—
ABB INDUSTRIAL DRIVES
ACS880-1604LC DC/DC converter modules
Hardware manual
Table of contents
1 Introduction to the manual
13Contents of this chapter ..........................................................................
13Applicability ........................................................................................
13Safety instructions ................................................................................
13Target audience ...................................................................................
14Categorization by frame size and option module ............................................
14Use of component designations ................................................................
14Terms and abbreviations .........................................................................
15Related documents ...............................................................................
2 Operation principle and hardware description
17Contents of this chapter ..........................................................................
17Operation principle ................................................................................
18Main circuit diagram ..........................................................................
20Overview diagram of a drive with a DC/DC converter unit ..................................
21Single-line circuit diagram of the DC/DC converter unit .....................................
22Converter module hardware .....................................................................
22Module layout ..................................................................................
22Coolant connectors ...........................................................................
23Connectors X50…X59 ........................................................................
24Fiber optic connectors ........................................................................
24DC bus connection and capacitor charging ...............................................
25BDCL filter module ................................................................................
26Overheating protection of the filter ..........................................................
26BCU control unit of frame R8i and multiples ..................................................
27Overview of the control connections of the BCU control unit ...............................
28Converter unit control devices ..................................................................
28DC switch/disconnector ......................................................................
28Charging switch ................................................................................
28Door lights ......................................................................................
28BCU control unit ...............................................................................
28ACX-AP-x control panel ......................................................................
29PC connection .................................................................................
29Fieldbus control ................................................................................
29BAMU voltage/current measurement unit .................................................
29CIO-01 I/O module ............................................................................
30Type designation labels ..........................................................................
30Type designation labels of the DC/DC converter module ...............................
31Type designation label of the BDCL filter module ........................................
32Type designation key .............................................................................
32Type designation key of the module ........................................................
32Type designation key of the filter module ..................................................
3 Moving and unpacking the module
33Contents of this chapter ..........................................................................
Table of contents 5
33Moving and unpacking the module .............................................................
4 Cabinet construction
35Contents of this chapter ..........................................................................
35Limitation of liability ...............................................................................
35Energy storage ....................................................................................
36Cabinet configuration overview .................................................................
37Installation examples .............................................................................
381×R8i DDC unit in Rittal VX25 enclosure ..................................................
38Layout with DC switch/disconnector and charging ....................................
39Layout without DC switch/disconnector and charging ................................
40Pipe routing example ......................................................................
41Installation stages ..........................................................................
42Kits for ACS880-1604LC R8i unit in Rittal VX25 cabinets ...........................
43Stage 1: Installation of common parts ..................................................
44
Stage 2: Side plates, busbars and quick connectors for connecting DDC module
and filter .....................................................................................
45Stage 3: Module installation parts .......................................................
46Stage 4: DDC and energy storage connection ........................................
47Stage 5A: DC connection with charging ................................................
48Stage 5B: DC connection without charging ............................................
49Stage 6: Cooling components ............................................................
50Stage 7: DDC module and filter installation ............................................
51Stage 8: Swing frame and shroud installation .........................................
522×R8i DDC unit ................................................................................
52Parallel connection ........................................................................
5 Guidelines for planning electrical installation
53Contents of this chapter ..........................................................................
53Limitation of liability ...............................................................................
53Generic guidelines ................................................................................
54Selecting the energy storage ....................................................................
55Implementing protections for the energy storage ............................................
55General principles .............................................................................
55Selecting the protective circuit breaker of the energy storage ..........................
55Energy storage disconnecting device ......................................................
55Overload protection of the system by the DC/DC converter ............................
55Protecting the energy storage cable ........................................................
55Energy storage discharging device .........................................................
56Implementing an interlocking between the disconnecting devices .....................
56Selecting and routing the energy storage cables ............................................
56Recommended cables ........................................................................
56Typical cable sizes ............................................................................
56Minimizing electromagnetic interference ...................................................
56Maximum cable length ........................................................................
57EMC compliance of the complete installation .............................................
57Parallel connection ...............................................................................
6 Electrical installation
59Contents of this chapter ..........................................................................
59Safety and liability ................................................................................
6 Table of contents
60Electrical safety precautions ....................................................................
61General notes .....................................................................................
61Printed circuit boards .........................................................................
61Optical components ...........................................................................
62Checking the insulation of the energy storage cable ........................................
63Connecting the power cables ...................................................................
63Connection diagram (frame 1×R8i) .........................................................
64Connection procedure for power connections inside the DC/DC converter cubicle ..
65Connection procedure of the energy storage cables .....................................
67Connecting the BDCL filter ......................................................................
