ABB ACS880 Series User manual

—
ABB INDUSTRIAL DRIVES
ACS880 multidrive cabinets and modules
Electrical planning instructions

ACS880 multidrive cabinets and
modules
Electrical planning instructions
Table of contents
3AUA0000102324 Rev D
EN
Original instructions
EFFECTIVE: 2021-02-04

Table of contents
1 Introduction to the manual
9Contents of this chapter ...........................................................................
9Applicability .........................................................................................
9Target audience ....................................................................................
10Terms and abbreviations ..........................................................................
11Related documents ................................................................................
11Cabinet-installed multidrive manuals ........................................................
12Multidrive module manuals ...................................................................
2 Electrical planning guidelines
15Contents of this chapter ...........................................................................
15Limitation of liability ................................................................................
15Selecting the supply disconnecting device .....................................................
15Cabinet-installed multidrives ..................................................................
15Multidrive modules .............................................................................
16European Union .............................................................................
16North America ...............................................................................
16Other regions ................................................................................
16Selecting the main contactor (breaker) .........................................................
16Cabinet-installed multidrives ..................................................................
16Multidrive modules .............................................................................
16North America ...............................................................................
16Other regions ................................................................................
17Selecting the supply transformer ................................................................
17Basic guidelines ................................................................................
18Additional notes .................................................................................
18
A drive larger than 500 kVA with an IGBT supply unit or a regenerative rectifier
unit ............................................................................................
19A drive with a 12-pulse diode supply unit ...............................................
19Two parallel-connected supply units .....................................................
20Examining the compatibility of the motor and drive ...........................................
20Protecting the motor insulation and bearings ..............................................
20Requirements table ............................................................................
23Availability of du/dtfilter and common mode filter by drive or inverter type ........
23Additional requirements for explosion-safe (EX) motors ..............................
23
Additional requirements for ABB motors of types other than M2_, M3_, M4_, HX_
and AM_ ......................................................................................
23Additional requirements for braking applications .......................................
23Additional requirements for drives with an IGBT supply unit ........................
23Additional requirements for ABB high-output and IP23 motors ......................
24Additional requirements for non-ABB high-output and IP23 motors .................
25Additional data for calculating the rise time and the peak line-to-line voltage .....
25Additional note for sine filters .............................................................
26Selecting the power cables .......................................................................
26General guidelines .............................................................................
27Typical power cable sizes .....................................................................
Table of contents 5

27Power cable types ..............................................................................
27Preferred power cable types ..............................................................
28Alternate power cable types ...............................................................
29Not allowed power cable types ...........................................................
29Power cable shield .............................................................................
30Selecting the control cables ......................................................................
30Shielding .........................................................................................
30Signals in separate cables ....................................................................
30Signals that can be run in the same cable ..................................................
30Relay cable ......................................................................................
30Control panel to drive cable ...................................................................
30PC tool cable ....................................................................................
31Routing the cables .................................................................................
31General guidelines – IEC ......................................................................
31
Continuous motor cable shield/conduit or enclosure for equipment on the motor
cable ..............................................................................................
32Separate control cable ducts .................................................................
33Implementing thermal overload and short circuit protections ................................
33Protecting the drive and input power cables in short-circuit ..............................
33Cabinet-installed multidrives ..............................................................
33Multidrive modules ..........................................................................
33Protecting the motor and motor cable in short-circuits ....................................
33Protecting the input power cable against thermal overload ..............................
33Cabinet-installed multidrives ..............................................................
33Multidrive modules ..........................................................................
33Protecting the drive against thermal overload ..............................................
33Cabinet-installed multidrives ..............................................................
34Multidrive modules ..........................................................................
34Protecting the motor cables against thermal overload ....................................
34Protecting the motor against thermal overload .............................................
34Protecting the motor against overload without thermal model or temperature sensors .
35Implementing a motor temperature sensor connection ......................................
35Connecting motor temperature sensor to the drive via an option module .............
36Implementing a ground fault detection function ...............................................
36Cabinet-installed multidrives ..................................................................
36Residual current device compatibility ....................................................
36Multidrives modules ............................................................................
36Residual current device compatibility ....................................................
37Implementing the Emergency stop function ....................................................
37Cabinet-installed multidrives ..................................................................
37Multidrive modules .............................................................................
37Implementing the Safe torque off function .....................................................
37Implementing the Prevention of unexpected start-up function ..............................
37Cabinet-installed multidrives ..................................................................
38Multidrive modules .............................................................................
38Implementing the Safely-limited speed function ...............................................
38Cabinet-installed multidrives ..................................................................
38Multidrive modules .............................................................................
38Implementing the functions provided by the FSO-xx safety functions module ............
38Cabinet-installed multidrives ..................................................................
39Multidrive modules .............................................................................
6 Table of contents

