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ABB ACS880-1604, Hardware Manual

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30   Operation principle and hardware description

Converter unit control devices

DC switch/disconnector

The DC/DC converter cabinet can be equipped with DC switch/disconnector [Q11.xx]. A 
converter unit with a DC switch/disconnector must also have a precharge circuit including 
a charging switch. 

The DC switch/disconnector allows the isolation of the unit from the DC bus. When the unit 
is reconnected to the DC bus, the capacitors of the converter modules are charged 
through a charging circuit.

For more information, see 

DC bus connection and capacitor charging

 on page 

24

.

WARNING!

 You must also switch off the charging switch to disconnect the DC/DC 

converter from the DC supply. Do not operate the DC switch/disconnector under 
load.

Charging switch

A converter unit with a DC switch/disconnector must also have a charging circuit including 
a charging switch [Q10.x]. 

If the switches are connected as shown in the 

Example circuit diagrams

, the charging 

switch is closed first when the converter unit is connected to an energized DC bus. When 
the charging is finished, the main DC switch/disconnector can be closed and the charging 
switch opened. (The converter unit will not start if the charging switch is closed.)

WARNING!

 You must also switch off the charging switch to disconnect the DC/DC 

converter from the DC supply.

Door lights

You can install, for example, the following lamps on the DC/DC converter cabinet door:

•

 If you have the DC switch/disconnector installed - Charging OK indicator and DC/DC 
converter disconnected indicator

•

You can connect a Load disconnected indicator to the disconnecting device of the 
energy storage.

BCU control unit

The DC/DC converter module is controlled by a BCU control unit.

For more information, see chapter 

Control unit

 on page 

161

.

ACS-AP-x control panel

The ACS-AP-x is the user interface of the converter unit. With the control panel, you can:

•

start and stop the converter unit

•

view and reset the fault and warning messages, and view the fault history

•

view actual signals

•

change parameter settings

•

change between local and external control.

The control panel can be mounted on the cabinet door using a DPMP-01 mounting 
platform (available separately).

Summary of Contents for ACS880-1604

Page 1: ...ABB industrial drives Hardware manual ACS880 1604 DC DC converter modules ...

Page 2: ...0000020457 ACS880 regenerative rectifier control program firmware manual 3AXD50000020827 Inverter module manuals and guides ACS880 104 inverter modules hardware manual 3AUA0000104271 ACS880 primary control program firmware manual 3AUA0000085967 ACS880 primary control program quick start up guide 3AUA0000098062 Brake module and DC DC converter module manuals ACS880 604 1 phase brake chopper units a...

Page 3: ...dware manual ACS880 1604 DC DC converter modules 3AXD50000023642 Rev B EN EFFECTIVE 2017 02 08 2017 ABB Oy All Rights Reserved 4 Cabinet construction 6 Electrical installation Table of contents 8 Start up ...

Page 4: ......

Page 5: ...odules 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 X53 26 BDCL filter module 27 Filter module connectors X30 and X55 28 Overview of the control...

Page 6: ...8 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 in...

Page 7: ...n procedure 76 Fiber optic connectors of the DC DC converter module 77 Installing optional modules 78 Connecting a PC 79 7 Installation checklist Contents of this chapter 81 Warnings 81 Checklist 82 8 Start up 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 ...

Page 8: ...net 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 M...

Page 9: ... 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 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 ...

Page 10: ...9 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 ...

Page 11: ... 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 2...

Page 12: ...12 ...

Page 13: ...efore you install commission use or service the converter The complete safety instructions are given in ACS880 multidrive and multidrive modules safety instructions 3AUA0000102301 English 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 install commission use and service the DC DC converte...

Page 14: ...h 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 lab...

Page 15: ... DI Digital input DOL Direct on line fan C188 Drive Frequency converter for controlling AC motors EMC Electromagnetic compatibility Energy storage Device that stores electrical energy for example a battery or a super capacitor Flat PLS Rittal TS 8 Flat PLS a busbar system for standard commercially available flat bars Frame size Refers to power modules that share a similar mechanical construction f...

Page 16: ...16 Introduction to the manual Supply unit Part of the drive system that rectifies the AC supply voltage and outputs a DC voltage Term Abbreviation Description ...

Page 17: ...ion principle and hardware description 17 2 Operation principle and hardware description Contents of this chapter This chapter describes the DC DC converter operation basics and the hardware of the converter ...

Page 18: ...C 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...

Page 19: ...ector if quick isolation of the module from the DC bus is required Main circuit diagram of DC DC converter without DC switch disconnector and charging circuit This figure shows a simplified main circuit diagram of a DC DC converter without a DC switch disconnector and charging circuit 1 Drive DC bus 2 DC DC converter module 3 Filter module 4 Energy storage B 8 9 8 9 6 6 6 6 6 L L 1 2 3 4 ...

Page 20: ...connector and charging circuit This figure shows a simplified main circuit diagram of a DC DC converter with the DC switch disconnector and charging circuit 1 Drive DC bus 2 DC switch disconnector 3 DC DC converter module 4 Filter module 5 Energy storage 6 Charging components B 8 9 8 9 6 6 6 6 6 1 3 4 5 2 6 ...

Page 21: ...disconnector and charging circuit Also the energy storage and related cabling and equipment are visible 1 DC DC converter cubicles 2 Energy storage cabinet 3 Drive DC bus 4 DC switch disconnector 5 Charging components 6 DC DC converter module 7 Filter module 8 Cabling between DC DC converter unit and energy storage 9 Energy storage disconnector 10 Contactor 11 Energy storage 6 6 6 6 6 6 6 6 6 6 1 ...

Page 22: ...e energy storage with fuses and a device for disconnecting the storage from the DC DC converter The disconnecting device does not belong to the DC DC module product offering 1 AC supply 2 Input AC fuses 3 Supply module 4 DC bus 5 Inverter DC fuses with or without a DC switch disconnector 6 Inverter modules 7 Motors 8 DC fuses DC bus side with or without a DC switch disconnector 9 DC DC converter u...

Page 23: ...he diagram It also indicates if customer can order the components from ABB or if the customer needs to acquire them separately Cubicle No Explanation Available through A DC DC converter cubicle 1 DC bus A 2 DC switch disconnector optional ABB or third party A 3 Charging switch fuse optional ABB or third party A 4 Charging resistors optional ABB or third party A 5 DC fuses DC bus side ABB or third ...

Page 24: ...nit contains the basic I Os and slots for optional I O modules For descriptions of the I O terminals on the control unit see chapter Control unit on page 161 and Fiber optic connectors of the DC DC converter module on page 77 See also the Installation examples in chapter Cabinet construction DC bus connection and capacitor charging The converter unit must be equipped with DC fuses on the DC bus si...

Page 25: ... to the control board 4 Fan 5 Quick connector BDCL connection The counterpart fastened to the cabinet behind the module 6 Wheels 7 Type designation label of the module 8 Terminal block X50 power supply for internal boards and module heating element option C183 DOL fan supply option C188 See also Converter module connectors X50 X53 on page 26 9 Connector X53 10 The unpainted grounding point PE betw...

Page 26: ... use X52 STO IN STO connectors of the module Must be connected to 24 V DC for the DC DC converter module to start X53 24V OUT 24 V DC for BCU and for STO IN to enable DC DC converter module operation Note The Safe torque off STO safety function is only implemented in inverter units Therefore the STO function cannot be used in DC DC converter and brake units In DC DC converter and brake units de en...

Page 27: ...1 Energy storage connection 2 Converter module connection 3 Terminal block X55 DOL fan supply option C188 ready connected 4 Handle 5 Fan 6 Wheels 7 Terminal block X30 module DOL fan supply option C188 8 Type designation label of the module 9 The unpainted grounding point 10 Lifting eyes A B 6 2 4 1 3 5 7 8 9 2 ...

Page 28: ...tion point for the filter fan power supply Note These terminals are wired further to connector X55 1 and A55 2 internally by ABB 1 BDCL module connector X55 This connector is plugged further to connector X55 of the filter cooling fan at the factory by ABB 4 Not in use 3 2 Plus code C188 DOL fan N These terminals are wired further to the filter connector X30 1 and X30 2 internally by ABB 1 Plus cod...

Page 29: ... Control unit The diagram shows the control connections and interfaces of the BCU control unit 1 2 3 Analog and digital I O extension modules and fieldbus communication modules can be inserted into slots 1 2 and 3 7 Control panel 4 Memory unit 8 Fiber optic links to converter modules 5 Slot 4 for RDCO 0x 9 Ethernet interface 6 Terminal blocks See chapter Control unit on page 161 10 Not in use in D...

Page 30: ...er unit is connected to an energized DC bus When the charging is finished the main DC switch disconnector can be closed and the charging switch opened The converter unit will not start if the charging switch is closed WARNING You must also switch off the charging switch to disconnect the DC DC converter from the DC supply Door lights You can install for example the following lamps on the DC DC con...

Page 31: ...front of the panel that can be used to connect a PC to the converter When a PC is connected to the control panel the control panel keypad is disabled See also section Connecting a PC on page 79 Fieldbus control You can control the converter unit through a fieldbus interface if the unit is equipped with an optional fieldbus adapter and when you have configured the control program for the fieldbus c...

Page 32: ... See section Type designation of the converter module on page 34 2 Frame size 3 Degree of protection 4 UL CSA data See section Input power DC bus connection on page 155 5 Ratings See also section Ratings on page 148 Input power DC bus connection on page 155 and Output power energy storage connection on page 155 6 Valid markings See Electrical planning instructions for ACS880 multidrive cabinets an...

Page 33: ... Type designation See Type designation of the filter module on page 35 2 Degree of protection 3 UL CSA data 4 Ratings 5 Code of the filter 6 Valid markings See Electrical planning instructions for ACS880 multidrive cabinets and modules 3AUA0000102324 English 7 Serial number The first digit of the serial number refers to the manufacturing plant The next four digits refer to the unit s manufacturing...

Page 34: ...f the DC DC converter module CODE DESCRIPTION Basic codes ACS880 Product series 104 Construction DC DC converter module The module delivery includes a speed controlled cooling fan as standard Size 600A Refer to the rating tables on page 148 Voltage range 3 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 35: ...owed by descriptive digits The plus codes are separated by plus signs CODE DESCRIPTION Basic codes BDCL 1x BDCL filter Voltage range 5 DC voltage corresponding AC input voltages 3 380 500 V AC This is indicated in the type designation label as typical input voltage levels 566 679 707 V DC 7 DC voltage corresponding AC input voltages 3 525 690 V This is indicated in the type designation label as ty...

