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ACS880-1604
ABB ACS880-1604 User Manual
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Maintenanc
e
115
Co
ntrol p
ane
l
Replacing the control
p
anel battery
1.
Tur
n the li
d
on th
e back o
f the p
anel counte
r-clockwi
se
unti
l the lid
opens.
2.
Rep
lace
the
batt
er
y wi
th a
new C
R2
03
2 ba
tte
ry
.
3.
Put
the lid
back
an
d tigh
ten it
by turn
ing
it clo
ckw
ise.
4.
Disp
os
e of
the old
batt
ery a
cco
rdi
ng to lo
cal di
spos
a
l rules
or ap
plic
abl
e laws.
Cleaning the control panel
See
ACX-AP-x a
ssist
a
nt cont
r
ol p
anels user
’
s manua
l
(
3A
UA0
00
008
5685
[
E
nglis
h]).
114
116
Table of Contents
Default Chapter
5
Table of Contents
5
1 Introduction to the Manual
13
Contents of this Chapter
13
Applicability
13
Safety Instructions
13
Target Audience
13
Contents of the Manual
14
Related Documents
14
Categorization by Frame Size and Option Code
14
Use of Component Designations
14
Terms and Abbreviations
15
2 Operation Principle and Hardware Description
17
Contents of this Chapter
17
Operation Principle
18
Main Circuit Diagram
19
Charging Circuit
19
Charging Circuit
20
Main Circuit Diagram of Parallel-Connected DC/DC Converter Modules
21
Overview Diagram of a Drive with a DC/DC Converter Unit
22
Single-Line Circuit Diagram of the DC/DC Converter Unit
23
Hardware Description
24
R8I and BDCL Filter Modules
24
DC Bus Connection and Capacitor Charging
24
Layout Drawings
25
R8I DC/DC Converter Module
25
Converter Module Connectors X50
26
BDCL Filter Module
27
Filter Module Connectors X30 and X55
28
Overview of the Control Connections on the BCU Control Unit
29
Converter Unit Control Devices
30
DC Switch/Disconnector
30
Charging Switch
30
Door Lights
30
BCU Control Unit
30
ACS-AP-X Control Panel
30
PC Connection
31
Fieldbus Control
31
Type Designation Labels
32
Type Designation Labels of the DC/DC Converter Module
32
Type Designation Label of the BDCL Filter Module
33
Type Designation Key
34
Type Designation of the Converter Module
34
Type Designation of the Filter Module
35
3 Moving and Unpacking the Module
37
Contents of this Chapter
37
Moving and Lifting the Transport Package
37
Unpacking
37
Lifting the Modules
38
Moving the Modules
38
4 Cabinet Construction
39
Contents of this Chapter
39
Liability
39
Energy Storage
39
Cooling and Mounting Orientations
39
Cabinet Configuration Overview
40
ACS880-1604 Configuration in Rittal TS 8 and Generic Enclosures
40
Installation Examples
41
1×R8I DDC Unit in a 800 MM Wide Rittal TS 8 Enclosure
42
Layout with DC Switch/Disconnector and Charging
42
Layout Without DC Switch/Disconnector and Charging
43
Installation Stages
44
Kits for DDC R8I Unit in 800 MM Rittal TS 8 Enclosure
45
Stage 1: Installation of Common Parts
46
Stage 2: Module and Bottom Cable Entry Installation Parts
47
Stage 3: Busbars and Quick Connectors for Connecting DDC Module and Filter
48
Stage 4A: DC Connection with Charging
49
Stage 4B: DC Connection Without Charging
50
Stage 5A: DC Connection with Charging
51
Stage 5B: DC Connection Without Charging
52
Stage 6: DDC and Energy Storage Connection
53
Stage 7: Control Unit Mounting Plate
54
Stage 8: DDC Shroud Installation
55
Stage 9: DDC Module and Filter Installation
56
1×R8I DDC Unit in a 800 MM Wide Generic Enclosure
57
Parts to be Installed
57
Kits for DDC R8I Unit in 800 MM Wide Generic Enclosure
58
5 Guidelines for Planning Electrical Installation
59
Contents of this Chapter
59
Liability
59
Generic Guidelines
59
Selecting the Energy Storage
60
Disconnection of Energy Storage at the Storage End
61
Implementing Load Current Switch-Off
61
Selecting and Routing the Energy Storage Cables
62
Recommended Cables
62
Typical Cable Sizes
62
Minimizing Electromagnetic Interference
63
Maximum Cable Length
63
EMC Compliance of the Complete Installation
63
Protecting the System against Thermal Overload
63
Protecting the Energy Storage Cable against Short-Circuits
63
6 Electrical Installation