67Internal circuit diagram for the BDCL filter .................................................
68Installing the charging circuit ....................................................................
68Connecting the external power supply cable for the auxiliary circuit ......................
68R8i DC/DC converter module ...............................................................
68BDCL filter module ............................................................................
69Connecting the control cables ..................................................................
69Default I/O connection diagram .............................................................
69Connection procedure ........................................................................
71Installing optional modules ......................................................................
71Connecting a PC ..................................................................................
7 Installation checklist of the drive
73Contents of this chapter ..........................................................................
73Checklist ...........................................................................................
8 Start-up
75Contents of this chapter ..........................................................................
76Start-up procedure ................................................................................
79Disconnecting the DC/DC converter with DC switch/disconnector ........................
80Reconnecting the DC/DC converter with DC switch/disconnector ........................
9 Maintenance
81Contents of this chapter ..........................................................................
81Maintenance intervals ............................................................................
82Maintenance timers and counters ..............................................................
83Power connections ...............................................................................
83Retightening the power connections .......................................................
84Fans ................................................................................................
84Replacing the cooling fans ...................................................................
85DC/DC converter module ........................................................................
85Replacing the R8i DC/DC converter module ..............................................
85Removing the module .....................................................................
87Reinstalling the module ...................................................................
87Capacitors .........................................................................................
87Reforming the capacitors .....................................................................
87Control panel ......................................................................................
87Cleaning the control panel ...................................................................
87Replacing the control panel battery .........................................................
88Control unit .........................................................................................
88BCU control unit types ........................................................................
88Replacing the memory unit ..................................................................
Table of contents 7
88Replacing the BCU control unit battery ....................................................
89LEDs and other status indicators ...............................................................
10 Ordering information
91Contents of this chapter ..........................................................................
91Kit code key ........................................................................................
93DC/DC converter modules .......................................................................
94BDCL filters ........................................................................................
95Control panel ......................................................................................
96Control electronics ................................................................................
96Control unit .....................................................................................
97Fiber optic cables ..............................................................................
97Options ..........................................................................................
98Mechanical installation accessories ............................................................
98Module installation parts .....................................................................
100Swing-out frame (for Rittal VX25 enclosures) .............................................
101Shrouds .........................................................................................
102Bottom cable entry ............................................................................
103Electrical installation accessories ..............................................................
103Busbars and quick connectors for connecting DDC module and filter ................
103Common DC Flat-PLS assembly ...........................................................
105DC connection with DC switch/disconnector and charging .............................
106DC switch/disconnector kits ..............................................................
107Charging kits ................................................................................
107Charging resistors .........................................................................
108DC connection without DC switch/disconnector and charging .........................
109Energy storage connection ..................................................................
109DC fuses (DC bus side) ......................................................................
110Output DC fuses (energy storage side) ....................................................
110Parallel connection busbar kit ...............................................................
111Cooling system parts .............................................................................
111Coolant distribution manifold kits ............................................................
112Piping ...........................................................................................
112Heat exchanger ................................................................................
113Cooling fan .....................................................................................
114Miscellaneous .....................................................................................
114BAMU voltage/current measurement unit .................................................
114CIO-01 I/O module ............................................................................
11 Internal cooling circuit
115Contents of this chapter ..........................................................................
115Applicability ........................................................................................
115Internal cooling system ..........................................................................
117Connection to a cooling unit .....................................................................
117Connection to an ACS880-1007LC cooling unit ..........................................
117Connection to a custom cooling unit ........................................................
117General requirements .....................................................................
117Coolant temperature control .............................................................
118Filling up and bleeding the internal cooling circuit ...........................................
118Drive line-ups with an ACS880-1007LC cooling unit .....................................
118Drive line-ups with a custom cooling unit ..................................................
8 Table of contents
120Draining the internal cooling circuit .............................................................
120Maintenance intervals ............................................................................
120Technical data .....................................................................................
120Coolant specification ..........................................................................
120Coolant type ................................................................................
120Temperature limits .............................................................................
122Pressure limits .................................................................................
122Coolant flow rate limits .......................................................................
122Cooling circuit materials ......................................................................
12 Technical data
125Contents of this chapter ..........................................................................
126Ratings .............................................................................................
126Definitions ......................................................................................
127Derating ............................................................................................
127Ambient temperature derating ...............................................................
127Altitude derating ...............................................................................
127Type equivalence table ..........................................................................
128Fuses ...............................................................................................
128Losses and cooling data .........................................................................
129Dimensions and weights .........................................................................
129R8i DC/DC converter module ...............................................................
129BDCL filter module ............................................................................
129Free space requirements ........................................................................
130Typical power cable sizes .......................................................................