Page 36: ...36 Operation principle and hardware description ...

Page 37: ...tion Use soft lifting slings Unpacking The module is delivered on a wooden base boxed in corrugated cardboard The cardboard box is tied to the base with PET bands 1 Cut off the bands 2 Lift off the cardboard box 3 Remove any filling material 4 Cut open the plastic wrapping of the module 5 Lift off the module 6 Check that there are no signs of damage 7 Dispose of or recycle the packaging according ...

Page 38: ...ules are heavy and have a high center of gravity They topple over easily if handled carelessly Do not tilt the module Do not leave the module unattended on a sloping floor Wear protective gloves and long sleeves Some parts have sharp edges For more information on placing the module into the cubicle see Replacing the R8i DC DC converter module on page 106 and Replacing the BDCL filter on page 110 R...

Page 39: ...rive modules 3AUA0000107668 English Liability The installation must always be designed and made according to applicable local laws and regulations ABB does not assume any liability whatsoever for any installation which breaches the local laws and or other regulations Energy storage Obey the energy storage manufacturer s instructions Cooling and mounting orientations For free space requirements coo...

Page 40: ...figuration that can be installed in the Rittal TS 8 and generic enclosures The figure shows the converter with a DC switch disconnector solution and without the DC switch disconnector BCU BCU control unit BDCL BDCL filter DDC DC DC converter unit R8i DC DC module frame R8i DDC 800 R8i BDCL BCU DDC 800 R8i BDCL BCU With DC switch disconnector Without DC switch disconnector ...

Page 41: ...equipment in the order in which the installation into the cabinet should be performed code of the step by step instructions equipment kit code kit ordering code You can find the kit specific assembly drawings step by step instructions and kit information on the Internet Go to https sites apps abb com sites lvacdrivesengineeringsupport content If needed contact your local ABB representative The exa...

Page 42: ...er module bottom cable entries for the energy storage connection DC switch disconnector and charging components Cubicle including 1 R8i DC DC converter module 2 BDCL filter module 3 Module cooling fan 4 Cable entries for energy storage cables 5 DC switch disconnector 6 Charging switch 7 Charging controller 8 Converter DC fuses on the drive DC bus side 9 Output DC fuses for energy storage connectio...

Page 43: ...cludes an R8i DC DC converter module a BDCL filter module and bottom cable entries for the energy storage connection Cubicle including 1 R8i DC DC converter module 2 BDCL filter module 3 Module cooling fan 4 Cable entries for energy storage cables 5 Control unit 6 Energy storage connection 7 Output DC fuses for energy storage connection 8 DC fuses DC bus side fuses for R8i DC DC module connection ...

Page 44: ...echanics Busbars 3AXD50000045378 3AXD50000004834 A 8 8 298 A 46 8 207 3AXD50000044815 3AXD50000004412 4B DC connection without DC switch disconnector and charging DC busbar mounting plate Busbars 3AXD50000023592 3AXD50000005729 A 8 8 264 A 46 8 206 3AXD50000021798 3AXD50000004411 5A DC connection with DC switch disconnector and charging DC busbars L shaped DC busbars 3AXD50000043411 3AXD5000004346...

Page 45: ...Cabinet construction 45 Kits for DDC R8i unit in 800 mm Rittal TS 8 enclosure ...

Page 46: ...46 Cabinet construction Stage 1 Installation of common parts ...

Page 47: ...Cabinet construction 47 Stage 2 Module and bottom cable entry installation parts ...

Page 48: ...48 Cabinet construction Stage 3 Busbars and quick connectors for connecting DDC module and filter ...

Page 49: ...Cabinet construction 49 Stage 4A DC connection with charging ...

Page 50: ...50 Cabinet construction Stage 4B DC connection without charging ...

Page 51: ...Cabinet construction 51 Stage 5A DC connection with charging ...

Page 52: ...52 Cabinet construction Stage 5B DC connection without charging ...

Page 53: ...Cabinet construction 53 Stage 6 DDC and energy storage connection ...

Page 54: ...54 Cabinet construction Stage 7 Control unit mounting plate ...

Page 55: ...Cabinet construction 55 Stage 8 DDC shroud installation ...

Page 56: ...56 Cabinet construction Stage 9 DDC module and filter installation ...

Page 57: ...connection with DC switch disconnector and charging Charging mechanics 3AXD50000044863 A 8 8 299 3AXD50000044814 DC connection without DC switch disconnector and charging DC busbar mounting plate 3AXD50000023291 A 8 8 268 3AXD50000023032 Common mode busbars and DC connection flanges with charging 3AXD50000043411 3AXD50000043466 A 468 8 247 A 468 8 248 3AXD50000044551 3AXD50000044553 DC busbars for...

Page 58: ...58 Cabinet construction Kits for DDC R8i unit in 800 mm wide generic enclosure ...

Page 59: ... laws and regulations ABB does not assume any liability whatsoever for any installation which breaches the local laws and or other regulations Furthermore if the recommendations given by ABB are not followed the drive may experience problems that the warranty does not cover Generic guidelines See Electrical planning instructions for ACS880 multidrive cabinets and modules 3AUA0000102324 English for...

Page 60: ...th IGBT supply units with modules ACS880 204 typically with regenerative rectifier units with modules ACS880 904 where We recommend to measure the energy storage voltage If you use a super capacitor as the energy storage voltage measurement is obligatory If the converter is equipped with the optional BAMU voltage current measurement unit the converter measures its output voltage and thus also the ...

Page 61: ...e does not belong to the module product offering In case of a super capacitor you may need a discharging device Make sure that the user cannot close the energy storage disconnector before the DC switch disconnector Q11 xx of the DC DC converter is closed Equip the system with appropriate interlockings Implementing load current switch off The customer must equip the energy storage also with a conta...

Page 62: ...A Cable data 3 conductor cable 4 conductor cable PVC T 70 C copper cable XLPE T 90 C copper cable PVC T 70 C copper cable XLPE T 90 C copper cable mm2 mm2 mm2 mm2 UN 400 V ACS880 1604 0600A 3 R8i 720 3 3 185 95 2 3 240 120 2 4 120 70 1 4 240 120 ACS880 1604 0900A 3 R8i 1080 4 3 240 120 4 3 150 70 2 4 240 120 2 4 185 95 ACS880 16041200A 3 2 R8i 1440 2 3 3 185 95 2 2 3 240 120 4 4 120 70 2 4 240 120...

Page 63: ...r the cable the higher the radiated emissions inductive load and voltage peaks over the IGBTs of the DC DC converter Maximum cable length The maximum cable length of the energy storage cable s is 100 m 328 ft EMC compliance of the complete installation Note ABB has not verified that the EMC requirements are fulfilled with external energy storage and its cabling The EMC compliance of the complete i...

Page 64: ...64 Guidelines for planning electrical installation ...

Page 65: ...mation on cable selection protections etc see Electrical planning instructions for ACS880 multidrive cabinets and modules 3AUA0000102324 English Safety and liability WARNING Read the safety instructions given in Safety instructions for ACS880 multidrive cabinets and modules 3AUA0000102301 English before you install commission use or service the drive Note The installation must always be designed a...

Page 66: ...ctors of the energy storage modules Open the main switch disconnector Q1 or rack out the main breaker Q1 of the drive whichever is present Open the disconnector of the supply transformer as the main disconnecting device of the drive does not remove the voltage from the input busbars of the drive or from the voltmeter if present Make sure that reconnection is not possible Lock the disconnectors to ...

Page 67: ...discharge ESD Wear a grounding wrist band when handling the boards Do not touch the boards unnecessarily Optical components Handle fiber optic cables with care When unplugging optic cables always grab the connector not the cable itself Do not touch the ends of the fibers with bare hands as the fiber is extremely sensitive to dirt ...

Page 68: ...lation between the main circuit and the chassis at the factory Check the insulation resistance of the energy storage as instructed by its manufacturer Check the energy storage cable as follows 1 Make sure that the cable is disconnected from the DC DC converter and energy storage all conductors and the shield 2 At the converter unit end connect all conductors and shield of the cable together and to...

Page 69: ...For tightening torques see Cabinet design and construction instructions for ACS880 multidrive modules 3AUA0000107668 English 1 DC DC converter cubicle 2 Energy storage cubicle 3 Charging circuit components For charging circuit connections see the example circuit diagrams 4 DC DC converter module R8i 5 BDCL filter module 6 Shielded 3 conductor or 4 conductor cable and 360 degree grounding of the ca...

Page 70: ...ve If the connections are ready check them against the final circuit diagrams Do not use the example circuit diagrams in this manual as the sole source of information when doing or checking the connections For the tightening torques see Tightening torques on page 154 4 Ground the modules by the top edge of the front plate The grounding point is marked on the module a Connect the front plate to the...

Page 71: ...Electrical installation 71 5 Refit any shrouding removed earlier and close the cubicle doors 4 a b b ...

Page 72: ... converter cubicle and remove the shrouding if any 3 Lead the cables into the cubicle 4 Ground the cable shield 360 degrees at the cable entry See the instructions by the cabinet installer An example grounding arrangement is shown below 5 Cut the cables to suitable length Strip the cables and conductors and install the cable lugs at the end of the conductors 6 Connect the conductors to appropriate...

Page 73: ...nnect the module thermistors X30 5 X30 6 to the thermistor input XD1 of the control unit See the connection diagram below By default the BDCL filter is protected against overheating caused by a faulty fan for example with a thermistor and the temperature monitoring function of the control program If the filter temperature becomes too high the temperature monitoring function stops the DC DC convert...

Page 74: ...CONNECTION INVERTER CONNECTION plug connector FILTER MODULE BDCL 1x x A DOL FAN C188 t U2 PE Z M 1 U1 G41 X1 1 X1 2 X1 3 X1 4 LCLTP 1 2 3 4 6 5 7 X30 9 8 7 6 5 4 3 2 1 3 2 1 N HEATER L HEATER TP2 TP1 N FAN L FAN 2 1 3 N L L N H07Z K1 5 X55 4 X55 4 N HEATER L HEATER N FAN L FAN V2 W2 B C ...

