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

ABB ACS880-1607 Hardware Manual

Dc/dc-converter units
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ABB INDUSTRIAL DRIVES
ACS880-1607 DC/DC-converter units
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Summary of Contents for ABB ACS880-1607

  • Page 1 — ABB INDUSTRIAL DRIVES ACS880-1607 DC/DC-converter units Hardware manual...
  • Page 3 ACS880-1607 DC/DC-converter units Hardware manual Table of contents 3. Mechanical installation 5. Electrical installation 9. Start-up 3AXD50000023644 Rev D Original instructions EFFECTIVE: 2024-06-14...

  • 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 4 Guidelines for planning electrical installation Contents of this chapter ............... . Limitation of liability .
  • Page 7 Table of contents 7 Safe torque off (XSTO, XSTO OUT) ............MicroSDHC memory card slot .
  • Page 8 Cabinets with ABB air outlet kits ........
  • Page 9 Table of contents 9 Ambient conditions ................Colors .

  • Page 11: 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 ACS880-1607 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 Cabling between DC/DC-converter unit and energy storage...
  • 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 ￭ The DC/DC-converter cubicle includes a converter module, a BDCL filter module and a BCU or UCU control unit. Each converter is equipped with dedicated DC fuses. A DC switch-disconnector is optional (option +F286) but commonly used.
  • Page 21 Operation principle and hardware description 21 Charging switch [Q10.1] shaft X33.1 Connection from the energy storage disconnecting device to the load disconnected indicator [P13.x] T22.1 24 V DC power supply Q26.1 Contactor for filter fan control Control panel P11.1…P13.1 Door lights: Charging OK ([P11.x], green), DC/DC-converter disconnected ([P12.x], white), Load disconnected ([P13.x], white) Q11.1 DC switch-disconnector (option +F286) handle...

  • Page 22: Converter Module Hardware

    22 Operation principle and hardware description F11.xx DC fuses (DC bus side) X33.1 Connection from the energy storage disconnecting device to the load disconnected indicator [P13.x] T22.1 24 V DC power supply Q26.1 Contactor for filter fan control P13.1 Door light: Load disconnected ([P13.x], white) Converter module hardware Frame R8i layout ￭...

  • Page 23: Bdcl Filter Module

    Operation principle and hardware description 23 Type designation label Terminal block [X50] (power supply for internal boards and module heating element, option +C183; DOL fan supply, option +C188) Connectors [X51], [X52], [X53] The unpainted grounding point (PE) between module frame and cabinet frame. Lifting eyes Circuit board compartment fan BDCL filter module...

  • Page 24: Control Unit

    24 Operation principle and hardware description Terminal block [X30] (module DOL fan supply, option +C188) Type designation label of the module The unpainted grounding point Lifting eyes Control unit DC/DC-converter units use a UCU or BCU control unit. The control unit has inputs, outputs, and slots for option modules.

  • Page 25: Overview Of The Control Connections Of The Bcu Control Unit

    Operation principle and hardware description 25 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 module...

  • Page 26: Converter Unit Control Devices

    26 Operation principle and hardware description Converter unit 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. DC switch-disconnector (option +F286) Charging switch (option +F286) Charging OK indicator, green (option +F286) DC/DC converter disconnected indicator, white (option +F286)

  • Page 27: Control Panel [A49]

    Operation principle and hardware description 27 The charging OK indicator ([P11], green) and DC/DC converter disconnected indicator ([P12], white) are installed when the converter has the DC switch-disconnector (option +F286). Control panel [A49] ￭ The control panel is the user interface of the unit. An example control panel is shown below.

  • Page 28: Type Designation Labels

    28 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 29: Type Designation Labels Of The Dc/Dc-Converter Module

    Operation principle and hardware description 29 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 module. Example labels are shown below.

  • Page 30: Type Designation Label Of The Bdcl Filter Module

    30 Operation principle and hardware description Type designation label of the BDCL filter module ￭ Each filter module has a type designation label attached to it. An example label is shown below. ABB Oy Hiomotie 13 00380 Helsinki Finland Description...