39
Implementing the functions provided by the FSPS-21 PROFIsafe safety functions
module ...............................................................................................
39Cabinet-installed multidrives ..................................................................
39Multidrive modules .............................................................................
39Supplying power for the auxiliary circuits .......................................................
39Cabinet-installed multidrives ..................................................................
39Multidrive modules .............................................................................
40Using power factor compensation capacitors with the drive .................................
40Using a safety switch between the drive and the motor ......................................
40Implementing the control of a contactor between drive and motor .........................
41Implementing a bypass connection .............................................................
41Protecting the contacts of relay outputs ........................................................
3 Standards and markings
43Contents of this chapter ...........................................................................
44Applicable standards ..............................................................................
46Markings .............................................................................................
47EMC compliance (IEC/EN 61800-3:2004 + A2012) ..........................................
47Definitions .......................................................................................
47Category C2 .....................................................................................
48Category C3 .....................................................................................
49Category C4 .....................................................................................
50EU Declaration of Conformity (Machinery Directive) .........................................
52UL and CSA checklist .............................................................................
52Approvals ...........................................................................................
52Disclaimers .........................................................................................
52Generic disclaimer .............................................................................
53Cybersecurity disclaimer ......................................................................
Further information
Table of contents 7

8

Introduction to the manual
Contents of this chapter
This chapter contains general information of the manual, a list of related manuals, and a
list of terms and abbreviations.
Applicability
This manual is applicable with the air-cooled ACS880 multidrives cabinets and multidrive
modules.
Target audience
This manual is intended for people who plan electrical installation of the drive. The reader
is expected to know the fundamentals of electricity, wiring, electrical components and
electrical schematic symbols.
1
Introduction to the manual 9

Terms and abbreviations
DescriptionTerm
Assistant control panelACS-AP-…
Type of control unitBCU
Series of LCL-filters, for example BLCL-15-5BLCL
Brake chopper modules and the necessary auxiliary equipment, such as control
electronics, fusing and cabling
Brake unit
An enclosure that consists of one or more cubiclesCabinet
Common mode filteringCMF
Circuit board in which the control program runsControl board
Control board built in a housing (often rail-mountable)Control unit
One section of a cabinet-installed drive. A cubicle is typically behind a door of its own.Cubicle
DC/DC converter module(s) under control of one control board, and related componentsDC/DC converter unit
DC circuit between rectifier and inverterDC link
Distributed drives communication system protocolDDCS
Diode rectifier and related components enclosed in a metal frame or enclosure. Inten-
ded for cabinet installation.
Diode supply module
Diode supply modules under control of one control board, and related components.Diode supply unit
Frequency converter for controlling AC motorsDrive
Diode supply unitDSU
Electromagnetic compatibilityEMC
Optional digital I/O extension moduleFDIO-01
Optional TTL incremental encoder interface moduleFEN-01
Optional TTL absolute encoder interface moduleFEN-11
Optional resolver interface moduleFEN-21
Optional HTL incremental encoder interface moduleFEN-31
Device through which the drive is connected to an external communication network,
that is, a fieldbus
Fieldbus adapter mod-
ule
Optional digital I/O extension moduleFIO-01
Optional analog I/O extension moduleFIO-11
Optional functional safety modulesFSO-12, FSO-21
Incoming unitICU
IGBT bridge and related components enclosed inside a metal frame or enclosure.
Intended for cabinet installation.
IGBT supply module
IGBT supply module(s) under control of one control unit, and related components.IGBT supply unit
Part of the cabinet line-up that contains the input power cable terminals. Can also
contain switching equipment etc.
Incoming unit
DC circuit between rectifier and inverterIntermediate circuit
Inverter unitINU
Converts direct current and voltage to alternating current and voltage.Inverter
Inverter bridge, related components and drive DC link capacitors enclosed in a metal
frame or enclosure. Intended for cabinet installation.
Inverter module
Inverter module(s) under control of one control unit, and related components. One
inverter unit typically controls one motor.
Inverter unit
IGBT supply unitISU
Inductor-capacitor-inductor filterLCL filter
Inductor filterL-filter
Drive for controlling several motors which are typically coupled to the same machinery.
Includes one supply unit, and one or several inverter units.
Multidrive
In the drive control program, user-adjustable operation instruction to the drive, or
signal measured or calculated by the drive.
In some (for example fieldbus) contexts, a value that can be accessed as an object,
eg, variable, constant, or signal.
Parameter
10 Introduction to the manual

