ABB ACS880-1607 Hardware Manual
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ABB ACS880-1607 Hardware Manual

Dc/dc converter units
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ACS880-1607 DC/DC converter units

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Summary of Contents for ABB ACS880-1607

  • Page 1 ABB industrial drives Hardware manual ACS880-1607 DC/DC converter units...
  • Page 2 ACS880-607 1-phase brake units hardware manual 3AUA0000102559 ACS880-607 3-phase brake units hardware manual 3AXD50000022034 ACS880 brake control program firmware manual 3AXD50000020967 ACS880-1607 DC/DC converter units hardware manual 3AXD50000023644 ACS880 DC/DC converter control program firmware 3AXD50000024671 manual Option manuals and guides ACX-AP-x assistant control panels user’s manual...
  • Page 3 Hardware manual ACS880-1607 DC/DC converter units Table of contents 3. Mechanical installation 5. Electrical installation 8. Start-up  2017 ABB Oy. All Rights Reserved. 3AXD50000023644 Rev B EFFECTIVE: 2017-01-30...

  • Page 5: Table Of Contents

    Table of contents 1. Introduction to the manual Contents of this chapter ..........9 Applicability .
  • Page 6 Generic guidelines ........... . . 35 Selecting the energy storage .
  • Page 7 Checks/Settings with no voltage connected ......64 Connecting voltage to the drive and converter control unit ....64 Setting the parameters .
  • Page 8 Product training ............121 Providing feedback on ABB Drives manuals ....... . 121...

  • Page 9: Introduction To The Manual

    Contents of this chapter This chapter gives basic information on the manual. Applicability The manual is applicable to ACS880-1607 DC/DC converter units that form a part of an ACS880 multidrive system. Safety instructions Follow all safety instructions delivered with the converter.

  • Page 10: Contents Of The Manual

    10 Introduction to the manual Contents of the manual • Introduction to the manual • Operation principle and hardware description • Mechanical installation • Guidelines for planning electrical installation • Electrical installation • Control unit • Installation checklist • Start-up •...

  • Page 11: Terms And Abbreviations

    Introduction to the manual 11 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. Control board Circuit board in which the control program runs Control unit Control board built in a rail-mountable housing Cubicle...
  • Page 12 12 Introduction to the manual...

  • Page 13: Operation Principle And Hardware Description

    Operation principle and hardware description 13 Operation principle and hardware description Contents of this chapter This chapter describes the DC/DC converter operation basics and the hardware of the converter unit.

  • Page 14: 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, energy storage instead of an additional generator and so on.

  • Page 15: Main Circuit Diagram

    Operation principle and hardware description 15 Main circuit diagram  The DC/DC converter has output DC fuses and DC fuses on the drive DC-link side. You can also equip the converter with a DC switch/disconnector (option +F286). This figure shows a simplified main circuit diagram of a DC/DC converter without the DC switch/disconnector and charging circuit.
  • Page 16 16 Operation principle and hardware description 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. Description DC/DC converter cubicles Energy storage cabinet Drive DC bus...

  • Page 17: Overview Diagram Of A Drive With A Converter Unit

    DC/DC converter unit includes a DC/DC converter module and a filter module. The customer must equip the energy storage with fuses and a device for disconnecting the storage from the DC/DC converter. The disconnecting device does not belong to the ACS880-1607 unit delivery. t° Description...

  • Page 18: Converter Unit Hardware

    18 Operation principle and hardware description Converter unit hardware Cabinet layout  The DC/DC converter cubicle includes a converter module, a BDCL filter module and a BCU control unit. Each converter is equipped with dedicated DC fuses; a DC switch/disconnector is optional (option +F286) but commonly used. A converter unit with a DC switch/disconnector also has a precharge circuit including a charging switch on the door.
  • Page 19 Operation principle and hardware description 19 Designation Description T11.1 R8i DC/DC converter module R13.1 Filter module Module cooling fans Lead-throughs for energy storage cables ES+, ES- Energy storage connection Control unit F13.xx Output DC fuses F11.xx DC fuses (DC bus side …...
  • Page 20 20 Operation principle and hardware description The figure shows a converter unit cubicle without the DC switch/disconnector (option +F286) and charging circuit. Without DC switch/disconnector and charging Door closed Door open 9,10,11 Design. Description T11.1 R8i DC/DC converter module R13.1 Filter module Module cooling fans Lead-throughs for energy storage cables...
  • Page 21 Operation principle and hardware description 21 Design. Description F13.xx Output DC fuses F11.xx DC fuses (DC-bus-side) X33.1 Connection from the energy storage disconnecting device to the load disconnected indicator [P13.x] 10. T22.1 24 V DC power supply Q26.1 Contactor for filter fan control 12.