  • Page 31: Option Codes

    Operation principle and hardware description 31 Code Description Voltage range DC voltage corresponding AC input voltages 3 ~ 380…415 V. This is indicated in the type designation label as typical input voltage level 566 V DC. 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 32: Type Designation Key Of The Converter Module

    32 Operation principle and hardware description Code Description H367 Control cabling through floor of cabinet H368 Control cabling through roof of cabinet J400 ACS-AP-W control panel (with Bluetooth) J410 Control panel mounting platform J425 ACS-AP-I control panel (without Bluetooth) K450 Panel bus (control of several units from one control panel) K451 FDNA-01 DeviceNet™...
  • Page 33 Operation principle and hardware description 33 The subcodes are described below. Code Description Basic codes ACS880 Product series Construction: 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…415 V. This is indicated in the type designation label as typical input voltage level 566 V DC.

  • Page 34: Type Designation Key Of The Filter Module

    34 Operation principle and hardware description Type designation key of the filter module ￭ The type designation contains information on the specifications and configuration of the filter module. The digits express the module type. The optional selections are given thereafter, separated by plus signs. Code Description Basic code...

  • Page 35: Mechanical Installation

    Mechanical installation 35 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 multidrives cabinets mechanical installation instructions (3AUA0000101764 [English]).

  • Page 37: 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 38: 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 39: 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 40: 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 41: 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 42: Parallel Connection

    42 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 43: Electrical Installation

    Electrical installation 43 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 multidrives cabinets and modules safety instructions (3AUA0000102301 [English]).
  • Page 44 44 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 45: Measuring The Insulation Resistance Of The Dc Cabling

    Electrical installation 45 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. • Make sure that the voltage between the energy storage terminals of the DC/DC converter unit (ES+ and ES-) and the grounding (PE) busbar is zero.

  • Page 46: Connecting The Energy Storage Cable And Load Disconnected Indicator Cable

    46 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 47: Connection Diagram

    Electrical installation 47 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 48: Connection Procedure Of The Energy Storage Cables

    Roxtec cable entry plate (option +H394), or cable gland 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.

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

    Electrical installation 49 A cable entry with 360° grounding of the cable shield. Connection procedure of the load disconnected indicator cable ￭ WARNING! Obey the safety instructions given in ACS880 multidrives cabinets and modules safety instructions (3AUA0000102301 [English]). If you ignore the safety instructions, injury or death, or damage to the equipment can occur.

  • Page 50: Grounding The Outer Shields Of The Control Cables 360° At The Cabinet Entry

    50 Electrical installation Stop the drive (if running) and do the steps in section Electrical safety precautions (page 43) before you start the work. Put the control cables into the cabinet as described in section Grounding the outer shields of the control cables 360° at the cabinet entry (page 50).
  • Page 51 Electrical installation 51 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 52: Routing The Control Cables Inside The Cabinet

    52 Electrical installation 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 53: Installing Option Modules

    Electrical installation 53 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 54: Connecting A Pc

    54 Electrical installation 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 55 Electrical installation 55 USB connected Stop Start Loc/Rem Start Stop Loc/Rem...

  • Page 57: Control Unit (Ucu)

    14 power module connections. The UCU control units have integrated branching unit functionality for collecting and storing real-time data from the power modules to help fault tracing and analysis. The data is stored on a memory card which can be analyzed by ABB service personnel.

  • Page 58: Layout

    58 Control unit (UCU) Layout The figures below show an example UCU-24 control unit. Description I/O terminals SLOT 1 I/O extension, encoder interface or fieldbus SLOT 2 adapter module connection. For F-type modules with USCA-02 adapter. SLOT 3 SLOT 4 RDCO-0x DDCS communication option module connection UMU-01 memory unit connection.
  • Page 59 Control unit (UCU) 59 Description Analog input Analog output XCAN Not in use XCAN TERM CAN bus termination switch Digital input XDIO Digital input/output XD2D Drive-to-drive link XD24 +24 V output (for digital input) XETH1 Ethernet ports for fieldbus, internal switch XETH2 XETH3 Ethernet ports for tool communication, internal...
  • Page 60 60 Control unit (UCU) Description XFSO Not in use Humidity and temperature measurements XFSO...