Page 75: ...s 24 V DC from the auxiliary voltage for the internal circuit boards The 24 V DC voltage provided by the BDPS is available on X53 and can used to power up one BCU control unit It is not allowed to use the 24 V DC output on terminal X53 for any other purpose than for powering up the BCU control unit If a direct on line fan option C188 is used connect the fan supply 400 V AC 50 Hz 60 Hz to the modul...

Page 76: ...les 3AUA0000102301 English Ignoring the instructions can cause physical injury or death or damage to the equipment 1 Open the cubicle door 2 Remove the shrouds if any from the cubicle 3 Run the cables into the cabinet If possible arrange for a 360 grounding of the cable shield at the cable entry through If the outer surface of the shield is non conductive turn the shield inside out as shown below ...

Page 77: ...module 2 3 4 1 Keep as short as possible If no dedicated shield connector is provided ground the inner cable shields to the chassis SHIELD Where grounding clamps are not available twist the shield strands into a bundle crimp a lug terminal onto it and fasten the lug to the chassis Secure the cable into place with eg cable ties At the other end of the cable leave the shield unconnected or connect i...

Page 78: ...Ensure by measuring that the I O terminals of the control unit especially the relay output terminals are safe 3 Insert the module into a free option module slot on the control unit Refer to chapter Control unit 4 Fasten the module For instructions see the documentation of the module 5 Connect the necessary wiring to the module following the instructions given in the documentation of the module and...

Page 79: ...ctly to the control panel connector of the DC DC converter unit as this can cause damage 2 Remove the USB connector cover on the front of the control panel 3 Connect an USB cable Type A to Type Mini B between the USB connector on the control panel and a free USB port on the PC 4 The panel displays an indication whenever the connection is active 5 See the documentation of the PC tool for setup inst...

Page 80: ...80 Electrical installation ...

Page 81: ...ete before you start up the converter Warnings WARNING Obey the safety instructions for the drive See Safety instructions for ACS880 multidrive cabinets and modules 3AUA0000102301 English If you ignore the safety instructions injury or death or damage to the equipment can occur Only a qualified electrician is allowed to work on the installation ...

Page 82: ...lvanic connection to the cabinet protective earth ground busbar The connection surfaces at the fastening points are bare unpainted and the connections are tight or separate grounding conductors have been installed The main circuit connections inside the drive cabinet correspond to the circuit diagrams The energy storage has been equipped with fuses for protecting the energy storage cable in a cabl...

Page 83: ... to the circuit diagram of the example installation by ABB Note The instructions do not cover all possible cabinet constructions and energy storage media WARNING Only qualified by ABB electricians engineers are allowed to do the work described in this chapter In addition the electrician engineer must know the energy storage system he is about to take in use and the DC DC converter control program ...

Page 84: ...n customer installed device Make sure that the mechanical and electrical installation of the converter unit has been inspected and is OK See chapter Installation checklist Make sure that the drive is ready for the converter unit start up The supply and inverter units have been installed according to the instructions given in their hardware manuals The supply unit has been started up according to t...

Page 85: ...5 01 Supply voltage Reboot the control unit again by parameter 196 08 Control board boot Charging the DC DC converter and connecting voltage to the converter WARNING Make sure that the energy storage disconnecting device is still open Always keep the energy storage disconnected from DC DC converter until the DC DC converter is charged Power up and charge the DC DC converter DC DC converter with th...

Page 86: ...gy storage disconnector customer installed device Close the energy storage contactor customer installed device Testing the DC DC converter operation Contact your local ABB representative for testing instructions Make sure that the DC DC converter module and filter module cooling fan rotates freely in the right direction A paper sheet set on the intake door gratings stays The fans run noiselessly T...

Page 87: ...DC converter Stop the converter unit See DC DC converter control program firmware manual 3AXD50000024671 English Disconnecting the energy storage Open the contactor of the energy storage Open the disconnector of the energy storage Lock out and tag out Disconnecting the DC DC converter Open the DC switch disconnector Q11 Lock out and tag out Working inside the DC DC converter cubicle If you need to...

Page 88: ...ing inside the DC DC converter cubicle close the cubicle door and obey the instructions of Connecting voltage to the drive and converter control unit Charging the DC DC converter and connecting voltage to the converter and Connecting the energy storage to the DC DC converter on page 85 Starting the DC DC converter Start the converter unit See DC DC converter control program firmware manual 3AXD500...

Page 89: ...d example cabinet installations of the modules Note The instructions do not cover all possible cabinet constructions WARNING Only qualified electricians are allowed to do the work described in this chapter Read the complete safety instructions before you install commission use or service the converter The complete safety instructions are given in Safety instructions for ACS880 multidrive cabinets ...

Page 90: ...for additional maintenance recommendations Maintenance task object Years from start up 0 1 2 3 4 5 6 7 8 9 10 11 12 Cooling fans Main cooling fan speed controlled R Main cooling fan direct on line 50 Hz R R Main cooling fan direct on line 60 Hz R R BDCL filter cooling fan DOL 50 Hz R R BDCL filter cooling fan DOL 60 Hz R R Internal cooling fan for circuit boards R R Cabinet cooling fan internal R ...

Page 91: ...h before you service the drive If you ignore them injury or death or damage to the equipment can occur WARNING Use a vacuum cleaner with an antistatic hose and nozzle and wear a grounding wristband Otherwise an electrostatic charge might build up and damage the circuit boards 1 Disconnect the drive from the AC power line and DC DC converter from the energy storage and obey the instructions in sect...

Page 92: ...If the dust cannot be removed by vacuum cleaning from outside through the grating holes with a small nozzle proceed as follows 1 Recommendation De energize the fans by switching off the DC DC converter unit obey the instructions in section Electrical safety precautions on page 66 2 Remove the fasteners at the top of the grating 3 Lift the grating and pull it away from the door 4 Vacuum clean or wa...

Page 93: ...ns on page 66 2 Remove the fasteners at the top of the grating 3 Lift the grating and pull it away from the door 4 Remove the air filter mat 5 Place the new filter mat in the grating the metal wire side facing the door 6 Reinstall the grating in reverse order Cleaning the outlet roof filters IP54 The outlet roof filter in IP54 units can be accessed by pulling the grating upwards 2 3 4 5 6 ...

Page 94: ... injury or death or damage to the equipment can occur 1 Disconnect the drive from the AC power line and DC DC converter from the energy storage and obey the instructions in section Electrical safety precautions on page 66 See Disconnecting the DC DC converter with DC switch disconnector on page 87 2 Check the tightness of the cable connections For the tightening torques see Cabinet design and cons...

Page 95: ... service the drive If you ignore them injury or death or damage to the equipment can occur WARNING Wear protective gloves and long sleeves Some parts have sharp edges 1 Disconnect the drive from the AC power line and DC DC converter from the energy storage and obey the instructions in section Electrical safety precautions on page 66 See Disconnecting the DC DC converter with DC switch disconnector...

Page 96: ... or damage to the equipment can occur WARNING Wear protective gloves and long sleeves Some parts have sharp edges 1 Disconnect the drive from the AC power line and DC DC converter from the energy storage and obey the instructions in section Electrical safety precautions on page 66 See Disconnecting the DC DC converter with DC switch disconnector on page 87 2 Open the door and remove the shroud if ...

Page 97: ...Maintenance 97 7 3 4 5 6 ...

Page 98: ...ent can occur WARNING Wear protective gloves and long sleeves Some parts have sharp edges 1 Disconnect the drive from the AC power line and DC DC converter from the energy storage and obey the instructions in section Electrical safety precautions on page 66 See Disconnecting the DC DC converter with DC switch disconnector on page 87 2 Open the door and remove the shroud if any in front of the fan ...

Page 99: ...Maintenance 99 3 4 5 6 7 8 9 9 ...

Page 100: ...02301 English before you service the drive If you ignore them injury or death or damage to the equipment can occur WARNING Wear protective gloves and long sleeves Some parts have sharp edges 1 Disconnect the drive from the AC power line and DC DC converter from the energy storage and obey the instructions in section Electrical safety precautions on page 66 See Disconnecting the DC DC converter wit...

Page 101: ...rom the fan holder 8 Put the new fan onto the threaded studs on the fan holder with the airflow direction arrow pointing towards the fan holder 9 Install and tighten the four nuts removed earlier 10 Connect the fan cable 11 Align and push the fan holder into the module 7 6 9 8 ...

Page 102: ...102 Maintenance 12 Install and tighten the two screws 10 11 12 ...

Page 103: ...ath or damage to the equipment can occur WARNING Wear protective gloves and long sleeves Some parts have sharp edges 1 Disconnect the drive from the AC power line and DC DC converter from the energy storage and obey the instructions in section Electrical safety precautions on page 66 See Disconnecting the DC DC converter with DC switch disconnector on page 87 2 Open the door 3 Remove the screws in...

Page 104: ...d for each air outlet kit in section Air outlet kits on page 143 contains an exploded view of the outlet Remove all gratings and filters and finally remove the plate on top of the outlet Unscrew all necessary screws securing the fan and remove it 3 Install new fan in reverse order Cabinets with other fan types WARNING Only qualified electricians are allowed to do this work Read the complete safety...

Page 105: ...es Some parts have sharp edges WARNING Use a vacuum cleaner with an antistatic hose and nozzle Using a normal vacuum cleaner creates static discharges which can damage circuit boards 1 Disconnect the drive from the AC power line and DC DC converter from the energy storage and obey the instructions in section Electrical safety precautions on page 66 See Disconnecting the DC DC converter with DC swi...

Page 106: ... cubicle along the ramp While pulling on the handle keep a constant pressure with one foot on the base of the module to prevent the module from falling on its back When replacing a module push the module up the ramp and back into the cubicle Keep your fingers away from the edge of the module front plate to avoid pinching them between the module and the cubicle Also keep a constant pressure with on...

Page 107: ...dule from the cabinet If the ramp is used install it by placing the hooks of the ramp between the bottom plate and Rittal frame 9 Pull the module carefully out of the cabinet along the ramp or use any other lifting device to remove the module 10 Replace the module 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...

Page 108: ...108 Maintenance 6 6 6 7 5 4 ...

Page 109: ...Maintenance 109 8 9 8 ...

