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ABB ACS880-1607LC Hardware Manual

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

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Summary of Contents for ABB ACS880-1607LC

  • Page 1 — ABB INDUSTRIAL DRIVES ACS880-1607LC DC/DC converter units Hardware manual...
  • Page 3 ACS880-1607LC DC/DC converter units Hardware manual Table of contents 3. Mechanical installation 5. Electrical installation 8. Start-up 3AXD50000431342 Rev C Original instructions EFFECTIVE: 2023-12-29...

  • Page 5: Table Of Contents

    Table of contents 5 Table of contents 1 Introduction to the manual Contents of this chapter ............... . Applicability .
  • Page 6 6 Table of contents Type designation labels of the DC/DC converter module ......Type designation label of the BDCL filter module .
  • Page 7 Table of contents 7 Connecting control cabling ............. Installing option modules .
  • Page 8 8 Table of contents Frame R8i fan replacement ..............R7i converter module .
  • Page 9 Table of contents 9 Ratings ....................Derating .

  • Page 11: Introduction To The Manual

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

  • Page 12: Categorization By Frame Size And Option Module

    12 Introduction to the manual Categorization by frame size and option module Some descriptions, instructions and technical data which concern only certain module or frame sizes are marked with the size identifier (such as "2×R8i", etc.). The marking derives from the quantity and basic construction of the converter modules that form the converter unit.

  • Page 13: Related Documents

    Uninterruptible power supply USCA-02 Adapter for installing F-series option modules onto the UCU control unit. Related documents You can find manuals on the Internet. See below for the relevant code/link. For more documentation, go to www.abb.com/drives/documents. Manuals for ACS880 multidrives cabinets...

  • Page 15: Operation Principle And Hardware Description

    Each parallel module must have the output cabling of its own. ABB also recommends that you use identical cablings (cable type, cross-sectional area, and length) and have identical load for each module. For other solutions, contact ABB.
  • Page 16 16 Operation principle and hardware description This figure shows a simplified main circuit diagram of a DC/DC converter without a DC switch-disconnector or charging circuit. DC/DC converter cubicle Energy storage cabinet Drive DC bus DC/DC converter module Filter module Cabling between DC/DC converter unit and energy storage Energy storage disconnecting device Energy storage protective circuit breaker Energy storage...
  • Page 17 Operation principle and hardware description 17 This figure shows a simplified main circuit diagram of a DC/DC converter with the DC switch-disconnector (option +F286) and charging circuit. DC/DC converter cubicle Energy storage cabinet Drive DC bus DC switch-disconnector (option +F286) Charging components (with option +F286) DC/DC converter module Filter module...
  • Page 18 18 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. DC/DC converter cubicles Energy storage cabinet Drive DC bus DC switch-disconnector (option +F286)

  • Page 19: Overview Diagram Of A Drive With A Dc/Dc Converter Unit

    Operation principle and hardware description 19 Overview diagram of a drive with a DC/DC converter unit This diagram shows a possible application of a converter unit in an example system. The DC/DC converter unit includes a DC/DC converter module and a filter module. t°...

  • Page 20: Converter Unit Hardware

    20 Operation principle and hardware description Converter unit hardware Cabinet layout – Frame R7i converter module ￭ This figure shows an example converter unit cubicle. Sym- Item desig- Description nation Door closed Door open Door open and shrouds removed Q11.1 DC switch-disconnector handle (with option +F286) Q10.1 Charging switch handle (with option +F286)
  • Page 21 Operation principle and hardware description 21 T11.1 R7i DC/DC converter module A11.1 Charging controller (with option +F286) Control unit Swing-out frame (with BAMU voltage measurement unit [A7] on the other side) G115.10 Cooling fan Inlet manifold with stop and drain valves Outlet manifold with stop and drain valves Heat exchanger (behind shrouding) R13.1...

  • Page 22: Cabinet Layout - Frame R8I Converter Module

    22 Operation principle and hardware description Cabinet layout – Frame R8i converter module ￭ This figure shows an example converter unit cubicle. Sym- Item desig- Description nation Doors closed Doors open and shrouds removed Q11.1 DC switch-disconnector handle (with option +F286) Charging switch handle (with option +F286) P11.1…P13.1 Door lights:...
  • Page 23 Operation principle and hardware description 23 F13.xx Output DC fuses Q10.1 Charging switch shaft (with option +F286) T11.1 R8i DC/DC converter module R13.1 BDCL filter module Control unit Heat exchanger ES+, ES- Energy storage connection Inlet manifold with stop and drain valves Module cooling fans Auxiliary measurement unit Auxiliary measurement unit fuses...

  • Page 24: Converter Module Hardware

    24 Operation principle and hardware description Converter module hardware Frame R7i ￭ Module layout – Handle Lifting eye, front Locking screw (for 6 mm hex key). Torque: 5 N·m (3.7 lbf·ft) maximum. Coolant out connector Coolant in connector Connectors X50, X52 and X53; fiber optic connectors; LEDs; auxiliary voltage selector X59. Lifting ring, rear Guide pin DC connection busbars.

  • Page 25: Connectors X50, X52 And X53; Auxiliary Voltage Selector X59

    Operation principle and hardware description 25 Connectors X50, X52 and X53; Auxiliary voltage selector X59 R7i modules contain a power supply board that provides 24 V DC for the circuit boards of the module. The power supply board of the module is powered internally from the DC link. Auxiliary voltage input for internal power supply of module.