65
Contents of this Chapter
65
Safety and Liability
65
Electrical Safety Precautions
66
General Notes
67
Static Electricity
67
Optical Components
67
Checking the Insulation of the Energy Storage Cable
68
Connecting the Power Cables
69
Connection Diagram (Frame 1×R8I)
69
Connection Procedure for Power Connections Inside the DC/DC Converter Cubicle
70
Connection Procedure for Energy Storage Cables
72
Connecting the BDCL Filter
73
Internal Circuit Diagram for the BDCL Filter
74
Installing the Charging Circuit
75
Connecting the External Power Supply Cable for the Auxiliary Circuit
75
R8I DC/DC Converter Module
75
BDCL Filter Module
75
Connecting the Control Cables
76
Default I/O Connection Diagram
76
Connection Procedure
76
Fiber Optic Connectors of the DC/DC Converter Module
77
Installing Optional Modules
78
Connecting a PC
79
7 Installation Checklist
81
Contents of this Chapter
81
Warnings
81
Checklist
82
8 Start-Up
83
Contents of this Chapter
83
Start-Up Procedure
84
Safety
84
Checks/Settings with no Voltage Connected
84
Connecting Voltage to the Drive and Converter Control Unit
84
Setting the Parameters
85
Charging the DC/DC Converter and Connecting Voltage to the Converter
85
Connecting the Energy Storage to the DC/DC Converter
85
Testing the DC/DC Converter Operation
86
Disconnecting the DC/DC Converter with DC Switch/Disconnector
87
Safety
87
Stopping the DC/DC Converter
87
Disconnecting the Energy Storage
87
Disconnecting the DC/DC Converter
87
Working Inside the DC/DC Converter Cubicle
87
Reconnecting the DC/DC Converter with DC Switch/Disconnector
88
Safety
88
Reconnecting the DC/DC Converter
88
Starting the DC/DC Converter
88
9 Maintenance
89
Contents of this Chapter
89
Maintenance Intervals
90
Maintenance Timers and Counters
91
Cabinet
91
Cleaning the Interior of the Cabinet
91
Cleaning the Door Air Inlets (IP42)
92
Cleaning the Door Air Inlets (IP54)
93
Cleaning the Outlet (Roof) Filters (IP54)
93
Power Connections
94
Retightening the Power Connections
94
Fans
95
Replacing the Cabinet Cooling Fan
95
Replacing the Speed-Controlled Cooling Fan of the DC/DC Converter Module
96
Replacing the Direct-On-Line Fan (Option +C188) of the DC/DC Converter Module
98
Replacing the Circuit Board Compartment Fan
100
Replacing the Fan of the BDCL Filter
103
Replacing the Roof Fan for IP54 Cabinet
104
Cabinets with ABB Air Outlet Kits
104
Cabinets with Other Fan Types
104
DC/DC Converter Module
105
Cleaning the Module
105
Replacing the R8I DC/DC Converter Module
106
BDCL Filter
110
Replacing the BDCL Filter
110
Capacitors
114
Reforming the Capacitors
114
Control Panel
115
Replacing the Control Panel Battery
115
Cleaning the Control Panel
115
Control Unit
116
BCU Control Unit Types
116
Memory Unit
116
Control Unit Battery
117
Leds and Other Status Indicators
118
10 Ordering Information
119
Contents of this Chapter
119
Kit Code
120
DC/DC Converter Modules
121
BDCL Filters
122
BDCL Filters (+C188)
122
BDCL Filters (+C188+G304)
123
Control Panel
124
Control Electronics
126
Control Unit
126
Fiber Optic Cables
127
Control Circuit Plug Connectors
127
Mechanical Installation Accessories and Tools
128
Module Installation Parts
128
Shrouds
129
Ramp
129
Bottom Cable Entry
130
Control Unit Mounting Plate
130
Electrical Installation Accessories
131
Busbars and Quick Connectors for Connecting DDC Module and Filter
131
Common DC Flat-PLS Assembly
132
DC Connection with DC Switch/Disconnector and Charging
133
DC Connection Without DC Switch/Disconnector and Charging
134
Energy Storage Connection
136
DC Fuses (DC Bus Side)
137
Output DC Fuses (Energy Storage Side)
137
DC Switch/Disconnector Kits
138
DC Switch/Disconnectors (IEC, 230 V, 50 Hz)
138
DC Switch/Disconnectors (IEC, 240 V, 60 Hz)
138
DC Switch/Disconnectors (UL/CSA, 110 V, 60 Hz)
139
Charging Kits
140
Charging Kits (IEC)
140
Charging Kits (UL)
141
Cabinet Ventilation Kits
142
Air Inlet Kits
142
Air Outlet Kits
143
Cooling Fans
145
Roof Fans
145
Internal Cabinet Fan
