Control Unit

    176 Dimension drawings BCU control unit...

  • Page 177: Bamu Voltage/Current Measurement Unit

    Dimension drawings 177 BAMU voltage/current measurement unit...

  • Page 178: Bamu Fuse Holders And Fuses

    178 Dimension drawings BAMU fuse holders and fuses PS272PREMCPS fuse disconnector and PS27 terminal cover  Twin terminal covers PS 27 Part #: A 220087 Weight: 30g Packaging: 3 twins MC PS ø11.5 ø6.5 V: 93 Connecting distance between centers W: 150 Without terminals cover length W’: 240 With terminals cover length Y: 196 Space factor with a 90°...

  • Page 179: Ramp

    Dimension drawings 179 Ramp...
  • Page 180 180 Dimension drawings...

  • Page 181: Internal Cabinet Fan

    Dimension drawings 181 Internal cabinet fan W2E 143-AA09-01, W2E 143-AA15-01  flow...

  • Page 182: Switchgear And Charging Components

    182 Dimension drawings Switchgear and charging components DC switch/disconnectors  OT1600E11 (IEC), OT1200U11 (UL) OT1000-1250E_ OT1600E_ 4,21 OT1000-1250X_ OT1600X_ 4,80 3,23 OT800U_ 13,5 OT1200U_ 0,53 1,97 9,13 5/16 3,27 4,57 4,80 14,65 223,2 12,05 8,11 8,79 5,31 0,43 1,57 0,24 22,5 0,89 6,93...

  • Page 183: Charging Switches

    Dimension drawings 183 Charging switches  OS160GD04F (IEC) 138...205 (OXP 6x161) 33,4 53,3 95,5 8,5 7,2 17,5 114,5 Back connection types: Ø9 14 min 181.5 17,5...

  • Page 184: Os100Gj04Fp (Ul/Csa)

    184 Dimension drawings OS100GJ04FP (UL/CSA) 138...205 (OXP 6x161) 33,4 53,3/2,10 1,77 5,35...8,07 1,31 17,5 81/3,19 0,69 0,79 69/2,72 0,33 60/2,36 95,5 3,76 0,43 0,10 1,81 0,24 125,5 8,66 1,42 4,94 138,5 6,77 5,45 2,56 1,50 min 14 0,55 1,38 1,81 104,5/4,11 17,5 0,39...

  • Page 185: Charging Controller

    Dimension drawings 185 Charging controller  79 (3.11”)

  • Page 186: Resistors

    186 Dimension drawings Resistors  ZRF 30X165 165 ±3 5.5 × 8 D MAX 6 (minimum) Handles  OHB65J6 Handle type L (mm) B (mm) Notes OHB65J6 6 × 6 Used with switch-disconnector units Dimensions in mm 1 mm = 0.0394 in...

  • Page 187: Contacts

    Dimension drawings 187 Contacts  Auxiliary contact OA3G01 2×0.75…2.5 mm (2×18…14 AWG) 0.8 N·m (7 lb.in) Pozidriv M3.5 Form 2...

  • Page 188: Dc Fuses

    188 Dimension drawings DC fuses 170M6415, 170M6419, 170M6545, 170M6549  690 V fuses (as used with 400 and 500 V units) Size A (mm) B (mm) D (mm) E (mm) G (mm) H (mm) 1000…1250 V fuses (as used with 690 V units) Size A (mm) B (mm)

  • Page 189: 170M6545, 170M6549

    Dimension drawings 189 170M6545, 170M6549  ø30 1 mm = 0.0394 in www.cooperindustries.com...
  • Page 190 190 Dimension drawings...

  • Page 191: Example Circuit Diagrams

    Example circuit diagrams 191 Example circuit diagrams Contents of this chapter This chapter contains example circuit diagrams of a DC/DC converter module. The purpose of these diagrams is to help in: • understanding the internal connections and operation of the cabinet-installed DC/DC converter unit, and •...

  • Page 192: Component Designations Used In The Diagrams

    192 Example circuit diagrams Component designations used in the diagrams DC/DC converter 1×R8i and 2×R8i without DC switch/disconnector  The circuit diagrams include: Designation Component BCU control unit DPMP-01 door mounting kit for control panel, including DDPI board ACS-AP-x control panel A232 BAMU Voltage/current measurement unit ES+, ES-...

