ABB ACS880 Series User manual

—
ABB INDUSTRIAL DRIVES
ACS880 multidrive for high-speed test
benches
Supplement

ACS880 multidrive for high-speed
test benches
Supplement
Table of contents
3AXD50000818013 Rev A
EN
Original instructions
EFFECTIVE: 2022-01-11

Table of contents
1 Safety
7Electrical safety precautions .....................................................................
8Additional instructions and notes ................................................................
9Optical components ............................................................................
9Printed circuit boards ..........................................................................
9Hot surfaces ........................................................................................
10Additional instructions for permanent magnet motor drives .................................
10Safety in installation, start-up, maintenance ................................................
10Safety in operation .............................................................................
2 Introduction
3 Description of the high-speed option
15The BLHF-2x-7 filter ...............................................................................
16BLHF-2x-7 layout and connections ..........................................................
17Terminal block X30 .........................................................................
17Type designation label .....................................................................
18Connection diagram ...............................................................................
19Ordering information ...............................................................................
19Cabinet-built ACS880 multidrives ............................................................
19Restrictions and notes .....................................................................
20Layout ........................................................................................
20ACS880 multidrive modules ..................................................................
4 Planning the drive system
21Dimensioning flowchart ...........................................................................
22Loading of BLHF filters ............................................................................
23Output contactor ...................................................................................
23Supply network .....................................................................................
23EMC compliance ...................................................................................
23Brake chopper ......................................................................................
24Encoder .............................................................................................
24Mechanical design .................................................................................
25IGBT supply unit dimensioning ..................................................................
5 Start-up
27Preparing the Drive Composer pro PC tool ....................................................
29Special settings related to high-speed drives ..................................................
29Limits .............................................................................................
29Dual use and maximum output frequency ..................................................
30Voltage reserve .................................................................................
30Switching frequency reference ...............................................................
30Internal speed limitation .......................................................................
30Encoder drift detection .........................................................................
30Overcurrent fault limit ..........................................................................
Table of contents 5

30Motor temperature protection .................................................................
30Motor ambient temperature ...................................................................
31Motor model temperature adaptation ........................................................
31Encoder settings ...................................................................................
31Encoder interface ...............................................................................
31Example: EnDat absolute encoder ..........................................................
33Checking the encoder position signal .......................................................
34Verifying that the rotor position is known by motor control ...............................
34Motor parameter settings .........................................................................
35Identification (ID) run ..............................................................................
35Performing a Standstill ID run and checking the direction of rotation ...................
36Activating encoder feedback ..................................................................
36Performing a Normal ID run ...................................................................
37Autophasing ........................................................................................
38Starting the drive ...................................................................................
6 Maintenance
42Fans ..................................................................................................
42Replacing the fan of the filter .................................................................
43Replacing the filter module .......................................................................
7 Technical data
49BLHF filter modules ................................................................................
49Definitions .......................................................................................
50Current derating ................................................................................
50Power loss .......................................................................................
50Noise .............................................................................................
51Auxiliary circuit current consumption ........................................................
51Definitions ....................................................................................
51Inverter units for increased switching frequency ..............................................
52Definitions .......................................................................................
52Switching frequency and output frequency derating ......................................
52Ambient temperature and altitude derating .................................................
53Inverter modules used .........................................................................
53Surrounding air temperature .....................................................................
53Maximum motor cable length ....................................................................
54Protection classes .................................................................................
54Weights ..............................................................................................
54Dimensions .........................................................................................
54Cabinet-built filter unit ..........................................................................
55Filter module ....................................................................................
56BLFH-2x-7 internal circuit diagram ..............................................................
Further information
6 Table of contents

Safety
Electrical safety precautions
These electrical safety precautions are for all personnel who do work on the drive, motor
cable or motor.
WARNING!
Obey these instructions. If you ignore them, injury or death, or damage to the
equipment can occur.
If you are not a qualified electrical professional, do not do installation or
maintenance work.
Go through these steps before you begin any installation or maintenance work.
1. Clearly identify the work location and equipment.
2. Disconnect all possible voltage sources. Make sure that re-connection is not possible.
Lock out and tag out.
• Open the main disconnecting device of the drive.
• Open the charging switch if present.
• Open the disconnector of the supply transformer. (The main disconnecting device
in the drive cabinet does not disconnect the voltage from the AC input power
busbars of the drive cabinet.)
• If the drive is equipped with a DC/DC converter unit (optional) or a DC feeder unit
(optional): Open the DC switch-disconnector ([Q11], option +F286 or +F290) of the
unit. Open the disconnecting device of the energy storage connected to the unit
(outside the drive cabinet).
• Open the auxiliary voltage switch-disconnector (if present), and all other possible
disconnecting devices that isolate the drive from dangerous voltage sources.
1
Safety 7