  • Page 61: Default I/O Diagram Of The Converter Control Unit

    Control unit (UCU) 61 Default I/O diagram of the converter control unit The table below shows the default I/O connections of the UCU control unit of the converter. Under normal circumstances, the factory-made wiring should not be changed. Terminal Description XD2D Drive-to-drive link Not supported in DC/DC converter units...
  • Page 62 62 Control unit (UCU) Terminal Description XRO4 Relay output 4 Norm. closed XRO4: Not supported COM4 Common 250 V AC / 30 V DC, 2 A Norm. open XSTO Safe torque off input connection SGND XSTO: STO1 and STO2 are connected to OUT at the factory. To enable start and operation, STO1 and STO2 must be connected to OUT.

  • Page 63: Additional Information On The Connections

    Control unit (UCU) 63 Terminal Description Analog inputs, reference voltage output 10 V DC, R +VREF 1…10 kohm -VREF -10 V DC, R 1…10 kohm AGND Ground AI1+ Not in use by default. 0(2)…10 V, R > 200 kohm AI1- AI2+ Not in use by default.

  • Page 64: Digital Interlock (Diil)

    The data is stored onto the microSDHC memory card inserted into the UMU-01 memory unit and can be analyzed by ABB service personnel. Connector data The wire size accepted by all screw terminals (for both stranded and solid wire) is 0.5 …...
  • Page 65 Control unit (UCU) 65 +24 V output (XD24:2 and XD24:4) Total load capacity of these outputs is 4.8 W (200 mA / 24 V) minus the power taken by DIO1 and DIO2. Digital inputs DI1…DI6 24 V logic levels: “0” < 5 V, “1” > 15 V (XDI:1…XDI:6) : 2.0 kohm Input type: NPN/PNP (DI1…DI5), PNP (DI6)
  • Page 66 66 Control unit (UCU) CAN connection (XCAN) Termination by switch (XCAN TERM) This connection is not supported by the ACS880 control programs. Safe torque off connection (XSTO) Input voltage range: -3…30 V DC Logic levels: "0" < 5 V, "1" > 17 V. Note: Both circuits must be closed to enable start and operation (STO1 and STO2 must be connected to OUT).

  • Page 67: Ground Isolation Diagram

    Control unit (UCU) 67 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 69: Control Unit (Bcu)

    12 power module connections. The BCU control units have integrated branching unit functionality for collecting and storing real-time data from the power modules to help fault tracing and analysis. The data is stored on a memory card which can be analyzed by ABB service personnel.

  • Page 70: Layout

    70 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 71 Control unit (BCU) 71 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 72: Default I/O Diagram Of The Converter Control Unit

    72 Control unit (BCU) Default I/O diagram of the converter control unit The table below shows the default I/O connections of the BCU control unit of the converter. Under normal circumstances, the factory-made wiring should not be changed. Terminal Description XD2D Drive-to-drive link Not supported in DC/DC converter units...
  • Page 73 Control unit (BCU) 73 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. DIIL is connected to XD24:5 at the factory. XDIO Digital input/outputs DIO1...

  • Page 74: Additional Information On The Connections

    The 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 75: Connector Data

    Control unit (BCU) 75 Connector data The wire size accepted by all screw terminals (for both stranded and solid wire) is 0.5 … 2.5 mm (22…12 AWG). Connector pitch is 5 mm. The maximum tightening torque for screw terminals is 0.45 N·m (4 lbf·in). Power supply (XPOW) 24 V DC (±10%), 2 A External power input.
  • Page 76 76 Control unit (BCU) XD2D connector Physical layer: RS-485 Transmission rate: 8 Mbit/s Cable type: Shielded twisted-pair cable with a twisted pair for data and a wire or another pair for signal ground (nominal impedance 100 … 165 ohm, for example Belden 9842) Maximum length of link: 50 m (164 ft) Termination by switch RS-485 connection (X485)

  • Page 77: Bcu Ground Isolation Diagram

    Control unit (BCU) 77 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 79: Installation Checklist

    Installation checklist 79 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 80 80 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 81: Start-Up

    Refer to the delivery-specific circuit diagrams when you do the start-up procedure. 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.