  • Page 193: Dc/Dc Converter 1×R8I And 2×R8I With Dc Switch/Disconnector

    Example circuit diagrams 193 DC/DC converter 1×R8i and 2×R8i with DC switch/disconnector  The diagrams include: Designation Component A11.1 Charging controller BCU control unit DPMP-01 door mounting kit for control panel, including DDPI board ACS-AP-x control panel A232 BAMU Voltage/current measurement unit ES+,ES- Energy storage connection F11.xx...
  • Page 194 194 Example circuit diagrams...

  • Page 195: Ddc 1×R8I Without Dc Switch/Disconnector

    BDCL MODULE =-F13.11 ;ESM.1- =-ESM.1 041/9K ;ESP.1+ =-ESP.1 =-T11.1 =-R13.1 =300 +CUSTOMER ES + ES - DC CONNECTION =-X11.1 =-X13.1 1.1PE 3.1PE 26.01.2017 Tuomi Joni ACS880-1604-0600A-7+C183 Circuit Diagram EFS2 26.01.2017 Asikainen Mika DDC 1xR8i DC main circuit 3AXD10000407345 ABB Drives...

  • Page 196: Sheet 005 (Module Connections)

    =-X53.1 GND BCON 24VDC BCON 24 VDC ;A41:V1R 040/4K ;A41:V1T DC FAN AC FAN AC FAN FAN BOX FAN BOX DC FAN HEATER 26.01.2017 Tuomi Joni ACS880-1604-0600A-7+C183 Circuit Diagram EFS2 26.01.2017 Asikainen Mika DDC 1xR8i Module connections 3AXD10000407345 ABB Drives...

  • Page 197: Sheet 020 (Auxiliary Voltage Distribution)

    MODULES HEATERS ;X21:6.1 ;HEAT.1:N =-T22.1 041/10G for option C183 ;X22:11.1 230VAC =-X21.1 ;X22:1.1 ;X21:1.1 040/3K 24VDC ;X21:3.1 041/10G ;HEAT.CTRL:L =-K95 ;HEAT.CTRL:N =-X22.1 =-20.1PE 26.01.2017 Tuomi Joni ACS880-1604-0600A-7+C183 Circuit Diagram EFS2 26.01.2017 Asikainen Mika DDC 1xR8i Aux. voltage distribution 3AXD10000407345 ABB Drives...

  • Page 198: Sheet 040 (Control Unit)

    DIAGNOSTICS AND PANEL INTERFACE =-XTE11 -X100 TERMINATION SWITCH S1 TERMINATED OPEN -DOOR =-A49 =-A48 CONTROL PANEL DPMP-01 ACS-AP-I PANEL KIT -X101 -X100 -X102 -X103 26.01.2017 Tuomi Joni ACS880-1604-0600A-7+C183 Circuit Diagram EFS2 26.01.2017 Asikainen Mika DDC 1xR8i Control unit BCU-02 3AXD10000407345 ABB Drives...

  • Page 199: Sheet 041 (Bamu Measurement Unit)

     Sheet 041 (BAMU measurement unit) =300 +300.1 =-A232 ;X21:3.1 020/7J ;X21:6.1 ;A41:V2R 040/5K ;A41:V2T =-F90.2 ;ESM.1- 001/11F ;ESP.1+ =-F90.1 26.01.2017 Tuomi Joni ACS880-1604-0600A-7+C183 Circuit Diagram EFS2 26.01.2017 Asikainen Mika DDC 1xR8i BAMU-11C Measurement Unit 3AXD10000407345 ABB Drives...

  • Page 200: Ddc 1×R8I With Dc Switch/Disconnector

    -X13 -X13 ES + ES - DC CONNECTION =-DOOR -P11.1 GREEN Load OK =-X11.1 =-X13.1 1.1PE 3.1PE 26.01.2017 Tuomi Joni ACS880-1604-0600A-7+C183+C188 Circuit Diagram EFS2 26.01.2017 Asikainen Mika DDC 1xR8i with DC switch DC main circuit, charging circuit 3AXD10000400874 ABB Drives...