  • Page 26: Leds

    26 Operation principle and hardware description LEDs Color Indication FAULT Continuous red There is an active fault in the module. ENABLE / STO Continuous green The module is ready for use. ENABLE / STO Continuous yellow XSTO connectors are de-energized. POWER OK Continuous green Supply voltage of the internal circuit boards is OK (>...

  • Page 27: Coolant Connectors

    Operation principle and hardware description 27 Terminal block X50 (auxiliary power input for internal boards) Terminal block X51 and X52 (Safe torque off in inverter modules only) Terminal block X53 (24 V DC power output) Auxiliary voltage selector X59 (115 or 230 V) Unpainted fastening hole.

  • Page 28: Leds

    28 Operation principle and hardware description LEDs Color Indication FAULT Continuous red There is an active fault in the module. ENABLE / STO Continuous green The module is ready for use. ENABLE / STO Continuous yellow XSTO connectors are de-energized. POWER OK Continuous green Supply voltage of the internal circuit boards is OK (>...

  • Page 29: Bdcl Filter Module For Frame R8I Converter Module

    Operation principle and hardware description 29 BDCL filter module for frame R8i converter module ￭ Filter module, front Filter module, back Energy storage connection (DC+) Terminal block [X30], temperature control Unpainted grounding point Handle Type designation label of the module Quick connector Converter module connection Overheating protection of the filter...

  • Page 30: Overview Of The Control Connections Of The Bcu Control Unit

    30 Operation principle and hardware description Overview of the control connections of the BCU control unit Analog and digital I/O extension modules and Control panel. fieldbus communication modules can be in- serted into slots 1, 2 and 3. Memory unit Fiber optic links to power modules (inverter, supply, brake or converter) Slot 4 for RDCO-0x...

  • Page 31: Overview Of The Control Connections Of The Ucu Control Unit

    Operation principle and hardware description 31 Overview of the control connections of the UCU control unit This diagram shows the control connections and interfaces of the UCU control unit. Analog and digital I/O extension modules and Control panel fieldbus communication modules can be in- serted into slots 1, 2 and 3.

  • Page 32: Dc Switch-Disconnector

    32 Operation principle and hardware description DC switch-disconnector (option +F286) Charging switch (option +F286) Charging OK indicator, green (option +F286) DC/DC converter disconnected indicator, white (option +F286) Load disconnected indicator, white ACS-AP-W control panel (option +J400) DC switch-disconnector ￭ The DC switch-disconnector [Q11] is optional (option +F286). The DC switch-disconnector has an operating handle on the cabinet door.

  • Page 33: Control Panel [A59]

    Operation principle and hardware description 33 Control panel [A59] ￭ The control panel is the user interface of the unit. An example control panel is shown below. With the control panel, the user can: • start and stop the unit •...

  • Page 34: Type Designation Labels

    34 Operation principle and hardware description 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, applicable markings, type designation and serial number of the unit.
  • Page 35 Operation principle and hardware description 35 Example labels are shown below. Type designation Frame size Degree of protection UL/CSA data Ratings Valid markings. See ACS880 liquid-cooled multidrives cabinets and modules electrical planning instructions (3AXD50000048634 [English]). Serial number. The first digit of the serial number refers to the manufacturing plant. The next four digits refer to the unit's manufacturing year and week, respectively.

  • Page 36: Type Designation Label Of The Bdcl Filter Module

    Type designation label of the BDCL filter module ￭ Each filter module has a type designation label attached to it. Example labels are shown below. BDCL-13LC-7 Rev. A MADE IN FINLAND 566/707/976 V DC ABB Oy Hiomotie 13 550/550/400 A 00380 Helsinki Finland 3AXD50000889990 Liquid cooling IP00...

  • Page 37: Option Codes

    Operation principle and hardware description 37 Code Description 1607LC Construction: cabinet-installed liquid-cooled DC/DC converter unit. When no options are selected: Supply frequency 50 Hz, control voltage 230 V AC, IP42, EN/IEC industrial cabinet construction, power and control cabling through the bottom of the cabinet, DC busbar material tin plated copper, cable supply conductors, standard wiring material, ACS880 DC/DC converter control program, complete documentation in English on a memory stick.

  • Page 38: Type Designation Key Of The Converter Module

    38 Operation principle and hardware description Code Description G314 Aluminum busbars G315 Tin-plated copper DC busbars G320 Control (auxiliary) voltage 230 V AC G330 Halogen-free wiring and materials G338 Wire marking class A1 G339 Wire marking class A2 G340 Wire marking class A3 G341 Wire marking class B1 G342...

  • Page 39: Type Designation Key Of The Filter Module

    Operation principle and hardware description 39 Code Description Basic code ACS880 Product series 104LC Construction: Liquid-cooled inverter, supply, converter or brake module. Size xxxxx Refer to the ratings table in the technical data. Voltage range DC voltage corresponding AC input voltages 3 ~ 380…500 V. This is indicated in the type designation label as typical input voltage level 566 / 679 / 707 V DC.

  • Page 41: Mechanical Installation

    Mechanical installation 41 Mechanical installation Contents of this chapter This chapter gives information on the mechanical installation of the converter units. DC/DC converter units For instructions how to examine the installation site, move the unit and install the cabinet, refer to ACS880 liquid-cooled multidrives cabinets mechanical installation instructions (3AXD50000048635 [English]).