132Tightening torques ................................................................................
132Electrical connections ........................................................................
132Mechanical connections ......................................................................
132Insulation supports ............................................................................
132Cable lugs ......................................................................................
132Input power (DC bus) connection ..............................................................
133Output power (energy storage) connection ...................................................
133Control accuracy – Current and voltage control performance data .......................
133Control unit connection data ....................................................................
133Coolant connections ..............................................................................
133Optical components ..............................................................................
134Protection classes ................................................................................
134Efficiency ...........................................................................................
134Ambient conditions ...............................................................................
136Materials ...........................................................................................
136Auxiliary current consumption ...................................................................
136Cooling fans ....................................................................................
136Definitions ......................................................................................
137Applicable standards .............................................................................
137Markings ...........................................................................................
137Disclaimers ........................................................................................
137Generic disclaimer ............................................................................
137Cybersecurity disclaimer .....................................................................
13 Control units of the drive
139Contents of this chapter ..........................................................................
Table of contents 9
140BCU-x2 control unit layout and connections ..................................................
142Default I/O diagram of the converter control unit .............................................
143External power supply for the control unit (XPOW) ..........................................
143The XD2D connector .............................................................................
144The X485 connector ..............................................................................
144Safe torque off (XSTO, XSTO OUT) ...........................................................
144FSO-xx safety functions module connection (X12) ..........................................
144SDHC memory card slot .........................................................................
145Connector data ....................................................................................
147BCU-x2 ground isolation diagram ...........................................................
14 Dimension drawings
149Contents of this chapter ..........................................................................
150R8i DC/DC converter module ...................................................................
151BDCL filter module ................................................................................
152Quick connector ...................................................................................
153BCU control unit ...................................................................................
154BAMU voltage/current measurement unit .....................................................
155BAMU accessories ...............................................................................
155Miniature circuit breaker S804S-UCB10 ...................................................
155Auxiliary contact S800-AUX .................................................................
156Shorting plug S802-LINK50 ..................................................................
157CIO-01 I/O module ................................................................................
158DPMP-01 door mounting kit .....................................................................
159Switchgear and charging components .........................................................
159DC switch/disconnectors .....................................................................
159OT1600E11 (IEC) ..........................................................................
160Charging switches .............................................................................
160OS160GD04F (IEC) .......................................................................
161Charging controller BSFC-12C ..............................................................
162Handles .........................................................................................
162OHB65J6 ....................................................................................
162OHB150J12P ...............................................................................
163Contacts ........................................................................................
163Auxiliary contact OA1G10 ................................................................
163Auxiliary contact OA3G01 ................................................................
164DC fuses ...........................................................................................
15 Example circuit diagrams
165Contents of this chapter ..........................................................................
165Content of the circuit diagrams .................................................................
165ACS880-1604LC DC/DC converter unit 1×R8i, 3AXD10000878887 ..................
166ACS880-1604LC DC/DC converter unit 2×R8i, 3AXD10000873230 ..................
167DDC 1×R8i with DC switch/disconnector .....................................................
167Sheet 001a (Main supply) ....................................................................
168Sheet 001b (Charging circuit) ...............................................................
169Sheet 002a (BDCL main circuit) ............................................................
170Sheet 005a (Module connections) ..........................................................
171Sheet 005b (BDCL module connections) ..................................................
172Sheet 007a (BAMU voltage measurement) ...............................................
173Sheet 020a (Auxiliary voltage distribution) ................................................
10 Table of contents
174Sheet 021a (Auxiliary voltage distribution) ................................................
175Sheet 022a (24 V DC distribution) ..........................................................
176Sheet 026a (Cabinet fans) ...................................................................
177Sheet 040a (Control board) ..................................................................
178Sheet 040b (Control board) ..................................................................
179Sheet 040c (Control board) ..................................................................
180Sheet 040d (Signal lamps) ...................................................................
181DDC 2×R8i with DC switch/disconnector .....................................................
181Sheet 001a (Main circuit, 1st cubicle) ......................................................
182Sheet 001b (Charging control, 1st cubicle) ................................................
183Sheet 001c (Main circuit, 2nd cubicle) .....................................................
184Sheet 001d (Charging control, 2nd cubicle) ...............................................
185Sheet 002a (BDCL main circuit, 1st cubicle) ..............................................
186Sheet 002b (BDCL main circuit, 2nd cubicle) .............................................
187Sheet 005a (Module connections, 1st cubicle) ...........................................
188Sheet 005b (BDCL module connections, 1st cubicle) ...................................
189Sheet 007a (BAMU voltage measurement, 1st cubicle) .................................