  • Page 201: Sheet 005 (Module Connections)

    24 VDC ;A41:V1R 040/4K ;A41:V1T ;I1V60 ;I1V50 001/4E DC FAN AC FAN AC FAN FAN BOX FAN BOX HEATER DOL FAN 26.01.2017 Tuomi Joni ACS880-1604-0600A-7+C183+C188 Circuit Diagram EFS2 26.01.2017 Asikainen Mika DDC 1xR8i with DC switch Module connections 3AXD10000400874 ABB Drives...

  • Page 202: Sheet 020 (Auxiliary Voltage Distribution)

    =-T22.1 041/10G for option C183 ;X22:11.1 230VAC =-X21.1 ;X22:1.1 ;X21:1.1 040/3K 24VDC ;X21:3.1 041/10G ;HEAT.CTRL:L =-K95 ;HEAT.CTRL:N =-X22.1 =-20.1PE 26.01.2017 Tuomi Joni ACS880-1604-0600A-7+C183+C188 Circuit Diagram EFS2 26.01.2017 Asikainen Mika DDC 1xR8i with DC switch Aux. voltage distribution 3AXD10000400874 ABB drives...

  • Page 203: Sheet 040 (Control Unit)

    -X100 TERMINATION SWITCH S1 TERMINATED OPEN -DOOR =-A48 =-A49 CONTROL PANEL DPMP-01 ACS-AP-I PANEL KIT -X101 -X100 -X102 -X103 26.01.2017 Tuomi Joni ACS880-1604-0600A-7+C183+C188 Circuit Diagram EFS2 26.01.2017 Asikainen Mika DDC 1xR8i with DC switch Control unit BCU-02 3AXD10000400874 ABB Drives...

  • Page 204: Sheet 041 (Bamu Measurement Unit)

    Sheet 041 (BAMU measurement unit) =300 +300.1 =-A232 ;X21:3.1 020/7J ;X21:6.1 ;A41:V2R 040/5K ;A41:V2T =-F90.2 ;ESM.1- 001/16H ;ESP.1+ =-F90.1 26.01.2017 Tuomi Joni ACS880-1604-0600A-7+C183+C188 Circuit Diagram EFS2 26.01.2017 Asikainen Mika DDC 1xR8i with DC switch BAMU-11C Measurement Unit 3AXD10000400874 ABB Drives...

  • Page 205: Ddc 2×R8I Without Dc Switch/Disconnector

    =-ESM.1 041/9K ;ESP.1+ =-ESP.1 =-T11.1 =-R13.1 =300 +CUSTOMER ES + ES - DC CONNECTION =-X11.1 =-X13.1 1.1PE 3.1PE 26.01.2017 Tuomi Joni ACS880-1604-1200A-7+C183 Product Circuit Diagram EFS2 26.01.2017 Asikainen Mika DDC 2xR8i ACS880-1604-1200A-7+C183 DC main circuit 3AXD10000578961 Without DC switch ACS880-1604-1200A-7...

  • Page 206: Sheet 002 (Dc Main Circuit)

    R8i MODULE BDCL MODULE =300 =-T11.2 =-R13.2 +CUSTOMER ES + ES - DC CONNECTION =-X11.2 =-X13.2 1.1PE 3.1PE 26.01.2017 Tuomi Joni ACS880-1604-1200A-7+C183 Product Circuit Diagram EFS2 26.01.2017 Asikainen Mika DDC 2xR8i ACS880-1604-1200A-7+C183 DC main circuit 3AXD10000578961 Without DC switch ACS880-1604-1200A-7...

  • Page 207: Sheet 005 (Module Connections)

    24VDC BCON 24 VDC ;A41:V1R 040/4K ;A41:V1T DC FAN AC FAN AC FAN FAN BOX FAN BOX DC FAN HEATER 26.01.2017 Tuomi Joni ACS880-1604-1200A-7+C183 Product Circuit Diagram EFS2 26.01.2017 Asikainen Mika DDC 2xR8i ACS880-1604-1200A-7+C183 Module connections 3AXD10000578961 Without DC switch ACS880-1604-1200A-7...