  • Page 43: Guidelines For Planning Electrical Installation

    Canadian Electrical Code (CE) along with state and local codes for your location and application. National Fire Protection Association 70 (National Electric Code). ABB is not responsible for the energy storage selection or protection of the energy storage. Generic guidelines...

  • Page 44: Selecting The Energy Storage

    = Drive input voltage (AC) • ABB recommends to measure the energy storage voltage. If the energy storage is a super capacitor, voltage measurement is obligatory unless the capacitor withstands the maximum DC voltage of the drive or contains internal overvoltage protection.

  • Page 45: Implementing Protections For The Energy Storage

    Energy storage discharging device ￭ When necessary, the customer (or the system integrator) must equip the energy storage with a discharging device. If the energy storage is a super capacitor, ABB recommends to install a discharging device.

  • Page 46: Implementing Earth Fault Protection

    Recommended cables ￭ The customer (or the system integrator) must acquire and connect the energy storage cables. It is possible to use shielded cables with 2, 3 or 4 conductors. ABB recommends to use shielded cables with 4 conductors.

  • Page 47: Typical Cable Sizes

    1) The shield must meet the requirements of IEC 61439-1. If the shield does not meet the requirements, an additional PE conductor or cable is required. ABB does not recommend to use single core cables. If it necessary to use single core cables, obey these guidelines: •...

  • Page 48: Parallel Connection

    48 Guidelines for planning electrical installation Parallel connection It is possible to connect multiple DC/DC converter units in parallel. In the parallel connection, both the inputs and the outputs of the units must be connected together. The inputs are connected through the common DC bus of the drive as standard. The outputs (ES+ to ES+, ES- to ES-) must be connected together at the energy storage end by the customer (or the system integrator).

  • Page 49: Electrical Installation

    Electrical installation 49 Electrical installation Contents of this chapter This chapter contains instructions on wiring the converter units. Note: The instructions do not cover all possible cabinet constructions and energy storage media. Safety WARNING! Obey the safety instructions given in ACS880 liquid-cooled multidrives cabinets and modules safety instructions (3AXD50000048633 [English]).
  • Page 50 50 Electrical installation WARNING! Obey these instructions. If you ignore them, injury or death, or damage to the equipment can occur. If you are not a qualified electrical professional, do not do installation or maintenance work. Do these steps before you begin any installation or maintenance work. Prepare for the work.

  • Page 51: Measuring The Insulation Resistance Of The Dc Cabling

    Electrical installation 51 DC voltage charging due to leakage capacitances of the motor circuit. This voltage can remain charged for a long time after the drive power-off. The measurement discharges the voltage. • Make sure that the voltage between the drive DC busbars and the grounding (PE) busbar is zero.

  • Page 52: Connecting The Energy Storage Cable And Load Disconnected Indicator Cable

    52 Electrical installation Energy storage Converter unit Connecting the energy storage cable and load disconnected indicator cable Use of fasteners in cable lug connections ￭ Use the bolts, nuts and washers delivered with the drive. Install all the fasteners in the correct order.

  • Page 53: Connection Diagram

    Electrical installation 53 Connection diagram ￭ If the converter unit has parallel modules, each module must have its own output cables. The cables must also be identical (cable type, cross-sectional area, and length must be the same). This diagram shows the connections between the DC/DC converter unit and an energy storage.
  • Page 54 54 Electrical installation plate (option +H358), refer also to the instruction of the related non-ABB installation accessories. For example, the Roxtec instructions or the instructions by the cable gland manufacturer. WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur.
  • Page 55 Electrical installation 55 WARNING! Apply grease to stripped aluminum conductors before you attach them to non-coated aluminum cable lugs. Obey the grease manufacturer’s instructions. Aluminum-aluminum contact can cause oxidation in the contact surfaces. For each cable, attach the conductive sleeve (a) to the bare cable shield with a cable tie.

  • Page 56: Connecting The Control Cables

    56 Electrical installation of fasteners in cable lug connections (page 52). Tighten the fasteners to the torque given in the technical data. 4-conductor shielded cable 3-conductor shielded cable If there are more than 3 cables, attach additional cable support brackets for them. 10.

  • Page 57: Grounding The Outer Shields Of The Control Cables 360° At The Cabinet Entry

    Electrical installation 57 Route the control cables as described in section Routing the control cables inside the cabinet (page 59). Connect the control cables as described in section Connecting control cabling (page 59). Grounding the outer shields of the control cables 360° at the cabinet entry Ground the outer shields of all control cables 360°...
  • Page 58 58 Electrical installation If the outer surface of the shield is non-conductive: • Cut the shield at the midpoint of the peeled part. Be careful not to cut the conductors or the grounding wire. • Turn the conductive side of the shield inside out over the insulation. •...

  • Page 59: Routing The Control Cables Inside The Cabinet

    Electrical installation 59 Routing the control cables inside the cabinet Use the existing trunking in the cabinet where possible. Use sleeving if cables are laid against sharp edges. When running cables to or from a swing-out frame, leave enough slack at the hinge to allow the frame to open fully. Connecting control cabling Connect the conductors to the appropriate terminals.

  • Page 60: Installing Option Modules

    60 Electrical installation The drawing below represents the grounding of the control cabling when connecting to a terminal block inside the cabinet. The grounding is done in the same way when connecting directly to a component such as the control unit. Installing option modules WARNING! Obey the safety instructions of the drive.