190Sheet 020a (Auxiliary voltage distribution, 1st cubicle) ..................................
191Sheet 021a (Auxiliary voltage distribution, 1st cubicle) ..................................
192Sheet 022a (Auxiliary voltage distribution, 1st cubicle) ..................................
193Sheet 026a (Cabinet fan & CIO, 1st cubicle) ..............................................
194Sheet 026b (Cabinet fan, 2nd cubicle) .....................................................
195Sheet 040a (Control board, 1st cubicle) ...................................................
196Sheet 040b (Control board, 1st cubicle) ...................................................
197Sheet 040c (Control board, 1st cubicle) ...................................................
198Sheet 040d (Signal lamps, 1st cubicle) ....................................................
Further information
Table of contents 11
12
Introduction to the manual
Contents of this chapter
This chapter gives basic information on the manual.
Applicability
The manual is applicable to ACS880-1604LC DC/DC converter modules for user-defined
cabinet installations.
Safety instructions
Follow all safety instructions delivered with the drive.
• Read the complete safety instructions before you install, commission, use or service
the drive. The complete safety instructions are given in ACS880 liquid-cooled multidrive
cabinets and modules safety instructions (3AXD50000048633 [English]).
• Read the software-function-specific warnings and notes before changing the default
settings of a function. For each function, the warnings and notes are given in the section
describing the related user-adjustable parameters.
• Read the task-specific safety instructions before starting the task. See the section
describing the task.
Target audience
This manual is intended for people who plan the installation, install, start up and service the
drive, or create instructions for the end user of the drive concerning the installation and
maintenance of the drive.
Read the manual before working on the drive. You are expected to know the fundamentals
of electricity, wiring, electrical components and electrical schematic symbols.
1
Introduction to the manual 13
The manual is written for readers worldwide. Both SI and imperial units are shown.
Categorization by frame size and option module
Some descriptions, instructions and technical data which concern only certain module or
frame sizes are marked with the size identifier (such as "2×R8i", etc.). The marking derives
from the quantity and basic construction of the converter modules that form the converter
unit. For example, frame size "2×R8i" indicates that the converter unit consists of two frame
size R8i converter modules connected in parallel.
The frame size is marked on the type designation labels. The frame size of each drive
module is also shown in the rating tables.
The instructions and technical data which concern only certain optional selections are marked
with option codes (such as +E205). The options included in the drive can be identified from
the option codes visible on the type designation label.
Use of component designations
Some device names in the manual include the item designation in brackets, for example
[Q20], to make it possible to identify the components in the circuit diagrams of the drive.
Terms and abbreviations
DescriptionTerm
Auxiliary measurement unitBAMU
Type of control unitBCU
Series of L-filters, for example BDCL-14-5BDCL
Internal power supply board in frame R8i modulesBDPS
Control and power supply board for speed-controlled cooling fanBFPS
I/O module for controlling cabinet fansCIO
Circuit board in which the control program runsControl board
Control board built in a housing (often rail-mountable)Control unit
One section of a cabinet-installed drive. A cubicle is typically behind a door of its own.Cubicle
Charges or discharges an external energy storage (such as a battery or capacitor
bank) from or into the DC bus
DC/DC converter
Converter power electronics, related components and DC capacitors enclosed in a
metal frame or enclosure. Intended for cabinet installation.
DC/DC converter mod-
ule
DC/DC converter module(s) under control of one control board, and related componentsDC/DC converter unit
DC/DC converter unitDDC
Digital inputDI
Direct-on-lineDOL
Frequency converter for controlling AC motorsDrive
Electromagnetic compatibilityEMC
Device that stores electrical energy, for example, a battery or a super capacitor.Energy storage
Rittal Flat-PLS, a busbar system for standard, commercially available flat busbarsFlat-PLS
Physical size of the drive or power moduleFrame, frame size
Insulated gate bipolar transistorIGBT
Inverter unitINU
Converts direct current and voltage to alternating current and voltage.Inverter
Inverter module(s) under control of one control board, and related components. One
inverter unit typically controls one motor.
Inverter unit
Liquid cooling unitLCU
14 Introduction to the manual
DescriptionTerm
Drive for controlling several motors which are typically coupled to the same machinery.
Includes one supply unit, and one or several inverter units.
Multidrive
In the drive control program, user-adjustable operation instruction to the drive, or signal
measured or calculated by the drive.
In some (for example fieldbus) contexts, a value that can be accessed as an object,
eg, variable, constant, or signal.