  • Page 208: Sheet 006 (Module Connections)

    24VDC BCON 24 VDC ;A41:V2R 040/5K ;A41:V2T DC FAN AC FAN AC FAN FAN BOX FAN BOX DC FAN HEATER 26.01.2017 Tuomi Joni ACS880-1604-1200A-7+C183 Product Circuit Diagram EFS2 26.01.2017 Asikainen Mika DDC 2xR8i ACS880-1604-1200A-7+C183 Module connections 3AXD10000578961 Without DC switch ACS880-1604-1200A-7...

  • Page 209: Sheet 020 (Auxiliary Voltage Distribution)

    C183 ;X22:11.1 230VAC =-X21.1 ;X22:1.1 ;X21:2.1 040/3K 24VDC ;X21:2.1 ;X21:3.1 041/10G ;HEAT.CTRL:L =-K95 ;HEAT.CTRL:N =-X22.1 =-20.1PE 26.01.2017 Tuomi Joni ACS880-1604-1200A-7+C183 Product Circuit Diagram EFS2 26.01.2017 Asikainen Mika DDC 2xR8i ACS880-1604-1200A-7+C183 Aux. voltage distribution 3AXD10000578961 Without DC switch ACS880-1604-1200A-7...

  • Page 210: Sheet 021 (Auxiliary Voltage Distribution)

    =-F95.2 =-K95.2 ;HL:2 ;HEAT.2:L EXTERNAL SUPPLY FOR 006/3F MODULES HEATERS ;HN:2 ;HEAT.2:N for option C183 ;HEAT.CTRL:L:2 =-K95.2 ;HEAT.CTRL:N:2 26.01.2017 Tuomi Joni ACS880-1604-1200A-7+C183 Product Circuit Diagram EFS2 26.01.2017 Asikainen Mika DDC 2xR8i ACS880-1604-1200A-7+C183 Aux. voltage distribution 3AXD10000578961 Without DC switch ACS880-1604-1200A-7...

  • Page 211: Sheet 040 (Control Unit)

    TERMINATION SWITCH S1 TERMINATED OPEN -DOOR =-A48 =-A49 CONTROL PANEL DPMP-01 ACS-AP-I PANEL KIT -X101 -X100 -X102 -X103 26.01.2017 Tuomi Joni ACS880-1604-1200A-7+C183 Product Circuit Diagram EFS2 26.01.2017 Asikainen Mika DDC 2xR8i ACS880-1604-1200A-7+C183 Control unit BCU-02 3AXD10000578961 Without DC switch ACS880-1604-1200A-7...

  • Page 212: Sheet 041 (Bamu Measurement Unit)

    Sheet 041 (BAMU measurement unit) =300 +300.1 =-A232 ;X21:3.1 020/7J ;X21:6.1 ;A41:V3R 040/5K ;A41:V3T =-F90.2 ;ESM.1- 001/11F ;ESP.1+ =-F90.1 26.01.2017 Tuomi Joni ACS880-1604-1200A-7+C183 Product Circuit Diagram EFS2 26.01.2017 Asikainen Mika DDC 2xR8i ACS880-1604-1200A-7+C183 BAMU-11C Measurement Unit 3AXD10000578961 Without DC switch ACS880-1604-1200A-7...

  • Page 213: Ddc 2×R8I With Dc Switch/Disconnector

    DC CONNECTION =-DOOR -P11.1 GREEN Load OK =-X11.1 =-X13.1 1.1PE 3.1PE 26.01.2017 Tuomi Joni ACS880-1604-1200A-7+C183+C188 Product Circuit Diagram EFS2 26.01.2017 Asikainen Mika DDC 2xR8i with DC switch ACS880-1604-1200A-7+C183+C188 DC main circuit, charging circuit 3AXD10000564479 With DC switch ABB Drives ACS880-1604-1200A-7...

  • Page 214: Sheet 002 (Dc Main Circuit, Charging Circuit)

    DC CONNECTION =-DOOR -P11.2 GREEN Load OK =-X11.2 =-X13.2 1.1PE 3.1PE 26.01.2017 Tuomi Joni ACS880-1604-1200A-7+C183+C188 Product Circuit Diagram EFS2 26.01.2017 Asikainen Mika DDC 2xR8i with DC switch ACS880-1604-1200A-7+C183+C188 DC main circuit, charging circuit 3AXD10000564479 With DC switch ABB Drives ACS880-1604-1200A-7...