  • Page 61: Connecting A Pc

    Electrical installation 61 Note: The screw tightens the connections and grounds the module. It is essential for fulfilling the EMC requirements and for proper operation of the module. WARNING! Do not use excessive force, or leave the screw too loose. Over-tightening can cause damage to the screw or module.
  • Page 62 62 Electrical installation USB connected Stop Start Loc/Rem Start Stop Loc/Rem...

  • Page 63: The Control Unit

    The control unit 63 The control unit Contents of this chapter This chapter • describes the connections of the control unit • contains the specifications of the inputs and outputs of the control unit. General A BCU or UCU control unit controls the converter unit. The control unit is connected to the converter module(s) through fiber optic cables.

  • Page 64: Bcu Layout

    64 The control unit BCU layout Description I/O terminals (see following diagram) SLOT 1 I/O extension, encoder interface or fieldbus adapter module connection. (This is the sole location for an FDPI-02 diagnostics and panel interface.) SLOT 2 I/O extension, encoder interface or fieldbus adapter module connection SLOT 3 I/O extension, encoder interface, field-...
  • Page 65 The control unit 65 Description Analog inputs Analog outputs Digital inputs, Digital input interlock (DIIL) XRO3 XD24 XPOW XDIO Digital input/outputs XD2D Drive-to-drive link XRO2 XD24 +24 V output (for digital inputs) XDIO XETH Ethernet port – Not in use XPOW External power input XRO1...

  • Page 66: Ucu-22

    66 The control unit UCU-22…24 layout Description I/O terminals SLOT 1 I/O extension, encoder interface or fieldbus adapter module connection. For F-type modules with USCA-02 adapter. SLOT 2 I/O extension, encoder interface or fieldbus adapter module connection. For F-type modules with USCA-02 adapter. SLOT 3 I/O extension, encoder interface or fieldbus adapter module connection.
  • Page 67 The control unit 67 Description Analog input XRO4 XD24 XPOW Analog output XCAN Not in use XRO3 XCAN TERM CAN bus termination switch XDIO Digital input XDIO Digital input/output XRO2 XD2D Drive-to-drive link XD24 +24 V output (for digital input) XRO1 XETH1 Ethernet ports for fieldbus, internal switch...
  • Page 68 68 The control unit Description XFSO Not in use Environmental Humidity and temperature measurements sensors (1) XFSO...

  • Page 69: Default I/O Diagram Of The Converter Control Unit (Bcu)

    The control unit 69 Default I/O diagram of the converter control unit (BCU) The diagram below shows the default I/O connections of the BCU control unit of the converter, and describes the use of the signals/connections. Under normal circumstances, the factory-made wiring should not be changed. The wire size accepted by all screw terminals (for both stranded and solid wire) is 0.5 …...
  • Page 70 70 The control unit Terminal Description Digital inputs Temp fault (0 = overtemperature) Not in use by default Not in use by default Not in use by default Not in use by default Not in use by default DIIL Not in use by default XDIO Digital input/outputs DIO1...

  • Page 71: Default I/O Diagram Of The Converter Control Unit (Ucu-22

    The control unit 71 Terminal Description X205 Memory unit connection 1) Must be set to ON when the unit is the first or last unit on the drive-to-drive (D2D) link. On intermediate units, set termination to OFF. 2) Default use of the signal in the control program. The use can be changed by a parameter. See also the delivery-specific circuit diagrams.
  • Page 72 72 The control unit Terminal Description XCAN TERM CANopen termination switch XRO1 Relay output 1 Norm. closed XRO1: Not in use COM1 Common 250 V AC / 30 V DC, 2 A Norm. open XRO2 Relay output 2 Norm. closed XRO2: Fault (-1) (Energized = no fault) COM2...
  • Page 73 The control unit 73 Terminal Description +24VD +24 V DC 200 mA DICOM Digital input ground +24VD +24 V DC 200 mA DIGND Digital input/output ground Ground selection switch. Determines whether DICOM is separated from DICOM=DIOGND DIOGND (ie, common reference for digital inputs floats). ON: DICOM con- nected to DIOGND.

  • Page 74: Additional Information On The Connections

    74 The control unit Additional information on the connections Power supply for the control unit (XPOW) ￭ The control unit is powered from a 24 V DC, 2 A supply (ZCU, BCU) or a 24 V DC, 2.9 A supply (UCU) through terminal block XPOW. With a type BCU/UCU control unit, a second supply can be connected to the same terminal block for redundancy.

  • Page 75: Safe Torque Off (Xsto, Xsto Out)

    The BCU control unit has an on-board data logger that collects real-time data from the power modules 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 ABB service personnel.

  • Page 76: Connector Data

    76 The control unit Connector data Power supply (XPOW) Connector pitch 5 mm, wire size 0.5 … 2.5 mm (22…12 AWG) Maximum tightening torque 0.45 N·m (4 lbf·in) 24 V (±10%) DC, 2 A (BCU) 19…32 V DC, 2.9 A (UCU-22…24) External power input.
  • Page 77 The control unit 77 Reference voltage for analog inputs Connector pitch 5 mm, wire size 0.5 … 2.5 mm (22…12 AWG) +VREF and -VREF (XAI:1 and XAI:2) Maximum tightening torque 0.45 N·m (4 lbf·in) 10 V ±1% and -10 V ±1%, R 1…10 kohm load Maximum output current: 10 mA...
  • Page 78 78 The control unit Safe torque off connection (XSTO) Connector pitch 5 mm, wire size 0.5 … 2.5 mm (22…12 AWG) Maximum tightening torque 0.45 N·m (4 lbf·in) Input voltage range: -3…30 V DC Logic levels: "0" < 5 V, "1" > 17 V. Note: For the unit to start, both connections must be “1”.

