ABB ACS880-1607LC

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ACS880-1607LC DC/DC converter

units

Hardware manual

Table of contents

3. Mechanical installation

5. Electrical installation

8. Start-up

3AXD50000431342 Rev C

Original instructions

EFFECTIVE: 2023-12-29

Main Page

Table of Contents5
Introduction to the Manual11
Contents of this Chapter11
Applicability11
Safety Instructions11
Target Audience11
Categorization by Frame Size and Option Module12
Use of Component Designations12
Terms and Abbreviations12
Related Documents13
Operation Principle and Hardware Description15
Contents of this Chapter15
Operation Principle15
Main Circuit Diagram15
Overview Diagram of a Drive with a DC/DC Converter Unit19
Converter Unit Hardware20
Cabinet Layout - Frame R7I Converter Module20
Cabinet Layout - Frame R8I Converter Module22
Converter Module Hardware24
Frame R7I24
Module Layout24
Coolant Connectors24
Connectors X50, X52 and X53; Auxiliary Voltage Selector X5925
Fiber Optic Connectors25
Leds26
Frame R8I26
Module Layout26
Coolant Connectors27
Connectors X5027
Fiber Optic Connectors27
Leds28
BDCL Filter Module28
BDCL Filter Module for Frame R7I Converter Module28
BDCL Filter Module for Frame R8I Converter Module29
Overheating Protection of the Filter29
Overview of the Control Connections of the BCU Control Unit30
Overview of the Control Connections of the UCU Control Unit31
Converter Unit Control Devices31
DC Switch-Disconnector32
Charging Switch32
Door Lights32
Control Panel [A59]33
PC Connection33
Fieldbus Control33
Type Designation Labels34
Type Designation Label of the DC/DC Converter Unit34
Type Designation Labels of the DC/DC Converter Module34
Type Designation Label of the BDCL Filter Module36
Type Designation Key36
Type Designation Key of the Converter Unit36
Option Codes37
Type Designation Key of the Converter Module38
Type Designation Key of the Filter Module39
Mechanical Installation41
Contents of this Chapter41
DC/DC Converter Units41
Energy Storage41
Internal Cooling System41
Guidelines for Planning Electrical Installation43
Contents of this Chapter43
Limitation of Liability43
North America43
Generic Guidelines43
Selecting the Energy Storage44
Implementing Protections for the Energy Storage45
General Principles45
Selecting a Protective Device for the Energy Storage45
Energy Storage Disconnecting (Isolating) Device45
Overload Protection of the System by the DC/DC Converter45
Protecting the Energy Storage Cable45
Energy Storage Discharging Device45
Implementing Earth Fault Protection46
Implementing an Interlocking between the Disconnecting Devices46
Selecting and Routing the Energy Storage Cables46
Cable Selection Procedure46
Recommended Cables46
Typical Cable Sizes47
Minimizing Electromagnetic Interference47
Maximum Cable Length47
EMC Compliance of the Complete Installation47
Parallel Connection48
Electrical Installation49
Contents of this Chapter49
Safety49
Electrical Safety Precautions49
Measuring the Insulation Resistance of the DC Cabling51
Connecting the Energy Storage Cable and Load Disconnected Indicator Cable52
Use of Fasteners in Cable Lug Connections52
Connection Diagram53
Connection Procedure of the Energy Storage Cables53
Connecting the Control Cables56
Control Cable Connection Procedure56
Grounding the Outer Shields of the Control Cables 360° at the Cabinet Entry57
Routing the Control Cables Inside the Cabinet59
Connecting Control Cabling59
Installing Option Modules60
Connecting a PC61
The Control Unit63
Contents of this Chapter63
General63
BCU Layout64
Ucu-2266
Default I/O Diagram of the Converter Control Unit (BCU)69
Default I/O Diagram of the Converter Control Unit (UCU-2271
Additional Information on the Connections74