  • Page 215: Sheet 005 (Module Connections)

    ;I1V50 001/4E DC FAN AC FAN AC FAN FAN BOX FAN BOX HEATER DOL FAN 26.01.2017 Tuomi Joni ACS880-1604-1200A-7+C183+C188 Product Circuit Diagram EFS2 26.01.2017 Asikainen Mika DDC 2xR8i with DC switch ACS880-1604-1200A-7+C183+C188 Module connections 3AXD10000564479 With DC switch ABB Drives...

  • Page 216: Sheet 006 (Module Connections)

    ;I1V50.2 002/4E DC FAN AC FAN AC FAN FAN BOX FAN BOX HEATER DOL FAN 26.01.2017 Tuomi Joni ACS880-1604-1200A-7+C183+C188 Product Circuit Diagram EFS2 26.01.2017 Asikainen Mika DDC 2xR8i with DC switch ACS880-1604-1200A-7+C183+C188 Module connections 3AXD10000564479 With DC switch ABB Drives...

  • Page 217: Sheet 020 (Auxiliary Voltage Distribution)

    =-X21.1 ;X22:1.1 ;X21:1.1 040/3K 24VDC ;X21:2.1 ;X21:3.1 041/10G ;HEAT.CTRL:L =-K95 ;HEAT.CTRL:N =-X22.1 =-20.1PE 26.01.2017 Tuomi Joni ACS880-1604-1200A-7+C183+C188 Product Circuit Diagram EFS2 26.01.2017 Asikainen Mika DDC 2xR8i with DC switch ACS880-1604-1200A-7+C183+C188 Aux. voltage distribution 3AXD10000564479 With DC switch ABB Drives ACS880-1604-1200A-7...

  • Page 218: Sheet 021 (Auxiliary Voltage Distribution)

    EXTERNAL SUPPLY FOR 006/3F MODULES HEATERS ;HN.2 ;HEAT.2:N for option C183 ;HEAT.CTRL:L.2 =-K95.2 ;HEAT.CTRL:N.2 26.01.2017 Tuomi Joni ACS880-1604-1200A-7+C183+C188 Product Circuit Diagram EFS2 26.01.2017 Asikainen Mika DDC 2xR8i with DC switch ACS880-1604-1200A-7+C183+C188 Aux. voltage distribution 3AXD10000564479 With DC switch ABB Drives...

  • Page 219: Sheet 040 (Control Unit)

    -DOOR =-A49 =-A48 CONTROL PANEL DPMP-01 ACS-AP-I PANEL KIT -X101 -X100 -X102 -X103 26.01.2017 Tuomi Joni ACS880-1604-1200A-7+C183+C188 Product Circuit Diagram EFS2 26.01.2017 Asikainen Mika DDC 2xR8i with DC switch ACS880-1604-1200A-7+C183+C188 Control unit BCU-02 3AXD10000564479 With DC switch ABB Drives ACS880-1604-1200A-7...

  • Page 220: Sheet 041 (Bamu Measurement Unit)

    +300.1 =-A232 ;X21:3.1 020/7J ;X21:6.1 ;A41:V3R 040/5K ;A41:V3T =-F90.2 ;ESM.1- 001/16H ;ESP.1+ =-F90.1 26.01.2017 Tuomi Joni ACS880-1604-1200A-7+C183+C188 Product Circuit Diagram EFS2 26.01.2017 Asikainen Mika DDC 2xR8i with DC switch ACS880-1604-1200A-7+C183+C188 BAMU-11C Measurement Unit 3AXD10000564479 With DC switch ABB Drives ACS880-1604-1200A-7...

  • Page 221: Further Information

    Product and service inquiries Address any inquiries about the product to your local ABB representative, quoting the type designation and serial number of the unit in question. A listing of ABB sales, support and service contacts can be found by navigating to www.abb.com/searchchannels.
  • Page 222 Contact us www.abb.com/drives www.abb.com/drivespartners 3AXD50000023642 Rev B (EN) 2017-02-08...

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