Parameter
Programmable logic controllerPLC
Supply module(s) under control of one control board, and related components.Supply unit
Related documents
CodeManual
General manuals
3AXD50000048633
ACS880 liquid-cooled multidrive cabinets and modules safety instructions
3AXD50000048634
ACS880 liquid-cooled multidrive cabinets and modules electrical planning instructions
3AUA0000107668
Drive modules cabinet design and construction instructions
3AUA0000113605
BCU-02/12/22 control units hardware manual
3AXD50000126880
CIO-01 I/O module for distributed I/O bus control user's manual
Supply module manuals
3AXD50000284436
ACS880-204LC IGBT supply modules hardware manual
3AUA0000131562
ACS880 IGBT supply control program firmware manual
3AXD50000045157
ACS880-304LC+A019 diode supply modules hardware manual
3AUA0000103295
ACS880 diode supply control program firmware manual
Inverter module manuals and guides
3AXD50000045610
ACS880-104LC inverter modules hardware manual
3AUA0000085967
ACS880 primary control program firmware manual
3AUA0000098062
ACS880 primary control program quick start-up guide
Brake module and DC/DC converter module manuals
3AXD50000184378
ACS880-604LC 1-phase brake chopper modules hardware manual
3AXD50000371631
ACS880-1604LC DC/DC converter modules hardware manual
3AXD50000024671
ACS880 DC/DC converter control program firmware manual
Option manuals
3AXD50000129607
ACS880-1007LC liquid cooling unit user's manual
3AUA0000085685
ACX-AP-x assistant control panels user’s manual
3AXD50000117840
BAMU-12C auxiliary measurement unit hardware manual
3AUA0000094606
Drive composer start-up and maintenance PC tool user’s manual
3AUA0000127808
Drive application programming (IEC 61131-3) manual
Manuals and quick guides for I/O extension modules, fieldbus adapters, safety functions modules, etc.
See www.abb.com/drives/documents for all manuals on the Internet.
You can find all documentation related to the multidrive modules on the Internet at
https://sites-apps.abb.com/sites/lvacdrivesengineeringsupport/content.
Introduction to the manual 15
16
Operation principle and hardware
description
Contents of this chapter
This chapter describes the DC/DC converter operation basics and the hardware of the
converter.
Operation principle
The DC/DC converter unit (DDC) transfers energy from a common DC bus of a drive into
an external energy storage and discharges energy back to the DC bus. The energy storage
can be, for example, a battery or super capacitor. The energy storage media does not belong
to the DC/DC module product offering.
The DC/DC converter unit has a single converter module or parallel converter modules
under the command of one control unit. Parallel DC/DC converter modules must have a
common energy storage. Each parallel module must have the output cabling of its own. 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 storing instead of an additional
generator and so on. The DC/DC converter can also be used in automotive applications
such as electric car charging systems and also in several other applications where energy
storing and reuse is needed.
2
Operation principle and hardware description 17
ï¿ Main circuit diagram
The DC/DC converter module must be equipped with external DC fuses. You can equip the
converter with a DC switch/disconnector, if quick isolation of the module from the DC bus
is required.
This figure shows a simplified main circuit diagram of a DC/DC converter without a DC
switch/disconnector and charging circuit.
+
_
U2
V2
W2
U2
V2
W2
ES+1
ES+
ES-
ES+2
ES+3
L+
L-
1
2
3
4
Drive DC bus1
DC/DC converter module2
Filter module3
Energy storage4
This figure shows a simplified main circuit diagram of a DC/DC converter with the DC
switch/disconnector and charging circuit.
L+
L-
+
_
U2
V2
W2
U2
V2
W2
ES+1
ES
ES
ES+2
ES+3
1
2
3
4
5
6
Drive DC bus1
DC switch/disconnector2
DC/DC converter module3
Filter module4
Energy storage5
Charging components6
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 and charging circuit. Also the energy storage and
related cabling and equipment are visible.
1
2
3
4
5
6
7
8
8
9
10
11
7
6
4
3
5
DC/DC converter cubicles1
Energy storage cabinet2
Drive DC bus3
DC switch/disconnector4
Charging components5
DC/DC converter module6
Filter module7
Cabling between DC/DC converter unit and energy storage8
Energy storage disconnecting device9
Energy storage protective circuit breaker10
Energy storage11
Operation principle and hardware description 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°
1
2
3
6
6
4
5
8
9
10
11
7
AC supply1
Input (AC) fuses2
Supply module3
DC bus (-,+)4
Inverter DC fuses (with or without a DC switch/disconnector)5
Inverter modules6
Motors7
DC fuses (DC bus side, with or without a DC switch/disconnector)8
DC/DC converter unit (converter and filter module)9
Output DC fuses10
Customer-defined energy storage with disconnecting and protection devices11
20 Operation principle and hardware description
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