• If you have a permanent magnet motor connected to the drive, disconnect the
motor from the drive with a safety switch or by other means.
• Disconnect all dangerous external voltages from the control circuits.
• After you disconnect power from the drive, always wait 5 minutes to let the
intermediate circuit capacitors discharge before you continue.
3. Protect any other energized parts in the work location against contact.
4. Take special precautions when close to bare conductors.
5. Measure that the installation is de-energized. Use a quality voltage tester. If the
measurement requires removal or disassembly of shrouding or other cabinet structures,
obey the local laws and regulations applicable to live working (including – but not limited
to – electric shock and arc protection).
•Before and after measuring the installation, verify the operation of the voltage tester
on a known voltage source.
• Make sure that the voltage between the drive input power terminals (L1, L2, L3)
and the grounding (PE) busbar is zero.
• Make sure that the voltage between the drive output terminals (T1/U, T2/V, T3/W)
and the grounding (PE) busbar is zero.
Important! Repeat the measurement also with the DC voltage setting of the tester.
Measure between each phase and ground. There is a risk of dangerous DC voltage
charging due to leakage capacitances of the motor circuit. This voltage can remain
charged for a long time after the drive power-off. The measurement discharges the
voltage.
• Make sure that the voltage between the drive DC terminals (UDC+ and UDC-) and
the grounding (PE) terminal is zero. In cabinet-built drives, measure between the
drive DC busbars (+ and -) and the grounding (PE) busbar.
6. Install temporary grounding as required by the local regulations.
7. Ask for a permit to work from the person in control of the electrical installation work.
Additional instructions and notes
WARNING!
Obey these instructions. If you ignore them, injury or death, or damage to the
equipment can occur.
If you are not a qualified electrical professional, do not do installation or
maintenance work.
• Keep the cabinet doors closed when the drive is powered. With the doors open, a risk
of a potentially fatal electric shock, arc flash or high-energy arc blast exists.
• Make sure that the electrical power network, motor/generator, and environmental
conditions agree with the drive data.
• Do not do insulation or voltage withstand tests on the drive.
• If you have a cardiac pacemaker or other electronic medical device, keep away from
the area near motor, drive, and the drive power cabling when the drive is in operation.
There are electromagnetic fields present which can interfere with the function of such
devices. This can cause a health hazard.
8 Safety

• ABB does not recommend attaching the cabinet by arc welding. If you have to, obey
the welding instructions in the drive manuals.
• Remove the code labels attached to mechanical parts such as busbars, shrouds and
sheet metal parts before installation. They may cause bad electrical connections, or,
after peeling off and collecting dust in time, cause arcing or block the cooling air flow.
Note:
• When the drive is connected to the input power, the motor cable terminals and the DC
bus are at a dangerous voltage.
After disconnecting the drive from the input power, these remain at a dangerous voltage
until the intermediate circuit capacitors have discharged.
• External wiring can supply dangerous voltages to the relay outputs of the control units
of the drive.
• The Safe torque off function does not remove the voltage from the main and auxiliary
circuits. The function is not effective against deliberate sabotage or misuse.
￭Optical components
WARNING!
Obey these instructions. If you ignore them, damage to the equipment can occur.
• Handle the fiber optic cables with care.
• When you unplug the fiber optic cables, always hold the connector, not the cable itself.
• Do not touch the ends of the fibers with bare hands as the ends are extremely sensitive
to dirt.
• Do not bend the fiber optic cables too tightly. The minimum allowed bend radius is
35 mm (1.4 in).
￭Printed circuit boards
WARNING!
Use a grounding wristband when you handle printed circuit boards. Do not touch
the boards unnecessarily. The boards contain components sensitive to electrostatic
discharge.
Hot surfaces
WARNING!
Beware of hot surfaces. Some parts, such as the inside surfaces of the filter cubicle,
heatsinks of power semiconductors, and brake resistors, become hot during use
and remain hot for a while after disconnection of the electrical supply.
Safety 9