  • Page 79: Bcu Ground Isolation Diagram

    The control unit 79 BCU ground isolation diagram ￭ XPOW +24VI +24VI +VREF -VREF AGND AI1+ AI1- AI2+ AI2- AGND AGND XD2D BGND SHIELD XRO1, XRO2, XRO3 XD24 +24VD DICOM +24VD DIOGND XDIO DIO1 DIO2 DIOGND DIOGND DIIL XSTO SGND XSTO OUT SGND SGND...

  • Page 80: Ucu-22

    80 The control unit UCU-22…24 ground isolation diagram ￭ XPOW XD2D X485 XCAN XETH1 XETH2 XETH3 XETH4 XPAN XRO1-XRO4 COM1 … COM4 XD24 +24VD DICOM +24VD DIOGND XDIO DIO1 DIO2 DIOGND DIOGND DIIL XSTO XSTO OUT Power supply ground *The maximum common mode voltage between each AI input and AGND is ±30 V **Ground selector (DICOM=DIOGND) settings DICOM=DIOGND: ON All digital inputs share a common ground (DICOM connected to DIOGND).

  • Page 81: Installation Checklist

    Installation checklist 81 Installation checklist Contents of this chapter This chapter contains a checklist for the mechanical and electrical installation of the drive. Checklist Examine the mechanical and electrical installation of the drive before start-up. Go through the checklist together with another person. WARNING! Obey the safety instructions of the drive.
  • Page 82 82 Installation checklist Make sure that … If the drive is connected to a network other than a symmetrically grounded TN-S system: You have done all the required modifications (for example, you may need to disconnect the EMC filter or ground-to-phase varistor) See the electrical installation instructions in the supply unit manual. There is an adequately sized protective earth (ground) conductor(s) between the drive and the switchboard, the conductor is connected to correct terminal, and the terminal is tightened to the correct torque.

  • Page 83: Start-Up

    (3AXD50000048633 [English]). Before you start, connect a control panel to the DC/DC converter unit. ABB recommends that you also have a PC with a drive commissioning tool (Drive Composer) connected. For information on the use of the control panel, refer to...

  • Page 84: Start-Up Procedure

    84 Start-up Start-up procedure Tasks Safety WARNING! Obey the safety instructions during the start-up procedure. See ACS880 liquid- cooled multidrives cabinets and modules safety instructions (3AXD50000048633 [English]). If you ignore the safety instructions, injury or death, or damage to the equipment can occur.
  • Page 85 Start-up 85 Tasks WARNING! When you connect voltage to the supply unit, the DC busbars and the converters connected to the DC bus will become energized. WARNING! Converter units with a DC switch-disconnector: Some types of converter modules can be energized through a charging circuit even if the DC switch-disconnector is open or the DC fuses are removed.
  • Page 86 86 Start-up Tasks Close the energy storage protective circuit breaker (customer or system integrator-installed device). Testing the DC/DC converter operation Set parameter 120.12 Run enable 1 to On. Set parameter 122.01 User Power ref to 0 A. Set current limits to low values, for example, •...

  • Page 87: Maintenance

    Contents of this chapter This chapter instructs how to maintain the DC/DC converter unit. The information is valid for cabinet-installed ACS880-1607LC DC/DC converter units. Maintenance intervals The tables below show the maintenance tasks which can be done by the end user. For ABB Service offering, refer to www.abb.com/drivesservices...
  • Page 88 Tightness of terminals Dustiness, corrosion and temperature Cooling liquid pipe connections Coolant antifreeze concentration Other ABB-SACE Air circuit breaker maintenance ABB Contactors maintenance Recommended every 2nd year actions by the user Inspection of coolant quality Inspection of expansion tank air pressure...

  • Page 89: Maintenance Timers And Counters

    • 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. • Long term operation near the specified maximum ratings or ambient conditions may require shorter maintenance intervals for certain components.

  • Page 90: Disconnecting The Dc/Dc Converter From The Drive System With The Dc Switch-Disconnector

    Push the Start key on the control panel. Liquid pipe connector installation instructions These instructions are applicable to the liquid pipe connectors that are used in ABB drives. There are two types of connectors: type A and type B. Refer to the illustrations...
  • Page 91 Maintenance 91 below. When you install a connector, identify the connector type first. Obey the type-specific instructions carefully. Reserve these materials and tools at hand: • LOCTITE 2700 threadlocker • Torque wrench (size depends on the connector size) • For the type B connector: adjustable pliers Type A Type B WARNING!
  • Page 92 92 Maintenance Push the screwing plug over the pipe, and place the pipe on the union nut. Pull down the screwing plug. a) Type A connector: Start to screw the plug in by hand. Tighten the plug with a torque wrench to 20 N·m. b) Type B connector: Start to screw the plug in by hand.

  • Page 93: Fuses

    Maintenance 93 Fuses Checking and replacing the fuses – frame R7i ￭ Replacing a converter fuse WARNING! Obey the safety instructions given in ACS880 liquid-cooled multidrives cabinets and modules safety instructions (3AXD50000048633 [English]). If you ignore the safety instructions, injury or death, or damage to the equipment can occur.