  • Page 22: R8I Dc/Dc Converter Module

    22 Operation principle and hardware description R8i DC/DC converter module  The converter modules run on wheels, which, along with the quick connector, enable quick extraction of a module for maintenance or replacement.The figure shows the layout of the converter module. Description DC/DC converter module, frame size R8i, front DC/DC converter module, frame size R8i, back...

  • Page 23: Bdcl Filter Module

    Operation principle and hardware description 23 BDCL filter module  The BDCL modules run on wheels, which enable quick extraction of a module for maintenance or replacement. Description Filter module, front Filter module, back Energy storage connection Converter module connection Terminal block [X55] (DOL fan supply, option +C188) (ready-connected) Handle Wheels...

  • Page 24: Overview Of The Control Connections On The Bcu Control Unit

    24 Operation principle and hardware description 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 25: Dc/Dc Converter Control Devices

    Operation principle and hardware description 25 DC/DC converter control devices The figure shows an example of the door control devices of the DC/DC converter. The selection and exact location of control devices varies in different deliveries. Description DC switch/disconnector (option +F286) Charging switch Charging OK indicator (See...

  • Page 26: Door Lights

    26 Operation principle and hardware description WARNING! You must also switch off the charging switch to disconnect the DC/DC converter from the DC supply. Door lights  The load disconnected indicator ([P13.x], white) is always installed on the cabinet door. The Charging OK indicator ([P11.x], green) and DC/DC converter disconnected indicator ([P12.x], white) are installed when the DC switch/disconnector (option +F286) is selected.

  • Page 27: Type Designation Labels

    Operation principle and hardware description 27 Type designation labels Type designation label of the DC/DC converter unit  Each converter unit has a type designation label attached onto the inside of the cubicle door. The type designation label includes the ratings, appropriate markings, a type designation and a serial number of the unit.

  • Page 28: Type Designation Labels Of The Dc/Dc Converter Module

    28 Operation principle and hardware description Type designation labels of the DC/DC converter module  Each converter module also has type designation labels attached to it. The type designation stated on the labels contains information on the specifications and configuration of the module. Example labels are shown below.

  • Page 29: Type Designation Label Of The Bdcl Filter Module

    Operation principle and hardware description 29 Type designation label of the BDCL filter module  Each BDCL filter module has a type designation label attached to it. An example label is shown below. Description Type designation. See Type designation key of the filter module on page 32.

  • Page 30: Type Designation Keys

    30 Operation principle and hardware description Type designation keys Type designation key of the converter unit  Type designation describes the composition of the unit in short. The type designation is visible on the label (sticker) which is attached to the cabinet. The complete designation code is divided in subcodes: •...
  • Page 31 Operation principle and hardware description 31 Code Description +G315 DC bus material Tin plated copper (UL) +G320 Auxiliary voltage distribution 230 V AC +G330 Wiring materials Halogen free wiring +G442 Voltage/current measurement unit BAMU voltage/current measurement unit +H352 Power cabling exit Bottom exit +H353 Power cabling exit...

  • Page 32: Type Designation Key Of The Converter Module

    32 Operation principle and hardware description Type designation key of the converter module  The type designation describes the composition of the module in short. The type designation is visible on the label (sticker) which is attached to the module. The complete designation code is divided in subcodes: •...

  • Page 33: Mechanical Installation

    Mechanical installation 33 Mechanical installation Contents of this chapter This chapter describes the mechanical installation of the converter units. DC/DC converter units For checking the installation site, moving the unit and installing cabinets, see Mechanical installation instructions for ACS880 multidrive cabinets (3AUA0000101764 [English]). Energy storage Obey the energy storage manufacturer’s instructions.
  • Page 34 34 Mechanical installation...

  • Page 35: 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 36: Selecting The Energy Storage

    36 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 37: Disconnection Of Energy Storage At The Storage End

    Guidelines for planning electrical installation 37 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 converter unit delivery.

  • Page 38: Selecting And Routing The Energy Storage Cables

    = 400 V ACS880-1607-0600A-3 3×(3×185+95) 2×(3×240+120) 2×(4×120+70) 1×(4×240+120) ACS880-1607-0900A-3 1080 4×(3×240+120) 4×(3×150+70) 2×(4×240+120) 2×(4×185+95) ACS880-1607-1200A-3 2×R8i 1440 2×(3×(3×185+95)) 2×(2×(3×240+120)) 4×(4×120+70) 2×(4×240+120) ACS880-1607-1800A-3 2×R8i 2160 2×(4×(3×240+120)) 2×(4×(3×150+70)) 4×(4×240+120) 4×(4×185+95) = 500 V ACS880-1607-0600A-5 3×(3×185+95) 2×(3×240+120) 2×(4×120+70) 1×(4×240+120) ACS880-1607-0900A-5 1080 4×(3×240+120)

  • Page 39: 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 40 40 Guidelines for planning electrical installation...