  • Page 82: Start-Up Procedure

    82 Start-up Start-up procedure Tasks Safety WARNING! Obey the safety instructions during the start-up procedure. See ACS880 multidrives cab- inets and modules safety instructions (3AUA0000102301 [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 83 Start-up 83 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 84 84 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 85: Maintenance

    If you are not a qualified electrical professional, do not do installation or maintenance work. Maintenance intervals The tables show the maintenance tasks that can be done by the end user. For the ABB Service offering, contact your local ABB Service representative (new.abb.com/contact-centers).

  • Page 86: Recommended Maintenance Intervals After Start-Up

    Inspections by user IP22 and IP42 air inlet and outlet meshes Tightness of terminals Dustiness, corrosion and temperature Heatsink cleaning Other ABB-SACE Air circuit breaker maintenance ABB Contactors maintenance Item Years from start-up Main cooling fan R8i direct online 50/60 Hz...

  • Page 87: Maintenance Timers And Counters

    • The maintenance and component replacement intervals are based on the assumption that the equipment operates 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 88: Disconnecting The Dc/Dc-Converter From The Drive System With The Dc Switch-Disconnector

    88 Maintenance Disconnecting the DC/DC-converter from the drive system with the ￭ DC switch-disconnector 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 89: Cabinet

    Maintenance 89 Cabinet Cleaning the interior of the cabinet ￭ 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. WARNING! Use a vacuum cleaner with antistatic hose and nozzle, and wear a grounding wristband.

  • Page 90: Replacing The Inlet Door Filters (Ip54)

    90 Maintenance Replacing the inlet door filters (IP54) ￭ Stop the drive and do the steps in section Electrical safety precautions (page 43) before you start the work. Remove the fasteners at the top of the grating. Lift the grating and pull it away from the door. Remove the air filter mat.
  • Page 91 Maintenance 91 • The converter fuses [F11.x] on the drive DC bus side are marked with a in the figure. • The output fuses [F13.x] on the energy storage side are marked with b in the figure. Converter unit with a DC switch-disconnector C onverter unit without a DC switch-disconnector WARNING! Obey the safety instructions given in ACS880 multidrives cabinets and modules...

  • Page 92: Fans

    See the firmware manual for the actual signal which indicates the running time of the cooling fan. Reset the running time signal after fan replacement. Replacement fans are available from ABB. Do not use other than ABB-specified spare parts.

  • Page 93: Replacing The Cabinet Cooling Fan

    Maintenance 93 Replacing the cabinet cooling fan ￭ 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. Stop the drive and do the steps in section Electrical safety precautions (page 43) before you start the work.
  • Page 94 If the connectors are not compatible, replace the connector at the end of the fan kit cable. Use the connector in the old fan kit, or order a suitable connector from ABB. Stop the drive and do the steps in section Electrical safety precautions (page 43) before you start the work.

  • Page 95: Replacing The Direct-On-Line Fan (Option +C188) Of The Dc/Dc-Converter Module

    If the connectors are not compatible, replace the connector at the end of the fan kit cable. Use the connector in the old fan kit, or order a suitable connector from ABB. Refer to Connector replacement guide for ACS880-x04 R8i/D8T, BLCL-2X, BL-2X and BLHF DOL fan (3AXD50001059903 [English]).

  • Page 96: Replacing The Circuit Board Compartment Fan

    96 Maintenance Replacing the circuit board compartment fan ￭ Frame R8i modules are equipped with a fan blowing air through the circuit board compartment. The fan is accessible from the front of the module. WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur.
  • Page 97 Maintenance 97 Pull the fan holder out of the module. Disconnect the fan cable. Remove the four M3 (5.5 mm) nuts which hold the fan. Remove the fan from the fan holder. Put the fan onto the threaded studs on the fan holder with the airflow direction arrow pointing towards the fan holder.

  • Page 98: Replacing The Fan Of The Bdcl Filter

    98 Maintenance 10. Connect the fan cable. 11. Align and push the fan holder into the module. 12. Install and tighten the two M4×12 (T20) screws. Replacing the fan of the BDCL filter ￭ WARNING! Obey the safety instructions given in ACS880 multidrives cabinets and modules safety instructions (3AUA0000102301 [English]).

  • Page 99: Replacing The Roof Fan For Ip54 Cabinet

    Maintenance 99 Replacing the roof fan for IP54 cabinet ￭ Cabinets with ABB air outlet kits WARNING! Obey the safety instructions given in ACS880 multidrives cabinets and modules safety instructions (3AUA0000102301 [English]). If you ignore the safety instructions, injury or death, or damage to the equipment can occur.