  • Page 94: Replacing An Output Fuse

    94 Maintenance Loosen the two nuts on the studs attached to the fuse. Slide the fuse block out. Remove the studs, nuts and washers from the fuse and install them to the new fuse. Make sure that you install the washers in the original order. Torque the nuts as follows: •...
  • Page 95 Maintenance 95 Stop the drive and do the steps in section Electrical safety precautions (page 49) before you start the work. Open the cubicle door. Remove the screws that hold the swing-out frame closed. Then open the frame. Loosen the two nuts on the studs attached to the fuse. Slide the fuse block out. Remove the studs, nuts and washers from the fuse and install them to the new fuse.

  • Page 96: Checking And Replacing The Fuses - Frame R8I

    96 Maintenance Torque the nuts as follows: • Bussmann fuses: 50 N·m (37 lbf·ft) • Other: Refer to the fuse manufacturer's instructions. Close the swing-out frame and install the screws. Checking and replacing the fuses – frame R8i ￭ The DC/DC converter unit has two sets of fuses: output fuses on the energy storage side and fuses on the DC bus side.

  • Page 97: Fans

    Reset the running time signal after fan replacement. See also CIO-01 I/O module for distributed I/O bus control user's manual (3AXD50000126880 [English]). Replacement fans are available from ABB. Do not use other than ABB-specified spare parts.

  • Page 98: Frame R7I Cabinet Fan Replacement

    98 Maintenance Frame R7i cabinet fan replacement ￭ WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. If you are not a qualified electrical professional, do not do installation, commissioning or maintenance work.

  • Page 99: Frame R7I - Internal Module Fan Replacement

    Maintenance 99 Remove the screws (a) that hold the finger guard (b) and fan (c) to the fan mounting plate (d). Assemble the fan assembly with a new fan. The airflow direction of the fan must be up. Install the fan assembly into the cubicle Connect the fan wiring.

  • Page 100: Frame R8I Fan Replacement

    100 Maintenance WARNING! Use the required personal protective equipment. Wear protective gloves and long sleeves. Some parts have sharp edges. Stop the drive and do the steps in section Electrical safety precautions (page 49) before you start the work. Detach and move aside the wiring in front of the module. Remove the four screws that hold the faceplate of the module.

  • Page 101: R7I Converter Module

    Maintenance 101 WARNING! Use the required personal protective equipment. Wear protective gloves and long sleeves. Some parts have sharp edges. Stop the drive and do the steps in section Electrical safety precautions (page 49) before you start the work. Remove any shrouding in front of the cooling fan in case of marine construction (option +C121).

  • Page 102: Removing The Module

    102 Maintenance WARNING! Stop the pumps and drain the coolant before you do work on the liquid cooling system. There is high-pressure hot coolant (6 bar, max. 50 °C) in the cooling circuit when it is in operation. WARNING! Use the required personal protective equipment. Wear protective gloves and long sleeves.

  • Page 103: Installing The Module

    Maintenance 103 Installing the module ￭ Install the module as follows: Push the module carefully into its bay. Install the module retaining screws and torque them to 5 N·m (3.6 lbf·ft). Connect the coolant pipes to the module. Tighten to 20 N·m (14.75 lbf·ft). Connect the power and control cables to the module.

  • Page 104: R8I Converter Module

    104 Maintenance R8i converter module Replacing an R8i converter module ￭ WARNING! Obey the safety instructions given in ACS880 liquid-cooled multidrives cabinets and modules safety instructions (3AXD50000048633 [English]). If you ignore the safety instructions, injury or death, or damage to the equipment can occur.

  • Page 105: Removing The Module

    Maintenance 105 Removing the module Do the steps in section Electrical safety precautions (page 49). Assemble the service platform delivered with the drive. Refer to section Assembling the service platform (page 104). Remove the shrouding in front of the module. Remove the locking screws of the swing-out frame (if present) and open it.
  • Page 106 106 Maintenance Remove the L-shaped DC busbars at the top of the module. Make note of the orientation of the screws as well as the order of the washers. Close the inlet valve (a) and outlet valve (located on the right-hand side of the cubicle).
  • Page 107 Maintenance 107 After the module has drained, disconnect the piping from the module. Remove the module retaining screws at the top and the bottom of the module.

  • Page 108: Reinstalling The Module

    Capacitor life can be extended by decreasing the surrounding air temperature. Capacitor failure is usually followed by damage to the unit and an input cable fuse failure, or a fault trip. If you think that any capacitors in the drive have failed, contact ABB.

  • Page 109: Reforming The Capacitors

    Maintenance 109 Reforming the capacitors ￭ The capacitors must be reformed if the drive has not been powered (either in storage or unused) for a year or more. The manufacturing date is on the type designation label. For information on reforming the capacitors, refer to Capacitor reforming instructions (3BFE64059629 [English]).

  • Page 110: Replacing The Memory Unit (Ucu-22

    110 Maintenance Replacing the memory unit (UCU-22…24) ￭ WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. If you are not a qualified electrical professional, do not do installation, commissioning or maintenance work.

  • Page 111: Replacing The Bcu Control Unit Battery

    Maintenance 111 Replacing the BCU control unit battery ￭ WARNING! Obey the safety instructions given in ACS880 liquid-cooled multidrives cabinets and modules safety instructions (3AXD50000048633 [English]). If you ignore the safety instructions, injury or death, or damage to the equipment can occur. If you are not a qualified electrical professional, do not do installation or maintenance work.