145
Miscellaneous
146
BAMU Voltage/Current Measurement Unit
146
11 Technical Data
147
Contents of this Chapter
147
Ratings
148
Definitions
149
Derating
150
Temperature Derating
150
Altitude Derating
150
Type Equivalence Table
151
Fuses
151
Fuses on BFPS Board
151
Fuses and Fuse Bases for BAMU Unit
151
Charging Component Ratings
151
Dimensions and Weights
152
R8I DC/DC Converter Module
152
BDCL Filter Module
152
Free Space Requirements
152
Allowable Mounting Orientations
153
Losses, Cooling Data and Noise
153
Tightening Torques
154
Cable Lugs
154
Electrical Connections
154
Mechanical Connections
154
Insulation Supports
154
Input Power (DC Bus) Connection
155
Output Power (Energy Storage) Connection
155
Control Accuracy - Current and Voltage Control Performance Data
156
Control Unit Connection Data
156
Optical Components
156
Degree of Protection
156
Ambient Conditions
157
Materials
158
Auxiliary Current Consumption
159
Cooling Fans
159
Applicable Standards
159
Markings
159
Disclaimer
160
Generic Disclaimer
160
Cybersecurity Disclaimer
160
12 Control Unit
161
Contents of this Chapter
161
General
161
Default I/O Connection Diagram
162
External Power Supply for the Control Unit (XPOW)
163
SDHC Memory Card Slot
163
Layout and Connections
164
Control Unit Connector Data
166
Ground Isolation Diagram
168
13 Dimension Drawings
169
Contents of this Chapter
169
R8I DC/DC Converter Module
170
Quick Connectors of the DC/DC Converter Module
172
Quick Connectors
173
BDCL Filter Module
174
ACS-AP-X Control Panel with Door Mounting Kit
175
BCU Control Unit
176
BAMU Voltage/Current Measurement Unit
177
BAMU Fuse Holders and Fuses
178
PS272PREMCPS Fuse Disconnector and PS27 Terminal Cover
178
Fuse, 27 × 60 MM
178
Ramp
179
Internal Cabinet Fan
181
W2E 143-Aa09-01, W2E 143-Aa15-01
181
Switchgear and Charging Components
182
DC Switch/Disconnectors
182
Ot1600E11 (Iec), Ot1200U11 (Ul)
182
Charging Switches
183
Os160Gd04F (Iec)
183
Os100Gj04Fp (Ul/Csa)
184
Charging Controller
185
Resistors
186
Zrf 30X165
186
Handles
186
Ohb65J6
186
Contacts
187
Auxiliary Contact OA3G01
187
DC Fuses
188
170M6415, 170M6419, 170M6545, 170M6549
188
170M6545, 170M6549
189
14 Example Circuit Diagrams
191
Contents of this Chapter
191
Component Designations Used in the Diagrams
192
DC/DC Converter 1×R8I and 2×R8I Without DC Switch/Disconnector
192
DC/DC Converter 1×R8I and 2×R8I with DC Switch/Disconnector
193
DDC 1×R8I Without DC Switch/Disconnector
195
Sheet 001 (DC Main Circuit)
195
Sheet 005 (Module Connections)
196
Sheet 020 (Auxiliary Voltage Distribution)
197
Sheet 040 (Control Unit)
198
Sheet 041 (BAMU Measurement Unit)
199
DDC 1×R8I with DC Switch/Disconnector
200
Sheet 001 (DC Main Circuit, Charging Circuit)
200
Sheet 005 (Module Connections)
201
Sheet 020 (Auxiliary Voltage Distribution)
202
Sheet 040 (Control Unit)
203
Sheet 041 (BAMU Measurement Unit)
204
DDC 2×R8I Without DC Switch/Disconnector
205
Sheet 001 (DC Main Circuit)
205
Sheet 002 (DC Main Circuit)
206
Sheet 005 (Module Connections)
207
Sheet 006 (Module Connections)
208
Sheet 020 (Auxiliary Voltage Distribution)
209
Sheet 021 (Auxiliary Voltage Distribution)
210
Sheet 040 (Control Unit)
211
Sheet 041 (BAMU Measurement Unit)
212
DDC 2×R8I with DC Switch/Disconnector
213
Sheet 001 (DC Main Circuit, Charging Circuit)
213
Sheet 002 (DC Main Circuit, Charging Circuit)
214
Sheet 005 (Module Connections)
215
Sheet 006 (Module Connections)
216
Sheet 020 (Auxiliary Voltage Distribution)
217
Sheet 021 (Auxiliary Voltage Distribution)
218
Sheet 040 (Control Unit)
219
Sheet 041 (BAMU Measurement Unit)
220
Further Information
221
Product and Service Inquiries
221
Product Training
221
Providing Feedback on ABB Drives Manuals
221
Document Library on the Internet
221
4
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ABB ACS880-1604 Specifications
General
Brand
ABB
Model
ACS880-1604
Category
Control Unit
Language
English
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