Page 110: ...cubicle along the ramp While pulling on the handle keep a constant pressure with one foot on the base of the module to prevent the module from falling on its back When replacing a module push the module up the ramp and back into the cubicle Keep your fingers away from the edge of the module front plate to avoid pinching them between the module and the cubicle Also keep a constant pressure with one...

Page 111: ...bolts on the DC connection 7 Remove the four fastening screws in the lower part of the filter module 8 Pull the module carefully out of the cabinet along the ramp or use any other lifting device to remove the module 9 Replace the module Push the module back in and fasten Be careful not to break the fastening screws tighten the fastening screws to 22 N m 16 2 lbf ft and fastening bolts to 70 N m 51...

Page 112: ...112 Maintenance 4 4 ...

Page 113: ...Maintenance 113 6 6 5 7 7 8 ...

Page 114: ...f capacitor failure is suspected Replacements are available from ABB Do not use other than ABB specified spare parts Contact an ABB service representative for spare parts and repair services Reforming the capacitors The DC circuit capacitors must be reformed if the converter module has not been powered either in storage or unused for a year or more See section Type designation labels page 32 for i...

Page 115: ...ockwise until the lid opens 2 Replace the battery with a new CR2032 battery 3 Put the lid back and tighten it by turning it clockwise 4 Dispose of the old battery according to local disposal rules or applicable laws Cleaning the control panel See ACX AP x assistant control panels user s manual 3AUA0000085685 English ...

Page 116: ... unit from the defective unit to the new unit WARNING Only qualified electricians are allowed to do this work Read the complete safety instructions of the drive Ignoring the instructions can cause physical injury or death or damage to the equipment WARNING Do not remove or insert the memory unit when the control unit is powered 1 Disconnect the drive from the AC power line and DC DC converter from...

Page 117: ...nated when the control unit is powered For information on the LED see Layout and connections on page 164 1 Undo the fastening screw and remove the battery 2 Replace the battery with a new BR2032 battery 3 Dispose the old battery according to local disposal rules or applicable laws 4 Set the real time clock ...

Page 118: ...green The DC DC converter is functioning normally Flickering green Data is transferred between the PC tool and DC DC converter through the USB connection of the control panel Blinking green There is an active warning in the DC DC converter Continuous red There is an active fault in the DC DC converter Control panel mounting platform with the control panel removed Red There is an active fault in th...

Page 119: ...sourced from a third party such as Rittal by the system integrator For a listing refer to the kit specific installation instructions available at https sites apps abb com sites lvacdrivesengineeringsupport content For access contact your local ABB representative Parts that are labeled suitable for generic enclosures are not designed for any specific enclosure system These parts are intended as a b...

Page 120: ... related to DC connection for example busbars 300 399 Kits related to module installation for example mechanical supports 400 499 Other kits 500 599 Marine kits 001 019 Common AC and DC related kits 020 039 Air inlets 040 059 Air outlets 060 070 Air outlets with a fan 100 129 Kits with connection to AC 130 149 Kits with connection to module 150 199 Other kits related to AC connection 200 229 Kits ...

Page 121: ...ther parts listed may be required by the application or make the installation or use of the module easier DC DC converter unit Modules used Type Frame size Qty Ordering code for options see below Contents UN 400 V DC DC converter module s frame R8i with speed controlled cooling fan s ACS880 1604 0600A 3 R8i 1 ACS880 104 0640A 3 E205 ACS880 1604 0900A 3 R8i 1 ACS880 104 0900A 3 E205 ACS880 1604 120...

Page 122: ... 1200A 3 2 R8i ACS880 BDCL 14 5 C188 2 3AUA0000173022 1800A 3 2 R8i ACS880 BDCL 15 5 C188 2 3AUA0000173021 UN 500 V 0600A 5 R8i ACS880 BDCL 14 5 C188 1 3AUA0000173022 0900A 5 R8i ACS880 BDCL 15 5 C188 1 3AUA0000173021 1200A 5 2 R8i ACS880 BDCL 14 5 C188 2 3AUA0000173022 1800A 5 2 R8i ACS880 BDCL 15 5 C188 2 3AUA0000173021 UN 690 V 0400A 7 R8i ACS880 BDCL 14 7 C188 1 3AUA0000173010 0600A 7 R8i ACS8...

Page 123: ... R8i ACS880 BDCL 14 5 C188 G304 2 3AUA0000180031 1800A 3 2 R8i ACS880 BDCL 15 5 C188 G304 2 3AUA0000180030 UN 500 V 0600A 5 R8i ACS880 BDCL 14 5 C188 G304 1 3AUA0000180031 0900A 5 R8i ACS880 BDCL 15 5 C188 G304 1 3AUA0000180030 1200A 5 2 R8i ACS880 BDCL 14 5 C188 G304 2 3AUA0000180031 1800A 5 2 R8i ACS880 BDCL 15 5 C188 G304 2 3AUA0000180030 UN 690 V 0400A 7 R8i ACS880 BDCL 14 7 C188 G304 1 3AUA00...

Page 124: ...ing kit For more information on the control panel see ACX AP x assistant control panels user s manual 3AUA0000085685 English For the dimension drawing see section ACS AP x control panel with door mounting kit on page 175 The door mounting kit contains front cover flat cable between DDPI 01 board and the panel DDPI 01 board cover and M4 8 Combi screw for the cover Type Description Ordering code Ill...

Page 125: ...Ordering information 125 EMC shield control panel mounting platform grounding wire Ethernet cable 3 m DPMP 01 mounting platform for ACS AP control panel installation guide 3AUA0000100140 English ...

Page 126: ... cable Use appropriate X53 plug connector for the connection to the DC DC converter module See sections Converter module connectors X50 X53 on page 26 and Control circuit plug connectors on page 127 For more information on the control unit see chapter Control unit For the dimension drawings see section BCU control unit on page 176 DC DC converter module Frame size Control unit Qty Ordering code Il...

Page 127: ...ctors X51 X52 and X53 are included in the module kit For more information on the connectors see Converter module connectors X50 X53 on page 26 Filter module connectors X30 and X55 on page 28 Type Data Ordering code NLWC 02 2 2 m single core cables with connectors 58988821 NLWC 03 2 3 m single core cables with connectors 58948233 NLWC 05 2 5 m single core cables with connectors 58948250 NLWC 07 2 7...

Page 128: ...gns presented in this manual for Rittal TS 8 enclosures employ the Rittal Flat PLS busbar system Make sure that the current carrying capability of the busbars is not exceeded at any point of the drive system Enclosure Qty Ordering code Kit code Illustration 800 mm Rittal TS 8 1 per cubicle 3AXD50000021797 A 8 8 332 Generic 1 per cubicle 3AXD50000023031 A 8 8 333 Instruction code 3AXD50000023497 In...

Page 129: ...e ramp with plinth heights over 100 mm The ramp is designed for a plinth height of 100 mm the standard plinth height of Rittal TS 8 cabinets See the dimension drawing see section Ramp on page 179 Enclosure Qty Ordering code Kit code Illustration Rittal TS 8 1 per cubicle 3AXD50000045955 A 8 8 361 Frame size Enclosure Qty Ordering code Kit code Illustration R8i Rittal TS 8 1 3AUA0000120467 A 468 8 ...

Page 130: ... plate kit includes a mounting plate to which the control unit can be attached with a DIN rail It also includes a small shroud that can be used as an alternative upper side shroud with the shroud kit Enclosure Qty Ordering code Kit code Illustration Rittal TS 8 and generic 2 kits per cubicle 3AXD50000004385 A 468 8 441 Enclosure Qty Ordering code Kit code Illustration Rittal TS 8 and generic 1 3AX...

Page 131: ...rom the DC DC converter module to the BDCL filter For the dimension drawing of the quick connector see section 170M6545 170M6549 on page 189 Enclosure Qty Ordering code Kit code Illustration Rittal TS 8 1 per cubicle 3AXD50000021807 A 8 8 269 Generic 1 per cubicle 3AXD50000023007 A 8 8 270 Instruction code 3AXD50000023492 Instruction code 3AXD50000023212 ...

Page 132: ... TS 8 enclosures employ the Rittal Flat PLS busbar system Make sure that the current carrying capability of the busbars is not exceeded at any point of the drive system Rittal TS 8 and generic 1 per module 1 for DDC and 1 for filter module 3AUA0000119227 A 468 8 100 Enclosure Qty Ordering code Kit code Illustration Rittal TS 8 1 per cubicle 3AUA0000115906 A 468 X 001 Enclosure Qty Ordering code Ki...

Page 133: ... Enclosure Qty Ordering code Kit code Illustration Rittal TS 8 with DC switch disconnector and charging 1 3AXD50000044815 A 8 8 298 Generic with DC switch disconnector and charging 1 3AXD50000044814 A 8 8 299 Rittal TS 8 with DC switch disconnector and charging 1 kit 3AXD50000004412 A 46 8 207 Instruction code 3AXD50000045378 Instruction code 3AXD50000044863 Instruction code 3AXD50000004834 ...

Page 134: ...ng 1 kit per R8i module 3AXD50000044551 A 468 8 247 Rittal TS 8 and generic with DC switch disconnector and charging 1 kit per R8i module 3AXD50000044553 A 468 8 248 Enclosure Qty Ordering code Kit code Illustration Rittal TS 8 without DC switch disconnector and charging 1 3AXD50000021798 A 8 8 264 Enclosure Qty Ordering code Kit code Illustration Instruction code 3AXD50000043411 Instruction code ...

Page 135: ...and generic without DC switch disconnector and charging 1 kit per R8i module 3AXD50000023340 A 468 8 266 Rittal TS 8 and generic without DC switch disconnector and charging 1 kit per R8i module 3AXD50000003411 A 468 8 232 Enclosure Qty Ordering code Kit code Illustration Instruction code 3AXD50000023291 Instruction code 3AXD50000005729 Instruction code 3AXD50000023463 Instruction code 3AXD50000003...

Page 136: ...ovide the DDC and energy storage connection Enclosure Qty Ordering code Kit code Illustration Rittal TS 8 1 kit per cubicle 3AXD50000021808 A 8 8 243 Generic 1 kit per cubicle 3AXD50000023008 A 8 8 244 Instruction code 3AXD50000023567 Instruction code 3AXD50000023217 ...