Additional instructions for permanent magnet motor drives
￭Safety in installation, start-up, maintenance
These are additional warnings concerning permanent magnet motor drives. The other safety
instructions in this chapter are also valid.
WARNING!
Obey these instructions. If you ignore them, injury or death, or damage to the
equipment can occur.
If you are not a qualified electrical professional, do not do installation or
maintenance work.
• Do not do work on the drive when a rotating permanent magnet motor is connected to
it. A rotating permanent magnet motor energizes the drive including its input and output
power terminals.
Before installation, start-up and maintenance work on the drive:
• Stop the drive.
• Disconnect the motor from the drive with a safety switch or by other means.
• If you cannot disconnect the motor, make sure that the motor cannot rotate during work.
Make sure that no other system, like hydraulic crawling drives, can rotate the motor
directly or through any mechanical connection like felt, nip, rope, etc.
•Do the steps in section Electrical safety precautions (page 7).
• If the motor is connected to an inverter unit with a DC switch-disconnector, open the
disconnector, lock it, and tag it. If the motor is connected to an inverter unit without the
DC switch, remove the fuses in between the inverter module(s) and the drive DC link.
• Install temporary grounding to the drive output terminals (T1/U, T2/V, T3/W). Connect
the output terminals together as well as to the PE.
During the start-up:
• Make sure that the motor cannot run overspeed, for example, driven by the load. Motor
overspeed causes overvoltage that can damage or destroy the capacitors in the
intermediate circuit of the drive.
￭Safety in operation
WARNING!
Make sure that the motor cannot run overspeed, for example, driven by the load.
Motor overspeed causes overvoltage that can damage or destroy the capacitors
in the intermediate circuit of the drive.
10 Safety

Introduction
This supplement describes the high-speed drive option available as part of the ACS880
multidrive product offering. The option is available for both cabinet-built ACS880 multidrive
and ACS880 multidrive modules.
The supplement includes a description of the option as well as additional dimensioning,
start-up and maintenance instructions, and technical data. Apart from what is stated in this
supplement, the standard instructions delivered with the drive apply. See
•ACS880 multidrive cabinets and modules safety instructions (3AUA0000102301
[English])
•ACS880 multidrive cabinets and modules electrical planning instructions
(3AUA0000102324 [English])
•Cabinet-built ACS880 multidrive: ACS880-107 inverter units hardware manual
(3AUA0000102519 [English])
•Cabinet-built ACS880 multidrive: ACS880 multidrive cabinets mechanical installation
instructions (3AUA0000101764 [English])
•ACS880 multidrive modules: ACS880-104 inverter modules hardware manual
(3AUA0000104271 [English])
•ACS880 multidrive modules: Drive modules cabinet design and construction instructions
(3AUA0000107668 [English]).
2
Introduction 11

12

Description of the high-speed option
The high-speed option is intended for test bench applications with high-speed permanent
magnet motors rotating at up to 25000 rpm (with 3 pole pairs, corresponding to a maximum
frequency of 1250 Hz). The option involves installing a BLHF-2x-7 filter to the drive output.
High output frequencies inherently require high switching frequencies. With inverter modules
and units, option code +P967 denotes hardware that enables switching frequencies up to
13.33 kHz for 400 and 500 V modules and up to 12 kHz for 690 V modules. See Inverter
units for increased switching frequency (page 51).
The standard control program supports output frequencies up to 598 Hz. For higher output
frequencies, the inverter unit must be equipped with dual-use license +N8200.
Note: Drives that are able to operate above 600 Hz are considered dual-use goods, and
can be subject to export and import restrictions.
3
Description of the high-speed option 13

Inverter modules with +P967, no BLHF filter
ACS880
M
3
+P967
NOT ALLOWED. The du/dt of the motor voltage increases potentially enough to
damage the insulation. (Inverter modules with +P967 are not able to sufficiently
limit the du/dt.)
Inverter modules with +P967; BLHF filter when output filter is requested by motor
data sheet
ACS880
M
3
+P967
BLHF
OK for a maximum switching frequency of 13.3 kHz (with 400…500 V units) or
12 kHz (with 690 V units)
In the diagram, "BLHF" denotes either
• ACS880 cabinet-built multidrive option +E230, +E231 or +2E231, or
• BLHF-2x-7 filter module(s) available in the ACS880 multidrive modules product
offering.
Inverter modules without +P967; BLHF filter when output filter is requested by
motor data sheet
ACS880
M
3
BLHF
OK for a maximum switching frequency of 10.5 kHz (with 400…500 V units) or
7.5 kHz (with 690 V units)
In the diagram, "BLHF" denotes either
• ACS880 cabinet-built multidrive option +E230, +E231 or +2E231, or
• BLHF-2x-7 filter module(s) available in the ACS880 multidrive modules product
offering.
14 Description of the high-speed option