  • Page 41: Electrical Installation

    Electrical installation 41 Electrical installation Contents of this chapter This chapter contains instructions on wiring the converter units. Note: The instructions do not cover electrical installation of the energy storage media. Safety WARNING! Obey the safety instructions for the drive. See Safety instructions for ACS880 multidrive cabinets and modules (3AUA0000102301 [English]).

  • Page 42: Electrical Safety Precautions

    42 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 43: Static Electricity

    Electrical installation 43 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 44: Connecting The Control Cables For The Converter Unit

    44 Electrical installation Connecting the control cables for the converter unit Default I/O connection diagram  See chapter Control unit. Connection procedure of control cables  WARNING! Repeat the steps described in section Electrical safety precautions on page 42. The complete safety instructions are given in Safety instructions for ACS880 multidrive cabinets and modules (3AUA0000102301 [English]).
  • Page 45 Electrical installation 45 4. Tighten the two tightening screws so that the EMI conductive cushions press tightly round the bare shield. 5. Secure the cables mechanically at the lead-through strain relief. 6. Keep the shields continuous as close to the connection terminals as possible. EMI conductive cushion Strain relief Grommet...
  • Page 46 46 Electrical installation 5. Arrange the bunches according to size from thickest to the thinnest between the EMI conductive cushions. 6. If more than one cable go through a grommet, seal the grommet by applying Loctite 5221 (catalogue number 25551) inside the grommet.

  • Page 47: Connecting The Energy Storage Cable And Load Disconnected Indicator Cable

    Electrical installation 47 Connecting the energy storage cable and load disconnected indicator cable Connection diagram  This diagram shows the connections between the DC/DC converter unit and an energy storage. Connection with 3-conductor cable Connection with 4-conductor cable X33.1 X33.1 Notes: Connection of the DC/DC converter unit with parallel power modules: Each module must have the output cabling of its own.

  • Page 48: Connection Procedure Of The Energy Storage Cables

    48 Electrical installation Connection procedure of the energy storage cables  For the cable types, see Selecting and routing the energy storage cables on page 38. WARNING! Repeat the steps described in section Electrical safety precautions on page 42. The complete safety instructions are given in Safety instructions for ACS880 multidrive cabinets and modules (3AUA0000102301 [English]).

  • Page 49: Connection Procedure Of The Load Disconnected Indicator Cable

    Electrical installation 49 Connection procedure of the load disconnected indicator cable  WARNING! Repeat the steps described in section Electrical safety precautions on page 42. The complete safety instructions are given in Safety instructions for ACS880 multidrive cabinets and modules (3AUA0000102301 [English]).

  • Page 50: Installing Optional Modules

    50 Electrical installation Installing optional modules See section Overview of the control connections on the BCU control unit on page the available slots for each module. WARNING! Repeat the steps described in section Electrical safety precautions on page 42. The complete safety instructions are given in Safety instructions for ACS880 multidrive cabinets and modules (3AUA0000102301 [English]).

  • Page 51: Connecting A Pc

    Electrical installation 51 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 DC/DC converter control unit either by using an Ethernet (eg. CAT5E) networking cable, or by inserting the panel into the panel holder (if present).
  • Page 52 52 Electrical installation...

  • Page 53: Control Unit

    Control unit 53 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 BCU control unit consists of a BCON control board (and a BIOC I/O and power supply board) built in a metal housing.

  • Page 54: Default I/O Connection Diagram

    54 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 55: 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 56: Layout And Connections

    56 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 57 Control unit 57 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 58: Control Unit Connector Data

    58 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 59 Control unit 59 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 60: Ground Isolation Diagram

    60 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 61: Installation Checklist

    Installation checklist 61 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 62: Checklist

    62 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 160.

  • Page 63: Start-Up

    Always refer to the delivery-specific circuit diagrams when proceeding with the start-up. WARNING! Only qualified by ABB electricians/engineers are allowed to do the work described in this chapter. In addition, the electrician/engineer must know the energy storage system he is about to take in use, and the DC/DC converter control program and operation principle.

  • Page 64: 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 (option +J400), or preferably, you have a PC with the Drive composer tool connected to the converter control unit [A41].