DescriptionTerm
Converts alternating current and voltage to direct current and voltageRectifier
Rectifier bridge and related components enclosed in a metal frame or enclosure. In-
tended for cabinet installation.
Regenerative rectifier
module
Regenerative rectifier modules under control of one control board, and related com-
ponents
Regenerative rectifier
unit
Radio-frequency interferenceRFI
Regenerative rectifier unitRRU
Safety integrity level (1...3) (IEC 61508)SIL
Drive for controlling one motorSingle drive
Safe torque off (IEC/EN 61800-5-2)STO
Rectifier bridge and related components enclosed in a metal frame or enclosure. In-
tended for cabinet installation.
Supply module
Supply module(s) under control of one control unit, and related components.Supply unit
Type of control unitZCU
Related documents
￭Cabinet-installed multidrive manuals
CodeManual
General manuals
3AUA0000102301
ACS880 multidrive cabinets and modules safety instructions
3AUA0000102324
ACS880 multidrive cabinets and modules electrical planning instructions
3AUA0000101764
ACS880 multidrive cabinets mechanical installation instructions
Supply unit manuals
3AUA0000130644
ACS880-207 IGBT supply units hardware manual
3AUA0000131562
ACS880 IGBT supply control program firmware manual
3AUA0000102453
ACS880-307 +A003 diode supply units hardware manual
3AXD50000011408
ACS880-307…+A018 diode supply units hardware manual
3AUA0000103295
ACS880 diode supply control program firmware manual
3AXD50000020546
ACS880-907 regenerative rectifier units hardware manual
3AXD50000020827
ACS880 regenerative rectifier control program firmware manual
Inverter unit manuals
3AUA0000102519
ACS880-107 inverter units hardware manual
3AUA0000085967
ACS880 primary control program firmware manual
3AUA0000098062
ACS880 primary control program quick start-up guide
Manuals for application programs (Crane, Winder, etc.)
Brake unit and DC/DC converter unit manuals
3AUA0000102559
ACS880-607 1-phase brake units hardware manual
3AXD50000022034
ACS880-607 3-phase dynamic brake units hardware manual
3AXD50000020967
ACS880 (3-phase) brake control program firmware manual
3AXD50000023644
ACS880-1607 DC/DC converter units hardware manual
3AXD50000024671
ACS880 DC/DC converter control program firmware manual
Option manuals
3AXD50000039629
ACS880 +C132 marine type-approved cabinet-built drives supplement
Introduction to the manual 11