Page 137: ...A 5 2 R8i Bussmann 170M6419 1600 A 690 V 68393108 3 4 UN 690 V 0400A 7 R8i Bussmann 170M6545 700 A 1250 V 68735980 3 2 0600A 7 R8i Bussmann 170M6549 1100 A 1000 V 68736021 3 2 0800A 7 2 R8i Bussmann 170M6545 700 A 1250 V 68735980 3 4 1200A 7 2 R8i Bussmann 170M6549 1100 A 1000 V 68736021 3 4 ACS880 1604 Frame size Fuse IEC and UL Qty Type Data Ordering code Size UN 400 V 0600A 3 R8i Bussmann 170M6...

Page 138: ...1 3AXD50000009534 0900A 5 R8i 1 1200A 5 2 R8i 2 1800A 5 2 R8i 2 UN 690 V 0400A 7 R8i SWITCH KIT OT TYPE IEC 1600 E11 1600 A 1000 V ICW 50 kA 1 s ICM 110 kA 1 3AXD50000009534 0600A 7 R8i 1 0800A 7 2 R8i 2 1200A 7 2 R8i 2 ACS880 1604 Frame size DC switch disconnector Qty Ordering code Type Data UN 400 V 0600A 3 R8i SWITCH KIT OT TYPE IEC 1600 E11 60 Hz 1600 A 1000 V ICW 50 kA 1 s ICM 110 kA 1 3AXD50...

Page 139: ...itchgear and charging components on page 182 ACS880 1604 Frame size DC switch disconnector Qty Ordering code Type Data UN 400 V 0600A 3 R8i SWITCH KIT OT1200U11 UL 1200 A 600 V ICW 50 kA 1 s ICM 110 kA 1 3AXD50000009540 0900A 3 R8i 1 1200A 3 2 R8i 2 1800A 3 2 R8i 2 UN 500 V 0600A 5 R8i SWITCH KIT OT1200U11 UL 1200 A 600 V ICW 50 kA 1 s ICM 110 kA 1 3AXD50000009540 0900A 5 R8i 1 1200A 5 2 R8i 2 180...

Page 140: ...mally closed auxiliary contact OA3G01 charging resistors ZRF 30X165S24R 4 pcs or ZRF 30X165 SIK 4 pcs plugs and sockets for X11 ACS880 1604 Frame size Kit Qty Ordering code UN 400 V 0600A 3 R8i Charging kit 1 for DDC 500 V 1 3AXD50000022423 0900A 3 R8i 1 1200A 3 2 R8i 2 1800A 3 2 R8i 2 UN 500 V 0600A 5 R8i Charging kit 1 for DDC 500 V 1 3AXD50000022423 0900A 5 R8i 1 1200A 5 2 R8i 2 1800A 5 2 R8i 2...

Page 141: ...ly closed auxiliary contact OA3G01 charging resistors ZRF 30X165S24R 4 pcs or ZRF 30X165 SIK 4 pcs fuse clips 8 pcs plugs and sockets for X11 ACS880 1604 Frame size Kit Qty Ordering code UN 400 V 0600A 3 R8i Charging kit 1 UL for DDC 500 V 1 3AXD50000022425 0900A 3 R8i 1 1200A 3 2 R8i 2 1800A 3 2 R8i 2 UN 500 V 0600A 5 R8i Charging kit 1 UL for DDC 500 V 1 3AXD50000022425 0900A 5 R8i 1 1200A 5 2 R...

Page 142: ...osure Degree of protection Ordering code Kit code Illustration 800 mm IP20 3AUA0000117005 A 8 X 023 Instruction code 3AUA0000116887 800 mm IP42 3AUA0000117009 A 8 X 026 Instruction code 3AUA0000116875 800 mm IP54 3AXD50000009186 A 8 X 029 Instruction code 3AXD50000010001 ...

Page 143: ...re Degree of protection Qty Ordering code Kit code Illustration 800 mm IP20 2 3AUA0000125203 A 4 X 042 Instruction code 3AXD50000001983 800 mm IP42 2 3AUA0000114968 A 4 X 040 Instruction code 3AUA0000115292 800 mm IP54 IEC 2 3AXD50000009187 A 4 X 064 Instruction code 3AXD50000010284 Note Fan to be ordered separately ...

Page 144: ...4 Ordering information 800 mm IP54 UL 2 3AXD50000010362 A 4 X 067 Instruction code 3AXD50000010284 Note Fan to be ordered separately Enclosure Degree of protection Qty Ordering code Kit code Illustration ...

Page 145: ...6959 Connector SPB2 5 7 2 5 mm2 12AWG 2 3AXD50000000723 Connector SC 2 5 RZ 7 2 5 mm2 12AWG 2 3AXD50000000724 UL CSA Enclosure Degree of protection Component Qty Ordering code Name Data 800 mm IP54 115 V 50 60 Hz Fan RH35M 4EK 4F 1R 115 V 2 64750062 Capacitor 25 F 220 V 2 68713188 Connector SPB2 5 7 2 5 mm2 12AWG 2 3AXD50000000723 Connector SC 2 5 RZ 7 2 5 mm2 12AWG 2 3AXD50000000724 IEC UL Name D...

Page 146: ...age automatically You do not need any additional measurement for the converter BAMU voltage current measurement unit Qty Ordering code Type Data BAMU 11 BAMU voltage current measurement board 1 3AUA0000109935 NLWC 03 2 3 m single core fiber optic cables with connectors 2 58948233 Mersen PS272PREMCPS Fuse holder disconnector 1000 V AC 1250 V DC 250 A cartridge fuse 27 60 mm 1 3AXD50000012958 Mersen...

Page 147: ...Technical data 147 11 Technical data Contents of this chapter This chapter contains technical data for ACS880 1604 DC DC converter modules ...

Page 148: ...1800 1146 1536 2700 1146 20 24000 UN 690 V 0400A 7 R8i 400 400 351 471 600 351 38 12000 0600A 7 R8i 600 600 527 707 900 527 56 12000 0800A 7 2 R8i 800 800 703 942 1200 703 19 24000 1200A 7 2 R8i 1200 1200 1054 1413 1800 1054 28 24000 3AXD00000601909 Module type ACS880 1604 Frame High overload use Heavy duty use Ifast Pfast IHd PHd A kW A kW UN 400 V 0600A 3 R8i 450 229 510 260 0900A 3 R8i 675 343 ...

Page 149: ...y storage connection measured after the filter High overload use Ifast Continuous current allowing Imax for 10 s 60 s at 40 C 104 F Pfast Continuous power allowing Imax for 10 s 60 s at 40 C 104 F Heavy duty use IHd Continuous current allowing 150 IHd for 1 min 5 min at 40 C 104 F PHd Continuous power allowing 150 IHd for 1 min 5 min at 40 C 104 F Notes The ratings apply at an ambient temperature ...

Page 150: ...e output current can be calculated by multiplying the current given in the rating table by the derating factor k Altitude derating At altitudes 0 1000 m 3300 ft no derating At altitudes from 1000 to 4000 m 3300 to 13123 ft above sea level the continuous output currents given above must be derated 1 for every 100 m 328 ft T 1 00 0 90 40 C 104 F 50 C 122 F k 0 80 ...

Page 151: ... module type ACS880 104 3 Frame BDCL filters Type Qty UN 400 V 0600A 3 0600A 3 0640A 3 R8i BDCL 14 5 1 0900A 3 0900A 3 0900A 3 R8i BDCL 15 5 1 1200A 3 1200A 3 0640A 3 2 R8i BDCL 14 5 2 1800A 3 1800A 3 0900A 3 2 R8i BDCL 15 5 2 UN 500 V 0600A 5 0600A 5 0590A 5 R8i BDCL 14 5 1 0900A 5 0900A 5 0810A 5 R8i BDCL 15 5 1 1200A 5 1200A 5 0590A 5 2 R8i BDCL 14 5 2 1800A 5 1800A 5 0810A 5 2 R8i BDCL 15 5 2 ...

Page 152: ...7 47 in weight BDCL 14 5 195 0 kg 429 9 lb and BDCL 15 5 225 kg 496 0 lb For the dimensional drawing see BDCL filter module on page 174 One filter module is needed for each converter module Free space requirements Free space requirements for the DC DC converter modules are above the module to enable cooling air flow 200 0 mm 7 87 in in front of the module free space for cabling 10 0 mm 0 39 in lef...

Page 153: ...0640A 3 R8i 5 2 2200 1295 74 98 3 0900A 3 R8i 8 0 2200 1295 74 98 3 0640A 3 2 R8i 10 5 4400 2590 76 98 3 0900A 3 2 R8i 16 5 4400 2590 76 98 2 UN 500 V 0590A 5 R8i 6 0 2200 1295 74 98 5 0810A 5 R8i 9 1 2200 1295 74 98 4 0590A 5 2 R8i 12 1 4400 2590 76 98 4 0810A 5 2 R8i 18 8 4400 2590 76 98 4 UN 690 V 0410A 7 R8i 6 4 2200 1295 74 98 2 0600A 7 R8i 10 6 2200 1295 74 98 0 0410A 7 2 R8i 12 8 4400 2590 ...

Page 154: ... 8 8 M4 1 N m 9 lbf in Strength class 4 6 8 8 M5 4 N m 35 lbf in Strength class 8 8 M6 9 N m 6 6 lbf ft Strength class 8 8 M8 22 N m 16 lbf ft Strength class 8 8 M10 42 N m 31 lbf ft Strength class 8 8 M12 70 N m 52 lbf ft Strength class 8 8 M16 120 N m 90 lbf ft Strength class 8 8 Size Max torque Note M5 6 N m 53 lbf in Strength class 8 8 M6 10 N m 7 4 lbf ft Strength class 8 8 M8 24 N m 17 7 lbf...

Page 155: ...voltage 50 V 95 of UDC Drive DC voltage in the DC bus This is indicated in the type designation label as typical output voltage range 50 509 V DC Recommended output voltage 150 V 80 of UDC ACS880 104 xxxxx 5 Maximum output voltage 50 V 95 of UDC Drive DC voltage in the DC bus This is indicated in the type designation label as typical output voltage range 50 509 611 636 V DC Recommended output volt...