Inverter modules without +P967, no BLHF filter when no output filter is requested
by motor data sheet
ACS880
M
3
OK for a maximum switching frequency of 10.5 kHz (with 400…500 V units) or
7.5 kHz (with 690 V units)
The BLHF-2x-7 filter
The filter module is an inductor-type filter that is available in two types:
• BLHF-21-7: 40 µH, 1400 A
• BLHF-22-7: 20 µH, 2000 A
The suitable filter inductance should be chosen according to motor data.
The filter module has a direct-on-line cooling fan powered by the 3-phase supply. The fan
is controlled on and off by a 230/115 volt signal.
There are thermal breakers installed in the three windings as well as a fourth one in the
lower part of the module.
Description of the high-speed option 15

￭BLHF-2x-7 layout and connections
5
4
6
2
1
9
8
3
7
DescriptionNo.
AC connection1
AC connection2
Wheels3
Cooling fan4
Terminal block X55 (ready-connected)5
Type designation label. See Type designation label (page 17).
6
Handle7
Unpainted grounding point (PE)8
Terminal block X30. See Terminal block X30 (page 17).
9
16 Description of the high-speed option

Terminal block X30
Control of DOL fan contactor N (230 V AC or 115 V AC)9
Control of DOL fan contactor L (230 V AC or 115 V AC)8
Normally-open feedback contact 14 from DOL fan contactor7
Normally-open feedback contact 13 from DOL fan contactor6
TP2, thermal cutoff circuit5
TP1, thermal cutoff circuit4
400 V AC or option
+G427: 208 V AC
+C188: DOL fan W3
+C188: DOL fan V2
+C188: DOL fan U1
Type designation label
The type designation label includes ratings, appropriate markings, a type designation and
a serial number, which allow the identification of each unit. A sample label is shown below.
Quote the complete type designation and serial number when contacting technical support.

  C
 
  
� 13
Un   
 2 A
     UK

CA
e!
Air tlng
I  
  
1
3
24
5
Type designation1
Ratings2
Cooling method; degree of protection3
Valid markings4
Serial number5
Description of the high-speed option 17

Connection diagram
U2
V2
W2
PE
M
3~
U1
W1
V1
PE
BLHF filterInverter unit Motor
18 Description of the high-speed option

Ordering information
￭Cabinet-built ACS880 multidrives
In a cabinet-built multidrive, the following option codes for high-speed filter units (HSFU)
are selectable.
In
(A)
L
(µH)
Cubicle width (mm)Filter typeOption code
140040500BLHF-21-7+E230
200020500BLHF-22-7+E231
2000407002 × BLHF-22-7+2E231
Restrictions and notes
• The drive control cubicle (DCU) is located between the inverter unit and the filter unit.
The standard width of the DCU is 300 mm; 400 mm is optionally available.
• Option +F270 (output grounding switch) is not available.
• A common motor terminal cubicle (OPU), output disconnector cubicle (ODU) or output
contactor cubicle (OCU) is required. The table below shows the possible output
configurations and output cubicle widths.
Note: An output contactor is recommended. The contactor should open whenever the
drive trips on a fault. This prevents the voltage generated by a rotating motor from
energizing the drive.
Output disconnector (ODU) or
contactor (OCU) cubicle
Common motor terminal cubicle
(OPU)
Option code
600 mm
400 mm (default)
600 mm (optional)
+E230
400 mm (default with bottom exit)
600 mm (top exit, optional with
bottom exit)
+E231, +2E231
• The stop category 1 emergency stop methods (as specified by IEC 60204-1) available
for the drive are SS1-t (Safe Stop 1 time controlled, as specified by IEC 61800-5-2).
SS1-r (Safe Stop 1 ramp monitored) emergency stop methods implemented with FSO-xx
modules are not certified for use in the high-speed region.
Description of the high-speed option 19

Layout
HSFU with one filter module
1
1
2
3
4
5
HSFU with two filter modules
11
2
3
4
5
4
DescriptionNo.
AC input from drive control cubicle (DCU)1
Cooling air intake2
Cooling air outlet3
Filter module4
AC output to common motor terminal cubicle (OPU), output disconnector cubicle (ODU) or output
contactor cubicle (OCU)
5
￭ACS880 multidrive modules
Refer to ACS880-104 inverter modules hardware manual (3AUA0000104271 [English]).
20 Description of the high-speed option