CodeManual
3AUA0000085685
ACS-AP-x assistant control panels user’s manual
3AUA0000094606
Drive composer start-up and maintenance PC tool user’s manual
3AXD50000332588
Lifter for air-cooled drive modules user's guide
Manuals for I/O extension modules, fieldbus adapters, safety options etc.
You can find manuals on the Internet. See www.abb.com/drives/documents. For manuals
not available in the document library, contact your local ABB representative.
￭Multidrive module manuals
CodeManual
General manuals
3AUA0000102301
ACS880 multidrive cabinets and modules safety instructions
3AUA0000102324
ACS880 multidrive cabinets and modules electrical planning instructions
3AUA0000107668
Drive modules cabinet design and construction instructions
Supply module manuals
3AUA0000131525
ACS880-204 IGBT supply modules hardware manual
3AUA0000131562
ACS880 IGBT supply control program firmware manual
3AUA0000102452
ACS880-304…+A003 diode supply modules hardware manual
3AXD50000010104
ACS880-304…+A018 diode supply modules hardware manual
3AUA0000103295
ACS880 diode supply control program firmware manual
3AXD50000020457
ACS880-904 regenerative rectifier modules hardware manual
3AXD50000020827
ACS880 regenerative rectifier control program firmware manual
Inverter module manuals and guides
3AUA0000104271
ACS880-104 inverter modules hardware manual
3AUA0000085967
ACS880 primary control program firmware manual
3AUA0000098062
ACS880 primary control program quick start-up guide
Brake module and DC/DC converter module manuals
3AUA0000106244
ACS880-604 1-phase brake chopper modules hardware manual
3AXD50000022033
ACS880-604 3-phase dynamic brake modules as units hardware manual
3AXD50000020967
ACS880 (3-phase) brake control program firmware manual
3AXD50000023642
ACS880-1604 DC/DC converter modules hardware manual
3AXD50000024671
ACS880 DC/DC converter control program firmware manual
Module package hardware manuals
3AUA0000138495
ACS880-04 single drive module packages (560 to 2200 kW) hardware manual
3AXD50000022021
ACS880-14 and -34 single drive module packages hardware manual
Option manuals
3AXD50000037752
ACS880 +C132 marine type-approved drive modules and module packages supplement
3AUA0000085685
ACX-AP-x assistant control panels user’s manual
3AXD50000117840
BAMU-12C auxiliary measurement unit hardware manual
3AUA0000094606
Drive composer start-up and maintenance PC tool user’s manual
3AUA0000127808
Drive application programming (IEC 61131-3) manual
12 Introduction to the manual

CodeManual
3AXD50000010531
Installation frames for ACS880 multidrive modules hardware manual
Manuals and quick guides for I/O extension modules, fieldbus adapters, safety functions modules, etc.
See www.abb.com/drives/documents for all manuals on the Internet.
You can find all documentation related to the multidrive modules on the Internet at
https://sites-apps.abb.com/sites/lvacdrivesengineeringsupport/content.
Introduction to the manual 13

14

Electrical planning guidelines
Contents of this chapter
This chapter contains guidelines for planning the electrical installation of the drive.
Limitation of 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. Furthermore, if the recommendations given by ABB
are not followed, the drive may experience problems that the warranty does not cover.
Selecting the supply disconnecting device
￭Cabinet-installed multidrives
The drive is equipped with a main disconnecting device as standard. Depending on the size
of the drive, and the selected options, the type of disconnecting device may vary. Examples:
switch-disconnector, withdrawable air circuit breaker, etc.
￭Multidrive modules
You must equip the drive with a main supply disconnecting device which meets the local
safety regulations. You must be able to lock the disconnecting device to the open position
for installation and maintenance work.
2
Electrical planning guidelines 15

European Union
To meet the European Union Directives, according to standard EN 60204-1, Safety of
Machinery, the disconnecting device must be one of the following types:
•switch-disconnector of utilization category AC-23B (IEC 60947-3)
•disconnector that has an auxiliary contact that in all cases causes switching devices to
break the load circuit before the opening of the main contacts of the disconnector (EN
60947-3)
•a circuit-breaker suitable for isolation in accordance with IEC 60947-2.
North America
Installations must be compliant with NFPA 70 (NEC)1) and/or Canadian Electrical Code
(CE) along with state and local codes for your location and application.
1) National Fire Protection Association 70 (National Electric Code).
Other regions
The disconnecting device must conform to the applicable local safety regulations.
Selecting the main contactor (breaker)
￭Cabinet-installed multidrives
Depending on the drive size, you can order it either with a main contactor (option +F250),
or a main breaker (option +F255).
￭Multidrive modules
You can order a pre-selected main contactor (breaker) from ABB. See the appropriate drive
or supply module hardware manual.
Follow these guidelines when you select a customer-defined main contactor:
•Dimension the contactor according to the nominal voltage and current of the drive. Also
consider the environmental conditions such as surrounding air temperature.
•IEC devices only: Select contactor with utilization category AC-1 (number of operations
under load) according to IEC 60947-4, Low-voltage switch gear and control gear.
•Consider the application life time requirements.
North America
Installations must be compliant with NFPA 70 (NEC)1) and/or Canadian Electrical Code
(CE) along with state and local codes for your location and application.
1) National Fire Protection Association 70 (National Electric Code).
Other regions
The disconnecting device must conform to the applicable local safety regulations.
16 Electrical planning guidelines