Page 156: ...ptical fiber POF cables can be used with both 5 MBd and 10 MBd optical components 10 MBd components also enable the use of Hard Clad Silica HCS cables which allow longer connection distances thanks to their lower attenuation HCS cables cannot be used with 5 MBd optical components The maximum lengths of fiber optic links for POF and HCS cables are 20 and 200 meters respectively Degree of protection...

Page 157: ...ers and their severities Stationary use of weather protected locations IEC 60721 3 1 IEC 60721 3 2 Chemical gases Class 3C2 Class 1C2 Class 2C2 Solid particles Class 3S1 Class 1S3 packing must support this otherwise 1S2 Class 2S2 No conductive dust allowed Vibration IEC EN 61800 5 1 IEC 60068 2 6 2007 EN 60068 2 6 2008 Environmental testing Part 2 Tests Test Fc Vibration sinusoidal IEC EN 60721 3 ...

Page 158: ... product in polyethylene sheet Alternatively VCI protection is used Packaging is secured with plastic straps Disposal The module contains raw materials that should be recycled to preserve energy and natural resources The package materials are environmentally compatible and recyclable All metal parts can be recycled The plastic parts can either be recycled or burned under controlled circumstances a...

Page 159: ...ption G304 115 V auxiliary voltage supply 115 15 20 50 60 0 90 105 Control unit BCU x2 24 10 2 0 48 R8i module option C188 DOL fan 400 50 1 50 3 00 400 60 1 90 3 80 BDCL filter option C188 DOL fan as standard with 230 V supply 230 50 0 60 1 20 230 60 0 88 1 76 Options C188 G304 DOL fan with 115 V AC supply 115 60 1 80 3 60 R8i module heating element option C183 230 50 60 40 115 60 40 Cabinet fans ...

Page 160: ...vide and continuously ensure a secure connection between the product and Customer network or any other network as the case may be The Customer shall establish and maintain any appropriate measures such as but not limited to the installation of firewalls application of authentication measures encryption of data installation of anti virus programs etc to protect the product the network its system an...

Page 161: ...rol unit is built in a metal housing The BCU control unit consists of a BCON control board and a BIOC I O and power supply board built in a metal housing The BCU is mounted separately from the converter module s and connected to the module s by fiber optic cables In this manual the name BCU represents the control unit types BCU 02 BCU 12 and BCU 22 These have a different number of converter module...

Page 162: ...Not in use by default 3 DI3 4 DI4 5 DI5 6 DI6 7 DIIL XDIO Digital input outputs 1 DIO1 Not in use by default 2 DIO2 Not in use by default 3 DIOGND Digital input output ground 4 DIOGND Digital input output ground XD24 Auxiliary voltage output 5 24VD 24 V DC 200 mA 6 6 DICOM Digital input ground 7 24VD 24 V DC 200 mA 6 8 DIOGND Digital input output ground DICOM DIOGND Ground selection switch 7 XAI A...

Page 163: ...s 4 8 W 200 mA at 24 V minus the power taken by DIO1 and DIO2 7 Determines whether DICOM is separated from DIOGND ie common reference for digital inputs floats DICOM DIOGND ON DICOM connected to DIOGND OFF DICOM and DIOGND separate See section Ground isolation diagram on page 168 8 The Safe torque off STO function is only implemented in the inverter units When the control board is used in the DC D...

Page 164: ... AI1 I current U voltage AI2 Mode selector for analog input AI2 I current U voltage D2D TERM Termination switch for drive to drive link D2D DICOM DIOGND Ground selection Determines whether DICOM is separated from DIOGND ie the common reference for the digital inputs floats 7 segment display Multicharacter indications are displayed as repeated sequences of characters U is indicated briefly before o...

Page 165: ...ot in use in DC DC converter units X13 Control panel connection X485 Not in use V1T V1R V2T V2R Fiber optic connection to converter modules 1 and 2 VxT transmitter VxR receiver V3T V3R V7T V7R Fiber optic connection to converter modules 3 7 BCU 12 22 only VxT transmitter VxR receiver V8T V8R V12T V12R Fiber optic connection to converter modules 8 12 BCU 22 only VxT transmitter VxR receiver SD CARD...

Page 166: ...ing up to 8 ms Digital inputs outputs DIO1 and DIO2 XDIO 1 and XDIO 2 Input output mode selection by parameters DIO1 can be configured as a frequency input 0 16 kHz with hardware filtering of 4 microseconds for 24 V level square wave signal sinusoidal or other wave form cannot be used DIO2 can be configured as a 24 V level square wave frequency output See the firmware manual of the supply unit par...

Page 167: ...nel per module Note Safe torque off STO functionality is not available in the DC DC converter units See Default I O connection diagram on page 162 EMC immunity according to IEC 61326 3 1 Safe torque off output XSTO OUT Connector pitch 5 mm wire size 2 5 mm2 Output for powering XSTO inputs See Default I O connection diagram on page 162 Control panel connection X13 Connector RJ 45 Cable length 3 m E...

Page 168: ...DIO DIO1 1 DIO2 2 DIOGND 3 DIOGND 4 XDI DI1 1 DI2 2 DI3 3 DI4 4 DI5 5 DI6 6 DIIL 7 XSTO OUT 1 SGND 2 IN1 3 IN2 4 XSTO OUT IN1 5 SGND 6 IN2 7 SGND 8 Ground 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 This is the default setting DICOM DIOGND OFF Ground of digital in...

Page 169: ...Dimension drawings 169 13 Dimension drawings Contents of this chapter This chapter shows dimensions of the ACS880 1604 DC DC converter modules and accessories ...

Page 170: ...170 Dimension drawings R8i DC DC converter module ...

Page 171: ...Dimension drawings 171 ...

Page 172: ...172 Dimension drawings Quick connectors of the DC DC converter module ...

Page 173: ...Dimension drawings 173 Quick connectors Dimensions in mm 1 mm 0 0394 in ...

Page 174: ...174 Dimension drawings BDCL filter module ...

Page 175: ...Dimension drawings 175 ACS AP x control panel with door mounting kit Cutting in the cabinet door 109 mm 223 mm 4 29 in 8 78 in Plate thickness 1 5 2 5 mm 0 059 0 098 in ...

Page 176: ...176 Dimension drawings BCU control unit ...

Page 177: ...Dimension drawings 177 BAMU voltage current measurement unit ...

Page 178: ...tance between centers W 150 Without terminals cover length W 240 With terminals cover length Y 196 Space factor with a 90 fuse carrier position Z 284 Without terminal cover space factor with a 180 fuse carrier position Z 279 With terminal cover space factor with a 180 fuse carrier position Twin terminal covers PS 27 Part A 220087 Weight 30g Packaging 3 twins www mersen com 60 3 Ø 27 Ø 5 7 7mm indi...

Page 179: ...Dimension drawings 179 Ramp Dimensions in mm 1 mm 0 0394 in ...

Page 180: ...180 Dimension drawings Dimensions in mm 1 mm 0 0394 in ...

Page 181: ...Dimension drawings 181 Internal cabinet fan W2E 143 AA09 01 W2E 143 AA15 01 Air flow ...

Page 182: ... 116 4 57 206 8 11 189 7 44 A 50 1 97 M00136 OT800U 1600E G M8 5 16 B 223 2 122 B1 8 79 4 80 176 135 C1 5 31 6 93 232 107 A1 4 21 9 13 62 5 2 46 15 0 59 14 0 55 12 0 47 22 0 87 127 178 108 8 min 20 min 0 79 166 5 105 6 56 4 13 6 0 24 5 167 6 57 7 01 4 25 0 31 8 0 31 167 6 57 251 380 OXP12x280 9 84 14 96 131 5 5 18 54 80 70 274 10 79 2 13 2 76 3 15 _11 mm in _22 mm in A 254 50 10 02 414 50 16 32 B ...

Page 183: ...T O 0 ON 95 5 43 17 5 53 3 33 4 20 8 5 7 2 5 5 114 5 M5 46 35 A C 65 45 81 138 205 OXP 6x161 38 2 5 24 2 5 46 140 14 min B 6 Ø9 10 20 Back connection types T O 0 ON T O 0 ON T O 0 ON 10 114 A1 B1 110 17 5 C1 84 25 mm A 181 5 B 130 C 100 A1 160 B1 175 C1 190 ...

Page 184: ...72 6 77 min 14 0 55 104 5 4 11 65 2 56 125 5 4 94 138 5 5 45 mm in 45 1 77 6 0 24 33 4 1 31 20 0 79 8 5 0 33 T O 0 ON T O 0 ON T O 0 ON C1 25 0 98 84 3 31 B1 17 5 0 69 110 4 33 114 4 49 A1 10 0 39 M00291 OS100GJ01 04 B OS100GJ mm in J01 J02 J03 J04 A 76 5 3 01 111 5 4 39 146 5 5 77 181 5 7 15 A1 55 2 17 90 3 54 125 4 92 160 6 30 B1 70 2 76 105 4 13 140 5 51 175 6 89 C1 85 3 35 120 4 72 155 6 10 19...

Page 185: ...Dimension drawings 185 Charging controller BSFC 02C SWITCH FUSE CONTROLLER 79 3 11 247 9 72 66 5 2 62 ...

Page 186: ...ion drawings Resistors ZRF 30X165 Handles OHB65J6 L 165 3 LB 183 fxi 5 5 8 D MAX 34 k 6 minimum e 4 2 Handle type L mm B mm Notes OHB65J6 65 6 6 Used with switch disconnector units Dimensions in mm 1 mm 0 0394 in ...

Page 187: ...Dimension drawings 187 Contacts Auxiliary contact OA3G01 2 0 75 2 5 mm2 2 18 14 AWG 0 8 N m 7 lb in Pozidriv M3 5 Form 2 ...

Page 188: ...6549 A B D E E H G F F F in G H 690 V fuses as used with 400 and 500 V units Size A mm B mm D mm E mm F G mm H mm 3 51 53 92 76 M12 10 30 3 51 65 92 76 M12 10 30 1000 1250 V fuses as used with 690 V units Size A mm B mm D mm E mm F G mm H mm 3 81 83 92 76 M12 10 30 ...

Page 189: ...Dimension drawings 189 170M6545 170M6549 A B D E E H G F B D E F F in G H www cooperindustries com A B D E F G H 74 76 92 76 M12 10 ø30 1 mm 0 0394 in ...