  • Page 65: Setting The Parameters

    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 66: Disconnecting The Dc/Dc Converter With Dc Switch/Disconnector (Option +F286)

    66 Start-up Disconnecting the DC/DC converter with DC switch/disconnector (option +F286) 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 67: Reconnecting The Dc/Dc Converter With Dc Switch/Disconnector (Option +F286)

    Start-up 67 Reconnecting the DC/DC converter with DC switch/disconnector (option +F286) 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 68 68 Start-up...

  • Page 69: Maintenance

    Contents of this chapter This chapter instructs how to maintain the DC/DC converter unit. The information is valid for cabinet-installed ACS880-1607 DC/DC converter units. WARNING! Only qualified electricians are allowed to do the work described in this chapter. Read the complete safety instructions before you install, commission, use or service the converter.

  • Page 70: 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 71: Maintenance Timers And Counters

    Maintenance 71 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 72: Cabinet

    72 Maintenance Cabinet Cleaning the interior of the cabinet  WARNING! Only qualified electricians are allowed to do the work described below. 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 73: Cleaning The Door Air Inlets - Ip22 And Ip42 (Option +B053, +B054)

    Maintenance 73 Cleaning the door air inlets – IP22 and IP42 (option +B053, +B054)  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.

  • Page 74: Cleaning The Inlet (Door) Filters - Ip54 (Option +B055)

    74 Maintenance Cleaning the inlet (door) filters – IP54 (option +B055)  1. Recommendation: De-energize the fans by switching off the DC/DC converter unit. Obey the instructions in section Electrical safety precautions on page 2. Remove the fasteners at the top of the grating. 3.

  • Page 75: Power Connections

    Maintenance 75 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 76: Fuses

    76 Maintenance Fuses Checking and replacing the DC fuses  The DC/DC converter unit has two sets of DC fuses: output DC fuses on the energy storage side and DC fuses on the DC bus side. See Overview diagram of a drive with a converter unit on page 17.
  • Page 77 Maintenance 77 3. Undo the screws of the shroud in the upper part of the cubicle. Remove the shroud. 4. Slacken the nuts of the headless screws of the fuses so that you can slide out the fuse blocks. Make note of the order of the washers on the screws. 5.

  • Page 78: 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 79: Replacing The Speed-Controlled Cooling Fan Of Dc/Dc Converter Module

    Maintenance 79 Replacing the speed-controlled cooling fan of DC/DC converter  module If the module is equipped with a direct-on-line cooling fan (option +C188), see page 81. 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 80 80 Maintenance...

  • Page 81: Replacing The Direct-On-Line Fan (Option +C188) Of The Dc/Dc Converter Module

    Maintenance 81 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 79. 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 82 82 Maintenance...

  • Page 83: Replacing The Circuit Board Compartment Fan Of The Dc/Dc Converter Module

    Maintenance 83 Replacing the circuit board compartment fan of the DC/DC  converter module 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.
  • Page 84 84 Maintenance 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 85 Maintenance 85 12. Install and tighten the two screws.

  • Page 86: Replacing The Fan Of The Bdcl Filter

    86 Maintenance 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 87: Replacing The Roof Fan For Ip54 Cabinet (Option +B055)

    Maintenance 87 Replacing the roof fan for IP54 cabinet (option +B055)  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 88: Dc/Dc Converter Module

    88 Maintenance DC/DC converter module Cleaning the module  The converter 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 89: Replacing The Dc/Dc Converter Module

    Do not use the module pull-out ramp with plinth heights over 50 mm.The ramp supplied with the drive system is designed for a plinth height of 50 mm (the standard plinth height of ABB cabinets). Support the top and Do not tilt!
  • Page 90 90 Maintenance Lift the module by the upper part only Mind your fingers! Keep fingers Support the top and bottom using the lifting holes at the top! away from the edges of the of the module while front flange of the module! replacing! 1.
  • Page 91 Maintenance 91 12. Replace the module: install the module in reverse order. Mind you fingers. Keep a constant pressure with one foot on the base of the module to prevent the module from falling on its back. Note: Be careful not to break the fastening screws: tighten the fastening screws of the module to 22 N·m (16.2 lbf.ft) and fastening bolts of the DC output busbars to 70 N·m (51.6 lbf.ft).
  • Page 92 92 Maintenance...
  • Page 93 Maintenance 93...

  • Page 94: Bdcl Filter

    Do not tilt the module. Do not leave the module unattended on a sloping floor. • Do not use the ramp with plinth heights over 50 mm.The ramp supplied with the drive system is designed for a plinth height of 50 mm (the standard plinth height of ABB cabinets). Support the top and...
  • Page 95 Maintenance 95 Lift the module by the upper part only Mind your fingers! Keep fingers Support the top and bottom using the lifting holes at the top! away from the edges of the of the module while front flange of the module! replacing! 1.
  • Page 96 96 Maintenance...
  • Page 97 Maintenance 97...