  • Page 100: Cabinets With Other Fan Types

    100 Maintenance Cabinets with other fan types WARNING! Obey the safety instructions given in ACS880 multidrives cabinets and modules safety instructions (3AUA0000102301 [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 101: Replacing The R8I Dc/Dc-Converter Module

    Maintenance 101 Replacing the R8i DC/DC-converter module ￭ WARNING! Obey the safety instructions given in ACS880 multidrives cabinets and modules safety instructions (3AUA0000102301 [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 102 102 Maintenance • Wear protective gloves and long sleeves! Some parts have sharp edges. Note: There is a module lifter available from ABB Service. See Lifter for air-cooled drive modules user's guide (3AXD50000332588 [English]). Before you replace a converter module with a new one, make sure that the connector of the auxiliary power supply cable in the cabinet is compatible with the counterpart in the module (X50).
  • Page 103 Maintenance 103 • Push the module back in and fasten. 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 104 104 Maintenance...

  • Page 105: Bdcl Filter Module

    Maintenance 105 BDCL filter module Replacing the BDCL filter ￭ WARNING! Obey the safety instructions given in ACS880 multidrives cabinets and modules safety instructions (3AUA0000102301 [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 106 106 Maintenance • Wear protective gloves and long sleeves! Some parts have sharp edges. Note: There is a module lifter available from ABB Service. See Lifter for air-cooled drive modules user's guide (3AXD50000332588 [English]). Before you replace a filter module with a new one, make sure that the connector of the auxiliary power supply cable in the cabinet is compatible with the counterpart in the new module.
  • Page 107 Maintenance 107...
  • Page 108 108 Maintenance...

  • Page 109: Capacitors

    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. 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.

  • Page 110: Replacing The Real-Time Clock Battery (Ucu)

    110 Maintenance Replacing the real-time clock battery (UCU) ￭ 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. Replace the real-time clock battery if the BAT LED is off when the control unit is powered.

  • Page 111: Replacing The Microsdhc Memory Card (Ucu)

    Maintenance 111 Replacing the microSDHC memory card (UCU) ￭ 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. For the replacement card type, refer to the technical data.

  • Page 112: Bcu Control Unit

    112 Maintenance BCU control unit BCU control unit types ￭ There are three variants of the BCU control unit used in ACS880: BCU-02, BCU-12 and BCU-22. These have a different number of converter module connections but are otherwise identical. The BCU types are interchangeable if the number of connections is sufficient and the control program is the same.

  • Page 113: Leds And Other Status Indicators

    Maintenance 113 Stop the drive and do the steps in section Electrical safety precautions (page 43) before you start the work. Remove the fastening screw. Replace the battery with a new BR2032 battery. If necessary, set the real-time clock. Discard the old battery according to local disposal rules or applicable laws. LEDs and other status indicators This section gives information on how to read the status indications of the DC/DC-converter.

  • Page 114: R8I Module Leds

    114 Maintenance Location Indication Control panel Continuous green The unit is functioning normally. Flickering green Data is transferred between the PC and the unit through the USB connection of the control panel. Flashing green There is an active warning in the unit. Continuous red There is an active fault in the unit.

  • Page 115: Technical Data

    Technical data 115 Technical data Contents of this chapter This chapter contains technical data for the DC/DC converter units. Ratings No-overload use ACS880- max out- Frame contmax contmax 1607-… (input) (output) A (DC) A (DC) A (DC) = 400 V 0600A-3 12000 0900A-3...
  • Page 116 116 Technical data Short time overload use Heavy overload use ACS880- Frame short time short time 1607-… = 400 V 0600A-3 0900A-3 1200A-3 2×R8i 1020 1800A-3 2×R8i 1349 1529 = 500 V 0600A-5 0900A-5 1200A-5 2×R8i 1020 1800A-5 2×R8i 1349 1529 = 690 V 0400A-7...

  • Page 117: Derating

    Technical data 117 Derating Surrounding air temperature derating ￭ In the temperature range +40…50 °C (+104…122 °F), the rated output current is derated by 1 percentage point 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...