Selecting the supply transformer
￭Basic guidelines
1. Define the apparent power of the transformer:
•if the drive is equipped with a diode supply unit, or a regenerative supply unit, use
this equation:
SN(kVA) = 1.32 × sum of the motor shaft powers (kW)
•if the drive is equipped with an IGBT supply unit, use this equation:
SN(kVA) = 1.16 × sum of the motor shaft powers (kW)
2. Define the nominal voltage for the transformer secondary winding according to the
nominal input voltage of the drive. See the supply unit hardware manual.
3. Make sure that the transformer complies with the electrical power network specification
of the drive. See the appropriate drive or supply unit hardware manual for:
•nominal input voltage, allowed voltage variation and imbalance
•nominal frequency and allowed variation
•short-circuit withstand strength and short-circuit current protection requirements
•etc.
4. Consider the additional notes below.
5. Contact the transformer manufacturer for more information on the transformer selection.
Electrical planning guidelines 17

￭Additional notes
A drive larger than 500 kVA with an IGBT supply unit or a regenerative rectifier unit
Use a two-winding transformer dedicated to drives and motors. Alternatively, use a
three-winding transformer, and connect only drives and motors to the same secondary
winding.
WARNING!
Do not connect capacitive load (for example: lighting, PCs, PLCs, small power
factor compensation capacitors, etc.), to the same transformer secondary winding
with drive. It can cause current resonances which can damage the equipment.
2
3
54
5
6
1
12
3
4
5
6
Medium voltage network1.
Transformer2.
Low voltage network3.
Drive4.
Motors or other drives5.
Other load (not drives or motors)6.
18 Electrical planning guidelines

A drive with a 12-pulse diode supply unit
Use a three-winding transformer, or two two-winding transformers:
•Connection groups: three-winding trasformer: Dy11d0 (or Dd0y1). Two two-winding
transformers: Dy11 and Yy0.
•Phase shift between secondaries: 30° electrical
•Voltage difference between secondaries: < 0.5%
•Short-circuit impedance of secondaries: > 5%
•Short-circuit impedance difference between secondaries: Impedance of transformer
windings must be equal, maximum <3% difference of the percentage impedance allowed.
(If short-circuit impedance Zk = 5%, variation can be maximum + 0.15%.)
•No grounding of the secondaries
•Static shield is recommended.
Two two-winding transformers
~ ~
22
3 3
Three-winding transformer
~ ~
22
3 3
Two parallel-connected supply units
See the appropriate supplement for the parallel-connected supply units, or contact ABB for
instructions in selecting the transformer(s).
Electrical planning guidelines 19

Examining the compatibility of the motor and drive
Use asynchronous AC induction motors, permanent magnet synchronous motors, AC
induction servomotors or ABB synchronous reluctance motors (SynRM motors) with the
drive.
Select the motor size and drive type from the rating table on basis of the AC line voltage
and motor load. You can find the rating table in the appropriate hardware manual. You can
also use the DriveSize PC tool.
Make sure that the motor can be used with an AC drive. See Requirements table (page 20).
For basics of protecting the motor insulation and bearings in drive systems, see Protecting
the motor insulation and bearings (page 20).
Note:
•Consult the motor manufacturer before using a motor whose nominal voltage differs from
the AC line voltage connected to the drive input.
•The voltage peaks at the motor terminals are relative to the supply voltage of the drive,
not the drive output voltage.
￭Protecting the motor insulation and bearings
The drive employs modern IGBT inverter technology. Regardless of frequency, the drive
output comprises pulses of approximately the drive DC bus voltage with a very short rise
time. The pulse voltage can almost double at the motor terminals, depending on the
attenuation and reflection properties of the motor cable and the terminals. This can cause
additional stress on the motor and motor cable insulation.
Modern variable speed drives with their fast rising voltage pulses and high switching
frequencies can generate current pulses that flow through the motor bearings. This can
gradually erode the bearing races and rolling elements.
du/dtfilters protect motor insulation system and reduce bearing currents. Common mode
filters mainly reduce bearing currents. Insulated N-end (non-drive end) bearings protect the
motor bearings.
￭Requirements table
These tables show how to select the motor insulation system and when a drive du/dtand
common mode filters and insulated N-end (non-drive end) motor bearings are required.
Ignoring the requirements or improper installation may shorten motor life or damage the
motor bearings and voids the warranty.
20 Electrical planning guidelines