  • Page 98: 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 99: Control Panel

    Maintenance 99 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 100: Control Unit

    100 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 101: Control Unit Battery

    Maintenance 101 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 56. 1. Undo the fastening screw and remove the battery 2.

  • Page 102: Leds And Other Status Indicators

    102 Maintenance LEDs and other status indicators This section instructs how to interpret the status indications of the ACS880-1607 DC/DC converter unit. 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 103: Technical Data

    Technical data 103 Technical data Contents of this chapter This chapter contains the technical data for the DC/DC converter units.

  • Page 104: Ratings

    104 Technical data Ratings Consists of No-overload use Unit type module contmax contmax type ACS880- output Frame 1607-… ACS880- A (DC) A (DC) A (DC) 104-… = 400 V 0600A-3 0640A-3 12000 0900A-3 0900A-3 1350 12000 1200A-3 0640A-3 2×R8i 1200 1200 1800 24000...

  • Page 105: Definitions

    Technical data 105 Definitions  Supply voltage range. For U , see Input power (DC bus) connection on page 112. For U , see Output power (energy storage) connection on page 112. Nominal ratings DC input current Continuous output current (RMS) Maximum continuous active power contmax Nominal apparent power...

  • Page 106: Derating

    106 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 107: Fuses

    Technical data 107 Fuses DC fuses (DC bus side)  Unit type Example Rating Type (Bussman) ACS880-1607-... = 400 V 0600A-3 1100 A, 690 V, size 3 Flush end type 170M6415 0900A-3 1600 A, 690 V, size 3 Flush end type...

  • Page 108: Bdcl Filters

    108 Technical data BDCL filters Each DC/DC converter module has its own BDCL filter module. Unit type Frame BDCL filter type ACS880-1607-... = 400 V 0600A-3 1×R8i 1×BDCL-14-5 0900A-3 1×R8i 1×BDCL-15-5 1200A-3 2×R8i 2×BDCL-14-5 1800A-3 2×R8i 2×BDCL-15-5 = 500 V 0600A-5 1×R8i...

  • Page 109: Dimensions And Weights

    Technical data 109 Dimensions and weights Unit type Height 1 Height 2 Width 1 Depth 1 Depth 2 Weight ACS880-1607- … = 400 V 0600A-3 2145 84.4 2315 91.1 31.5 29.8 1433 0900A-3 2145 84.4 2315 91.1 31.5 29.8 1499...

  • Page 110: Losses, Cooling Data And Noise

    110 Technical data Losses, cooling data and noise Unit type Air flow Noise Efficiency loss Frame ACS880-1607-… /min = 400 V 0600A-3 2200 1295 98.3 0900A-3 2200 1295 98.3 1200A-3 2×R8i 10.5 4400 2590 98.3 1800A-3 2×R8i 16.5 4400 2590 98.2...

  • Page 111: Tightening Torques

    Technical data 111 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 112: Input Power (Dc Bus) Connection

    112 Technical data 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 113: Optical Components

    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 114: Ambient Conditions

    The unit is to be used in a heated indoor controlled environment. Operation Storage Transportation Altitude above sea level 0…2000 m (0…6561.7 ft) For altitudes over 2000 m (6561.7 ft), contact ABB. Air temperature 0…+40 °C -40…+70 °C -40…+70 °C (+32…+104 °F), no (-104…+158 °F)

  • Page 115: Materials

    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. Applicable standards See Electrical planning instructions for ACS880 multidrive cabinets and modules (3AUA0000102324 [English]).

  • Page 116: 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 117: Dimensions

    Dimensions 117 Dimensions What this chapter contains This chapter contains the following dimension data: • Dimension drawings of DC/DC converter unit • Location and size of output terminals for energy storage cables...

  • Page 118: Dimension Drawings

    118 Dimensions Dimension drawings Frame 1×R8i, bottom cable entry ...

  • Page 119: Frame 1×R8I, Top Cable Entry

    Dimensions 119 Frame 1×R8i, top cable entry ...

  • Page 120: Location And Size Of Input Terminals

    120 Dimensions Location and size of input terminals Frame 1×R8i, bottom cable entry  Frame 1×R8i, top cable entry ...

  • Page 121: 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 122 Contact us www.abb.com/drives www.abb.com/drivespartners 3AXD50000023644 Rev B (EN) 2017-01-30...

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