  • Page 112: Replacing The Microsdhc Memory Card (Ucu-22

    112 Maintenance Note: The real-time clock stays set for 2 minutes without battery. Close the battery cover. Set the real-time clock if necessary. Dispose of the old battery according to local disposal rules or applicable laws. Replacing the microSDHC memory card (UCU-22…24) ￭...

  • Page 113: Leds And Other Status Indicators

    Maintenance 113 LEDs and other status indicators This section gives information on how to read the status indications of the DC/DC converter. The control panel on the cabinet door shows the warnings and faults given by the control program. You can also use the Drive Composer PC tool to view the warnings and faults.

  • Page 114: Converter Unit Leds

    114 Maintenance Converter unit LEDs ￭ The converter unit cabinet has 1…3 door lamps. The indications are given in this table. Color Indication (When the LED is on) Charging OK indic- Green The DC bus of the converter modules is charged. The unit is ator ready for connection to the common DC bus.

  • Page 115: Internal Cooling Circuit

    Each cubicle has an inlet and an outlet manifold, fitted with a stop valve and a drain valve. The stop valves can be closed to isolate all modules in the cubicle from the main cooling circuit. In cabinet line-ups built by ABB, valves are color-coded: • Blue – Open during operation •...
  • Page 116 116 Internal cooling circuit Supply modules. The drawing shows the configuration of a diode supply unit with two modules, ie. there is a common air-to-liquid exchanger in the cubicle. With an IGBT supply unit, each module has a dedicated air-to-liquid exchanger as shown for item 2. Inverter modules To/From cooling unit Air-to-liquid heat exchanger...

  • Page 117: Connection To A Cooling Unit

    Internal cooling circuit 117 Connection to a cooling unit Connection to an ACS880-1007LC cooling unit ￭ Refer to ACS880-1007LC cooling unit user’s manual (3AXD50000129607 [English]). Connection to a custom cooling unit ￭ General requirements Equip the system with an expansion vessel to damp pressure rise due to volume changes when the temperature varies.

  • Page 118: Filling Up And Bleeding The Internal Cooling Circuit

    118 Internal cooling circuit Filling up and bleeding the internal cooling circuit Both the drive and coolant must be at room temperature before filling up the cooling circuit. WARNING! Make sure that the maximum permissible operating pressure is not exceeded. When necessary regulate the pressure to appropriate level by draining excess coolant out of the system.

  • Page 119: Draining The Internal Cooling Circuit

    Internal cooling circuit 119 Close the bleed valve at the cooling unit. 10. Continue to fill in coolant until a base pressure of approximately 250 kPa is achieved. 11. Open the bleed valve of the pump to let out any air. 12.

  • Page 120: Technical Data

    Coolant type Antifrogen® L (by Clariant International Ltd, www.clariant.com) 25% or 50% mixture, available from Clariant distributors and ABB Service representatives. Do not dilute the coolant. It is ready to use. Antifrogen® L 25% mixture is usable in storage temperatures down to -16 °C (3.2 °F).
  • Page 121 Internal cooling circuit 121 be derated by 6 percentage points per 1 °C (1.8 °F) temperature increase, as shown by curve (c). • If there are no components with a maximum operating temperature of 55 °C (131 °F) installed in the same space as the drive modules, drive output current must be derated by 2 percentage points per 1 °C (1.8 °F) temperature increase, as shown by curve (b).

  • Page 122: Pressure Limits

    122 Internal cooling circuit Pressure limits ￭ Base pressure: 250 kPa (recommended); 300 kPa (maximum). “Base pressure” denotes the pressure of the system compared with the atmospheric pressure when the cooling circuit is filled with coolant. Air counterpressure in expansion vessel (with ACS880-1007LC cooling unit): 80 kPa Design pressure (PS): 600 kPa Nominal pressure difference: 120 kPa with Antifrogen®...

  • Page 123: Technical Data

    Technical data 123 Technical data Contents of this chapter This chapter contains the technical data for the DC/DC converter units. Ratings No-overload use ACS880- DC input rms out- contmax contmax max output SW out Frame 1607LC-… A (DC) A (DC) A (DC) = 500 V 0150A-5...
  • Page 124 124 Technical data No-overload use ACS880- DC input rms out- contmax contmax max output SW out Frame 1607LC-… A (DC) A (DC) A (DC) 0400A-7 12000 0500A-7 12000 0600A-7 12000 0700A-7 12000 0800A-7 1000 12000 0900A-7 1060 1125 12000 1000A-7 2×R8i 1000 1178...

  • Page 125: Derating

    Technical data 125 Short time overload use Heavy overload use ACS880- Frame short time short time 1607LC-… 1400A-7 2×R8i 1058 1600A-7 2×R8i 1209 1062 1800A-7 2×R8i 1124 1360 1195 Nominal supply voltage of the drive Maximum continuous DC input current from DC bus DC input Maximum continuous output current to/from energy storage rms output...

  • Page 126: Altitude Derating

    For a more accurate derating, use the DriveSize PC tool. For coolant derating, refer to section Temperature limits (page 120). Type equivalence table Converter unit type Basic module type BDCL filter ACS880-1607LC-… ACS880-104LC-… Frame size Type = 500 V 0150A-5 0120A-5 BDCL-13LC-7...