Power Supply for the Control Unit (XPOW)74
The X485 Connector (BCU)74
The X485 Connector (UCU)74
Safe Torque off (XSTO, XSTO OUT)75
FSO Safety Functions Module Connection (X12, with BCU Only)75
SDHC Memory Card Slot75
Microsdhc Memory Card Slot75
Connector Data76
BCU Ground Isolation Diagram79
Ucu-2280
Installation Checklist81
Contents of this Chapter81
Checklist81
Start-Up83
Contents of this Chapter83
Start-Up Procedure84
Maintenance87
Contents of this Chapter87
Maintenance Intervals87
Description of Symbols87
Recommended Maintenance Intervals after Start-Up87
Maintenance Timers and Counters89
Disconnecting the DC/DC Converter89
Disconnecting the DC/DC Converter from the Energy Storage89
Disconnecting the DC/DC Converter from the Drive System with the DC Switch-Disconnector90
Connecting the DC/DC Converter90
Liquid Pipe Connector Installation Instructions90
Fuses93
Checking and Replacing the Fuses - Frame R7I93
Replacing a Converter Fuse93
Replacing an Output Fuse94
Checking and Replacing the Fuses - Frame R8I96
Fans97
Frame R7I Cabinet Fan Replacement98
Frame R7I - Internal Module Fan Replacement99
Frame R8I Fan Replacement100
R7I Converter Module101
Removing the Module102
Installing the Module103
R8I Converter Module104
Replacing an R8I Converter Module104
Assembling the Service Platform104
Removing the Module105
Reinstalling the Module108
Capacitors108
Reforming the Capacitors109
Control Panel109
Control Unit109
BCU Control Unit Types109
UCU Control Unit Types109
Replacing the Memory Unit (BCU)109
Replacing the Memory Unit (UCU-22110
Replacing the BCU Control Unit Battery111
Replacing the Real-Time Clock Battery (UCU-22111
Replacing the Microsdhc Memory Card (UCU-22112
Leds and Other Status Indicators113
Control Panel and Panel Platform/Holder Leds113
Converter Module Leds113
Converter Unit Leds114
Internal Cooling Circuit115
Contents of this Chapter115
Applicability115
Internal Cooling System115
Connection to a Cooling Unit117
Connection to an ACS880-1007LC Cooling Unit117
Connection to a Custom Cooling Unit117
General Requirements117
Coolant Temperature Control117
Filling up and Bleeding the Internal Cooling Circuit118
Drive Line-Ups with an ACS880-1007LC Cooling Unit118
Drive Line-Ups with a Custom Cooling Unit118
Draining the Internal Cooling Circuit119
Maintenance Intervals119
Technical Data120
Coolant Specification120
Coolant Type120
Temperature Limits120
Pressure Limits122
Coolant Flow Rate Limits122
Cooling Circuit Materials122
Technical Data123
Contents of this Chapter123
Ratings123
Derating125
Surrounding Air Temperature Derating125
Altitude Derating126
Type Equivalence Table126
Fuses127
DC Fuses127
BAMU Unit Fuses128
Filter Module Data128
Dimensions and Weights128
Free Space Requirements129
Losses, Cooling Data and Noise129
Tightening Torques131
Electrical Connections131
Mechanical Connections132
Insulation Supports132
Cable Lugs132
Input Power (DC Bus) Connection132
Output Power (Energy Storage) Connection132
Typical Power Cable Sizes133
Control Accuracy - Current and Voltage Control Performance Data134
Coolant Connections134
Protection Classes134
Energy Efficiency Data (Ecodesign)134
Ambient Conditions135
Colors136
Materials136
Drive136
Packaging of Drive136
Packaging of Options136
Manuals137
Disposal137
Applicable Standards137
Markings137
Disclaimers138
Generic Disclaimer138
Cyber Security Disclaimer138
Dimension Drawings139
Contents of this Chapter139
DC/DC Converter Unit with 1×R7I Converter Module140
DC/DC Converter Unit with 1×R8I Converter Module142
Location and Size of Energy Storage Connection Terminals - Frame R7I144
Location and Size of Energy Storage Connection Terminals - Frame R8I145

ABB ACS880-1607LC - Page 3

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