Page 190: ...190 Dimension drawings ...

Page 191: ...contains example circuit diagrams of a DC DC converter module The purpose of these diagrams is to help in understanding the internal connections and operation of the cabinet installed DC DC converter unit and learning how to wire a DC DC converter modules when installed in a user defined cabinet ...

Page 192: ...on Component A41 BCU control unit A48 DPMP 01 door mounting kit for control panel including DDPI board A49 ACS AP x control panel A232 BAMU Voltage current measurement unit ES ES Energy storage connection ES 1 ES 2 ES 3 Filter output terminals F11 xx DC fuses on the drive DC bus side F13 xx Output DC fuses on the energy storage side F90 1 F90 2 BAMU fuses R13 1 BDCL filter module T11 1 DC DC conve...

Page 193: ...DDPI board A49 ACS AP x control panel A232 BAMU Voltage current measurement unit ES ES Energy storage connection F11 xx DC fuses on the drive DC bus side F13 xx Output DC fuses on the energy storage side F90 1 F90 2 BAMU fuses Q10 1 Charging switch Q11 1 DC switch disconnector optional R10 1 Charging resistors R13 1 BDCL filter module T11 1 DC DC converter module R8i T22 1 24 V DC power supply X30...

Page 194: ...194 Example circuit diagrams ...

Page 195: ... 1xR8i DC main circuit Circuit Diagram EFS2 EN Tuomi Joni 26 01 2017 Asikainen Mika 26 01 2017 ABB Drives 1 1PE U2 V2 W2 X11 1 U2 V2 W2 T11 1 F11 11 1 2 F11 12 1 2 F13 12 1 2 DC CONNECTION F13 11 1 2 BDCL MODULE 3 1PE U2 V2 W2 X13 1 U2 V2 W2 R13 1 CUSTOMER 300 ES ES DC BUS DC MAIN CIRCUIT R8i MODULE ES 1 ES 2 ES 3 ESM 1 041 9K ESP 1 ESM 1 1 ESP 1 1 ...

Page 196: ... HEAT L HEAT N GND BCON 24VDC BCON 24 VDC GND A41 V1R 040 4K A41 V1T V10 V30 V20 V40 BDPS L 020 9D BDPS N 020 9G HEAT 1 L 020 13J HEAT 1 N 020 13J V2 V1 FAN BOX DC FAN AC FAN X55 X54 HEATER FE 1 2 3 4 5 4 5 6 7 8 9 FAN BOX AC FAN X55 BDCL MODULE V60 V50 R13 1 X50 1 X53 1 FAN V FAN U FAN W 1 2 3 R8i module 4 5 6 7 8 9 X30 1 1 2 3 FAN DC FAN X30 4 1 020 7D X30 5 1 020 7F TP1 TP2 XD24 7 040 14D XDI 1...

Page 197: ...24V CONTROL VOLTAGE DISTRIBUTION AUXILIARY VOLTAGE DISTRIBUTION BDPS L 005 3E BDPS N 005 3E X21 4 1 040 3K X21 1 1 040 3K X22 1 15 1 13 X22 1 4 X22 1 11 2 12 X22 1 5 EXTERNAL SUPPLY FOR MODULES HEATERS F95 2 4 3 1 I I 12 14 11 K95 22 24 21 12K HEAT CTRL L 6E HEAT CTRL N 6F 22 24 21 12J K95 A1 A2 HEAT 1 L 005 3F HEAT 1 N for option C183 HL HN T21 L AUXILIARY SUPPLY T21 N HEAT CTRL N 10L X22 2 1 005...

Page 198: ... 3 2 4 X9 XETH POWER STAGE LINKS CH1 CH2 NO NC COM NO NC COM NO NC COM AGND AGND DCCOM S7 24VD DICOM DIOGND 0VD 0VD 0VIN1 24VIN2 0VIN2 RS 485 FOR D2D LINK 2 3 XD2D 1 B A BGND 4 SHIELD IN1 SGND IN2 XSTO OUT 5 6 7 8 SGND B A BGND SHIELD V21 YELLOW POWER OK V22 GREEN BATTERY OK V23 GREEN WRITE V24 RED FAULT AI1 I U SELECTION S4 I U AI2 I U SELECTION S5 I U D2D LINK S6 ON OFF GROUND SELECTION S7 ON OF...

Page 199: ...1604 0600A 7 C183 DDC 1xR8i BAMU 11C Measurement Unit Circuit Diagram EFS2 EN Tuomi Joni 26 01 2017 Asikainen Mika 26 01 2017 ABB Drives A232 ESM 1 001 11F ESP 1 X21 3 1 020 7J X21 6 1 A41 V2R 040 5K A41 V2T S1 S2 S1 S2 S1 S2 N W V U N W V U 3 2 1 TX V1R F90 2 1 2 F90 1 1 2 12 14 11 ...

Page 200: ...US Q10 1 1 3 5 7 8 6 4 2 1 2 P11 1 X1 X2 GREEN Load OK DOOR UDC1 1 UDC1 1 GND GND1 1 1PE 1PE I1V60 005 6G I1V50 X13 3 14E X13 4 X13 5 15E X13 6 R1 1 1 2 3 R3 1 1 2 3 R2 1 1 2 3 R4 1 1 2 3 X11 4 2 X11 3 1 Q10 1 2 4D Q10 1 1 2H Q10 1 2 7D Q10 1 1 8D MAIN CIRCUIT CHARGING CIRCUIT R10 1 X22 13 1 020 6D X22 3 1 020 6F UDC2 1 UDC2 1 R8i MODULE DIS EN DIS EN DIS EN PE LSOL NSOL INV 2 INV 1 INV 3 S3 N L A...

Page 201: ...D A41 V1R 040 4K A41 V1T V10 V30 V20 V40 BDPS L 020 9D BDPS N 020 9G HEAT 1 L 020 13J HEAT 1 N 020 13J V2 V1 FAN BOX DC FAN AC FAN X55 X54 HEATER FE 1 2 3 4 5 4 5 6 7 8 9 FAN BOX AC FAN X55 X30 4 1 020 7D BDCL MODULE V60 V50 I1V60 001 4E I1V50 R13 1 X30 5 1 020 7F X50 1 X53 1 FAN V FAN U FAN W 1 2 3 F115 1 1 3 5 6 4 2 I I I 13 14 21 22 X115 1 X115 2 X115 3 DOL FAN SUPPLY for option C188 R8i module...

Page 202: ...ONTROL VOLTAGE DISTRIBUTION AUXILIARY VOLTAGE DISTRIBUTION BDPS L 005 3E BDPS N 005 3E X22 1 15 1 13 X22 1 4 X22 1 11 2 12 X22 1 5 EXTERNAL SUPPLY FOR MODULES HEATERS F95 2 4 3 1 I I 12 14 11 K95 22 24 21 12K HEAT CTRL L 6E HEAT CTRL N 6F 22 24 21 12J K95 A1 A2 HEAT 1 L 005 3F HEAT 1 N for option C183 HL HN T21 L AUXILIARY SUPPLY T21 N X22 13 1 001 2K HEAT CTRL N 10L X22 2 1 005 7E 14 HEAT CTRL L ...

Page 203: ...6 7 XDIO 1 3 2 4 X9 XETH POWER STAGE LINKS CH1 CH2 NO NC COM NO NC COM NO NC COM AGND AGND DCCOM S7 24VD DICOM DIOGND 0VD 0VD 0VIN1 24VIN2 0VIN2 RS 485 FOR D2D LINK 2 3 XD2D 1 B A BGND 4 SHIELD IN1 SGND IN2 XSTO OUT 5 6 7 8 SGND B A BGND SHIELD V21 YELLOW POWER OK V22 GREEN BATTERY OK V23 GREEN WRITE V24 RED FAULT AI1 I U SELECTION S4 I U AI2 I U SELECTION S5 I U D2D LINK S6 ON OFF GROUND SELECTIO...

Page 204: ... 7 C183 C188 DDC 1xR8i with DC switch BAMU 11C Measurement Unit Circuit Diagram EFS2 EN Tuomi Joni 26 01 2017 Asikainen Mika 26 01 2017 ABB Drives A232 ESM 1 001 16H ESP 1 A41 V2R 040 5K A41 V2T S1 S2 S1 S2 S1 S2 N W V U N W V U 3 2 1 TX V1R F90 2 1 2 F90 1 1 2 12 14 11 X21 3 1 020 7J X21 6 1 ...

Page 205: ...01 ACS880 1604 1200A 7 C183 DDC 2xR8i DC main circuit Product Circuit Diagram EFS2 EN Tuomi Joni 26 01 2017 Asikainen Mika 26 01 2017 1 1PE U2 V2 W2 X11 1 U2 V2 W2 T11 1 F11 11 1 2 F11 12 1 2 F13 12 1 2 DC CONNECTION F13 11 1 2 BDCL MODULE 3 1PE U2 V2 W2 X13 1 U2 V2 W2 R13 1 CUSTOMER 300 ES ES DC BUS DC MAIN CIRCUIT R8i MODULE ES 1 ES 2 ES 3 ESM 1 041 9K ESP 1 ESM 1 1 ESP 1 1 ...

Page 206: ...ACS880 1604 1200A 7 C183 DDC 2xR8i DC main circuit Product Circuit Diagram EFS2 EN Tuomi Joni 26 01 2017 Asikainen Mika 26 01 2017 1 1PE U2 V2 W2 X11 2 U2 V2 W2 T11 2 F11 21 1 2 F11 22 1 2 F13 22 1 2 DC CONNECTION F13 21 1 2 BDCL MODULE 3 1PE U2 V2 W2 X13 2 U2 V2 W2 R13 2 CUSTOMER 300 ES ES DC BUS DC MAIN CIRCUIT R8i MODULE ES 1 ES 2 ES 3 ...

Page 207: ...01 2017 T11 1 BDPS L BDPS N HEAT L HEAT N GND BCON 24VDC BCON 24 VDC GND A41 V1R 040 4K A41 V1T V10 V30 V20 V40 BDPS L 020 9D BDPS N 020 9G HEAT 1 L 020 13J HEAT 1 N 020 13J V2 V1 FAN BOX DC FAN AC FAN X55 X54 HEATER FE 1 2 3 4 5 4 5 6 7 8 9 FAN BOX AC FAN X55 BDCL MODULE V60 V50 R13 1 X50 1 X53 1 FAN V FAN U FAN W 1 2 3 R8i module 4 5 6 7 8 9 X30 1 1 2 3 FAN DC FAN X30 4 1 020 7D X30 5 1 020 7F T...