  • Page 127: Fuses

    Technical data 127 Converter unit type Basic module type BDCL filter ACS880-1607LC-… ACS880-104LC-… Frame size Type 1200A-7 0600A-7 BDCL-15LC-7 1400A-7 0670A-7 BDCL-15LC-7 1600A-7 0750A-7 BDCL-15LC-7 1800A-7 0850A-7 BDCL-15LC-7 Fuses DC fuses ￭ These fuses are used on the DC bus side and on the energy storage side.

  • Page 128: Bamu Unit Fuses

    128 Technical data BAMU unit fuses ￭ The BAMU voltage/current measurement unit (option +G442) typically has one of these protection devices: • a miniature circuit breaker of type S804S-UCB10 (IEC), or • two fuses of type 1021 CP URB 27X60/32 (UL) For the actual type of protection, refer to the documentation delivered with the drive.

  • Page 129: Free Space Requirements

    Technical data 129 Width Depth Weight Height ACS880- Frame 1607LC-… 1400A-7 2×R8i 2010 1600 1425 1600A-7 2×R8i 2010 1600 1425 1800A-7 2×R8i 2010 1600 1425 1) The top power cable entry (option +H351) increases height (+50 mm) and width (+300 mm) Free space requirements Free space requirements ￭...
  • Page 130 130 Technical data ACS880- Frame Noise Losses Effi- 1607LC-… ciency (con- loss (filter) total loss loss verter) 0399A-7 98.9 0599A-7 2xR7i 99.0 0799A-7 2xR7i 98.9 0400A-7 98.8 0500A-7 98.8 0600A-7 98.8 0700A-7 98.8 0800A-7 98.8 0900A-7 98.8 1000A-7 2×R8i 11.2 98.7 1200A-7 2×R8i...

  • Page 131: Tightening Torques

    Technical data 131 Pressure Coolant volume Coolant flow rate loss ACS880- Power Power Frame 1607LC-… mod- Filter Cabinet Total mod- Filter(s) Total ule(s) ule(s) l/min l/min l/min 0599A-7 2×R7i 0799A-7 2×R7i Pressure Coolant volume Coolant flow rate loss ACS880- Power Power Power Frame...

  • Page 132: Mechanical Connections

    Input power (DC bus) connection Voltage ( U ACS880-1607LC-xxxxx-5 = 566…707 V DC. This is indicated in the type desig- nation label as typical input voltage levels 566 / 679 / 707 V DC. ACS880-1607LC-xxxxx-7 = 742…976 V DC. This is indicated in the type desig- nation label as typical input voltage levels 742 / 849 / 976 V DC (849 V DC for UL/CSA).

  • Page 133: Typical Power Cable Sizes

    Technical data 133 Output terminals, cabin- See the dimension drawings. Maximum energy stor- 100 m (328 ft) age cable length Typical power cable sizes The tables below give the current carrying capacity ( I ) and typical size for copper Lmax and aluminum cables with PVC or XLPE insulation.

  • Page 134: Control Accuracy - Current And Voltage Control Performance Data

    134 Technical data Conductor cross-sec- PVC insulation XLPE insulation Typical dimensions of alumin- tion (aluminum) um cable Conductor temperat- Conductor temperat- ure 70° ure 90° AWG / Time Time Size ø [mm] Lmax Lmax kcmil const. (s) const. (s) 2042 1881 3 ×...

  • Page 135: Ambient Conditions

    Technical data 135 Ambient conditions This section gives the environmental requirements for the converter module. The converter module must be used in a heated indoor controlled environment. Operation installed for Storage in protective Transportation in pro- stationary use package tective package Altitude above sea level 0…4000 m (13123 ft)* Output derated above...

  • Page 136: Colors

    136 Technical data Operation installed for Storage in protective Transportation in pro- stationary use package tective package Vibration IEC 61800-5-1 IEC/EN 60721-3-1:1997 IEC/EN 60721-3-1:1997 IEC 60068-2-6:2007, EN 60068-2-6:2008 Envir- onmental testing Part 2: Tests -Test Fc: Vibration (sinusoidal) 10 … 57 Hz, max. 0.075 mm amplitude 57 …...

  • Page 137: Manuals

    Substances of Concern In articles as such or in complex objects (Products) established under the Waste Framework Directive (2008/98/EC). For further information, contact your local ABB distributor or consult European Chemicals Agency's SCIP database to find out which SVHCs are used in the drive, and to find out where those components are located.

  • Page 138: Disclaimers

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

  • Page 139: Dimension Drawings

    Dimension drawings 139 Dimension drawings Contents of this chapter 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 140: Dc/Dc Converter Unit With 1×R7I Converter Module

    140 Dimension drawings DC/DC converter unit with 1×R7i converter module...
  • Page 141 Dimension drawings 141...

  • Page 142: Dc/Dc Converter Unit With 1×R8I Converter Module

    142 Dimension drawings DC/DC converter unit with 1×R8i converter module...
  • Page 143 Dimension drawings 143...

  • Page 144: Location And Size Of Energy Storage Connection Terminals - Frame R7I

    144 Dimension drawings Location and size of energy storage connection terminals – Frame R7i...

  • Page 145: Location And Size Of Energy Storage Connection Terminals - Frame R8I

    Dimension drawings 145 Location and size of energy storage connection terminals – Frame R8i...
  • Page 147 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/contact-centers.
  • Page 148 3AXD50000431342C © Copyright 2023 ABB. All rights reserved. Specifications subject to change without notice.

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