  • Page 118: Type Equivalence Table

    Derating factor 0.90 Derating factor 0.85 Derating factor 0.80 For a more accurate derating, use the DriveSize PC tool. Type equivalence table Converter unit type Basic module type BDCL filter ACS880-1607-… ACS880-104-… Frame size Type = 400 V 0600A-3 0640A-3 BDCL-14-5...

  • Page 119: Fuses

    Technical data 119 Converter unit type Basic module type BDCL filter ACS880-1607-… ACS880-104-… Frame size Type 0800A-7 0410A-7 BDCL-14-7 1200A-7 0600A-7 BDCL-15-7 Fuses DC fuses (DC bus side) ￭ Unit type Example Rating Type ACS880-1607-… (Bussmann) = 400 V 0600A-3...

  • Page 120: Bamu Unit Fuses

    120 Technical data Unit type Example Rating Type ACS880-1607-… (Bussmann) 0800A-7 700 A, 1250 V, size 3 Flush end type 170M6545 1200A-7 1100 A, 1000 V, size 3 Flush end type 170M6549 BAMU unit fuses ￭ The BAMU voltage/current measurement unit (option +G442) typically has one of these protection devices: •...

  • Page 121: Free Space Requirements

    Technical data 121 Definitions Depth 2 Depth with option +C128 (extra air inlet channel at the bottom) Free space requirements Leave a minimum of 400 mm (15.75 in) of free space above the basic roof level. > 400 mm (15.75 in.) For the rest of the free space requirements, see ACS880 multidrive cabinets mechanical installation instructions (3AUA0000101764...

  • Page 122: Tightening Torques

    Input power (DC bus) connection Voltage ( U ACS880-1607-xxxxx-3 = 566 V DC. This is indicated in the type designation label as typical input voltage levels 566 V DC. ACS880-1607-xxxxx-5 = 566…707 V DC. This is indicated in the type designation label as typical input voltage levels 566 / 679 / 707 V DC.

  • Page 123: Output Power (Energy Storage) Connection

    20 mm (0.8 in). Output power (energy storage) connection Voltage ( U ACS880-1607-xxxxx-3 = Maximum output voltage 50 V…95% of U (Drive DC voltage in the DC bus). This is indicated in the type designation label as typical output voltage range 50…509 V DC.

  • Page 124: Terminal And Cable Entry Data For The Power Cables

    124 Technical data Conductor cross-sec- PVC insulation XLPE insulation Typical dimensions of copper tion (copper) cable Conductor temperat- Conductor temperat- ure 70° ure 90° AWG / Time Time Size ø [mm] Lmax Lmax kcmil const. (s) const. (s) 1613 1230 3 ×...

  • Page 125: Protection Classes

    Technical data 125 Protection classes Degrees of protection IP22 (standard), IP42 (option +B054), IP54 (option +B055) (IEC/EN 60529) Enclosure types (UL50) UL Type 1 (standard), UL Type 1 (option +B054), UL Type 12 (Standard). For indoor use only. Arcing class B –...

  • Page 126: Colors

    126 Technical data Operation Storage Transportation installed for stationary in the protective pack- in the protective pack- Relative humidity Max. 95% Max. 95% Max. 95% No condensation allowed. Maximum allowed relative humidity is 60% in the presence of corrosive gases. Contamination IEC/EN 60721-3-3:2002 IEC 60721-3-1:1997...

  • Page 127: Packaging Of Options

    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 128: 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 129: Dimension Drawings 129

    Dimension drawings 129 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 130: 130 Dimension Drawings

    130 Dimension drawings Dimension drawings Frame 1×R8i, bottom cable entry ￭...

  • Page 131: Frame 1×R8I, Top Cable Entry

    Dimension drawings 131 Frame 1×R8i, top cable entry ￭...

  • Page 132: Location And Size Of Input Terminals

    132 Dimension drawings Location and size of input terminals Frame 1×R8i, bottom cable entry ￭...

  • Page 133: Frame 1×R8I, Top Cable Entry

    Dimension drawings 133 Frame 1×R8i, top cable entry ￭...

  • Page 135: 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/contact-centers.
  • Page 136 3AXD50000023644D © Copyright 2024 ABB. All rights reserved. Specifications subject to change without notice.

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