Page 208: ...1 2017 T11 1 BDPS L BDPS N HEAT L HEAT N GND BCON 24VDC BCON 24 VDC GND A41 V2R 040 5K A41 V2T V10 V30 V20 V40 BDPS L 2 021 9D BDPS N 2 021 9G HEAT 2 L 021 13J HEAT 2 N 021 13J V2 V1 FAN BOX DC FAN AC FAN X55 X54 HEATER FE 1 2 3 4 5 4 5 6 7 8 9 FAN BOX AC FAN X55 BDCL MODULE V60 V50 R13 1 X50 2 X53 2 FAN V FAN U FAN W 1 2 3 R8i module 4 5 6 7 8 9 X30 2 1 2 3 FAN DC FAN X30 4 2 021 7D X30 5 2 021 7...

Page 209: ...201 X22 1 1 2J 24V CONTROL VOLTAGE DISTRIBUTION AUXILIARY VOLTAGE DISTRIBUTION BDPS L 005 3E BDPS N 005 3E X21 5 1 040 3K X21 2 1 040 3K X22 1 15 1 13 X22 1 4 X22 1 11 2 12 X22 1 5 EXTERNAL SUPPLY FOR MODULES HEATERS F95 2 4 3 1 I I 12 14 11 K95 22 24 21 12K HEAT CTRL L 6E HEAT CTRL N 6F 22 24 21 12J K95 A1 A2 HEAT 1 L 005 3F HEAT 1 N for option C183 HL HN T21 L AUXILIARY SUPPLY T21 N HEAT CTRL N ...

Page 210: ... 1 2 I X25 2 211 X25 2 201 AUXILIARY VOLTAGE DISTRIBUTION BDPS L 2 006 3E BDPS N 2 006 3E X22 2 15 1 13 X22 2 4 X22 2 11 2 12 X22 2 5 EXTERNAL SUPPLY FOR MODULES HEATERS F95 2 2 4 3 1 I I 12 14 11 K95 2 22 24 21 12K HEAT CTRL L 2 6E HEAT CTRL N 2 6F 22 24 21 12J K95 2 A1 A2 HEAT 2 L 006 3F HEAT 2 N for option C183 HL 2 HN 2 T21 L 2 AUXILIARY SUPPLY T21 N 2 HEAT CTRL N 2 10L 14 HEAT CTRL L 2 10K 3 ...

Page 211: ...E LINKS CH1 CH2 NO NC COM NO NC COM NO NC COM AGND AGND DCCOM S7 24VD DICOM DIOGND 0VD 0VD 0VIN1 24VIN2 0VIN2 RS 485 FOR D2D LINK 2 3 XD2D 1 B A BGND 4 SHIELD IN1 SGND IN2 XSTO OUT 5 6 7 8 SGND B A BGND SHIELD V21 YELLOW POWER OK V22 GREEN BATTERY OK V23 GREEN WRITE V24 RED FAULT AI1 I U SELECTION S4 I U AI2 I U SELECTION S5 I U D2D LINK S6 ON OFF GROUND SELECTION S7 ON OFF TERMINATION DICOM DIOGN...

Page 212: ...3AXD10000578961 041 041 ACS880 1604 1200A 7 C183 DDC 2xR8i BAMU 11C Measurement Unit Product Circuit Diagram EFS2 EN Tuomi Joni 26 01 2017 Asikainen Mika 26 01 2017 A232 ESM 1 001 11F ESP 1 A41 V3R 040 5K A41 V3T S1 S2 S1 S2 S1 S2 N W V U N W V U 3 2 1 TX V1R F90 2 1 2 F90 1 1 2 12 14 11 X21 3 1 020 7J X21 6 1 ...

Page 213: ... X13 6 DC BUS Q10 1 1 3 5 7 8 6 4 2 1 2 P11 1 X1 X2 GREEN Load OK DOOR UDC1 1 UDC1 1 GND GND1 1 1PE 1PE I1V60 005 6G I1V50 X13 3 14E X13 4 X13 5 15E X13 6 R1 1 1 2 3 R3 1 1 2 3 R2 1 1 2 3 R4 1 1 2 3 X11 4 2 X11 3 1 Q10 1 2 4D Q10 1 1 2H Q10 1 2 7D Q10 1 1 8D MAIN CIRCUIT CHARGING CIRCUIT R10 1 X22 13 1 020 6D X22 3 1 020 6F UDC2 1 UDC2 1 R8i MODULE DIS EN DIS EN DIS EN PE LSOL NSOL INV 2 INV 1 INV...

Page 214: ...6 2 DC BUS Q10 2 1 3 5 7 8 6 4 2 1 2 P11 2 X1 X2 GREEN Load OK DOOR UDC1 1 UDC1 1 GND GND2 1 1PE 1PE I1V60 2 006 6G I1V50 2 X13 3 2 14E X13 4 2 X13 5 2 15E X13 6 2 R1 1 1 2 3 R3 1 1 2 3 R2 1 1 2 3 R4 1 1 2 3 X11 4 2 X11 3 1 Q10 2 2 4D Q10 2 1 2H Q10 2 2 7D Q10 2 1 8D MAIN CIRCUIT CHARGING CIRCUIT R10 2 X22 13 2 021 6D X22 3 2 021 6F UDC2 1 UDC2 1 R8i MODULE DIS EN DIS EN DIS EN PE LSOL NSOL INV 2 ...

Page 215: ...T N GND BCON 24VDC BCON 24 VDC GND A41 V1R 040 4K A41 V1T V10 V30 V20 V40 BDPS L 020 9D BDPS N 020 9G HEAT 1 L 020 13J HEAT 1 N 020 13J V2 V1 FAN BOX DC FAN AC FAN X55 X54 HEATER FE 1 2 3 4 5 4 5 6 7 8 9 FAN BOX AC FAN X55 X30 4 1 020 7D BDCL MODULE V60 V50 I1V60 001 4E I1V50 R13 1 X30 5 1 020 7F X50 1 X53 1 FAN V FAN U FAN W 1 2 3 F115 1 1 3 5 6 4 2 I I I 13 14 21 22 X115 1 X115 2 X115 3 DOL FAN ...

Page 216: ...D BCON 24VDC BCON 24 VDC GND A41 V2R 040 5K A41 V2T V10 V30 V20 V40 BDPS L 2 021 9D BDPS N 2 021 9G HEAT 2 L 021 13J HEAT 2 N 021 13J V2 V1 FAN BOX DC FAN AC FAN X55 X54 HEATER FE 1 2 3 4 5 4 5 6 7 8 9 FAN BOX AC FAN X55 X30 4 2 021 7D BDCL MODULE V60 V50 I1V60 2 002 4E I1V50 2 R13 2 X30 5 2 021 7F X50 2 X53 1 FAN V FAN U FAN W 1 2 3 F115 2 1 3 5 6 4 2 I I I 13 14 21 22 X115 1 2 X115 2 2 X115 3 2 ...

Page 217: ...N 005 3E X21 4 1 040 3K X21 1 1 040 3K X22 1 15 1 13 X22 1 4 X22 1 11 2 12 X22 1 5 EXTERNAL SUPPLY FOR MODULES HEATERS F95 2 4 3 1 I I 12 14 11 K95 22 24 21 12K HEAT CTRL L 6E HEAT CTRL N 6F 22 24 21 12J K95 A1 A2 HEAT 1 L 005 3F HEAT 1 N for option C183 HL HN T21 L AUXILIARY SUPPLY T21 N X22 13 1 001 2K HEAT CTRL N 10L 14 HEAT CTRL L 10K 3 X22 3 1 001 2K G26 1 Fan unit N L M X1 1 3 2 X30 4 1 005 ...

Page 218: ...3E X22 2 15 1 13 X22 2 4 X22 2 11 2 12 X22 2 5 EXTERNAL SUPPLY FOR MODULES HEATERS F95 2 2 4 3 1 I I 12 14 11 K95 2 22 24 21 12K HEAT CTRL L 2 6E HEAT CTRL N 2 6F 22 24 21 12J K95 2 A1 A2 HEAT 2 L 006 3F HEAT 2 N for option C183 HL 2 HN 2 T21 L 2 AUXILIARY SUPPLY T21 N 2 X22 13 2 002 2K HEAT CTRL N 2 10L 14 HEAT CTRL L 2 10K 3 X22 3 2 002 2K G26 2 Fan unit N L M X1 1 3 2 X30 4 2 006 7E 13 14 9D 21...

Page 219: ...9 XETH POWER STAGE LINKS CH1 CH2 NO NC COM NO NC COM NO NC COM AGND AGND DCCOM S7 24VD DICOM DIOGND 0VD 0VD 0VIN1 24VIN2 0VIN2 RS 485 FOR D2D LINK 2 3 XD2D 1 B A BGND 4 SHIELD IN1 SGND IN2 XSTO OUT 5 6 7 8 SGND B A BGND SHIELD V21 YELLOW POWER OK V22 GREEN BATTERY OK V23 GREEN WRITE V24 RED FAULT AI1 I U SELECTION S4 I U AI2 I U SELECTION S5 I U D2D LINK S6 ON OFF GROUND SELECTION S7 ON OFF TERMIN...

Page 220: ... 041 041 ACS880 1604 1200A 7 C183 C188 DDC 2xR8i with DC switch BAMU 11C Measurement Unit Product Circuit Diagram EFS2 EN Tuomi Joni 26 01 2017 Asikainen Mika 26 01 2017 ABB Drives A232 ESM 1 001 16H ESP 1 A41 V3R 040 5K A41 V3T S1 S2 S1 S2 S1 S2 N W V U N W V U 3 2 1 TX V1R F90 2 1 2 F90 1 1 2 12 14 11 X21 3 1 020 7J X21 6 1 ...

Page 221: ...ntacts can be found by navigating to www abb com searchchannels Product training For information on ABB product training navigate to new abb com service training Providing feedback on ABB Drives manuals Your comments on our manuals are welcome Navigate to new abb com drives manuals feedback form Document library on the Internet You can find manuals and other product documents in PDF format on the ...

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