ABB ACS880 Series Technical manual

—
ABB INDUSTRIAL DRIVES
ACS880 liquid-cooled multidrive cabinets and
modules
Electrical planning

ACS880 liquid-cooled multidrive
cabinets and modules
Electrical planning
Table of contents
© 2019 ABB Oy. All Rights Reserved. 3AXD50000048634 Rev C
EN
EFFECTIVE: 2019-06-30

Table of contents
1 Introduction to the manual
9Contents of this chapter ..........................................................................
9Applicability ........................................................................................
9Safety instructions ................................................................................
9Target audience ...................................................................................
10Terms and abbreviations .........................................................................
11Related documents ...............................................................................
11Cabinet-installed multidrive manuals .......................................................
11Multidrive module manuals ..................................................................
2 Electrical planning guidelines
13Contents of this chapter ..........................................................................
13Limitation of liability ...............................................................................
13Selecting the supply disconnecting device ....................................................
13Cabinet-installed multidrives .................................................................
13Multidrive modules ............................................................................
13European Union ............................................................................
14North America ..............................................................................
14Other regions ...............................................................................
14Selecting the main contactor (breaker) ........................................................
14Cabinet-installed multidrives .................................................................
14Multidrive modules ............................................................................
15Selecting the supply transformer ...............................................................
15Cabinet-installed multidrives .................................................................
15Basic guidelines ............................................................................
16Additional notes ............................................................................
17Multidrive modules ............................................................................
17IGBT supply modules ACS880-204LC .................................................
17Diode supply modules ACS880-304LC+A019 ........................................
18Examining the compatibility of the motor and drive ..........................................
18Protecting the motor insulation and bearings .............................................
18Requirements table ...........................................................................
21Availability of du/dtfilter and common mode filter by drive or inverter type .......
21Additional requirements for explosion-safe (EX) motors .............................
21
Additional requirements for ABB motors of types other than M2_, M3_, M4_, HX_
and AM_ .....................................................................................
21Additional requirements for braking applications ......................................
21
Additional requirements for drives with an IGBT supply unit or regenerative rectifier
unit ...........................................................................................
21Additional requirements for ABB high-output and IP23 motors .....................
22Additional requirements for non-ABB high-output and IP23 motors ................
22Additional note for sine filters ............................................................
23Selecting the power cables ......................................................................
23General guidelines ............................................................................
23Typical power cable sizes ....................................................................
Table of contents 5

24Power cable types .............................................................................
24Recommended power cable types ......................................................
24Alternate power cable types ..............................................................
25Not allowed power cable types ..........................................................
25Power cable shield ............................................................................
27Selecting the control cables .....................................................................
27Shielding ........................................................................................
27Signals in separate cables ...................................................................
27Signals that can be run in the same cable .................................................
27Relay cable type ...............................................................................
27Control panel to drive connection ...........................................................
28Routing the cables ................................................................................
28General guidelines, IEC ......................................................................
28Continuous motor cable shield or enclosure for equipment on the motor cable .....
29Separate control cable ducts ................................................................
30Implementing thermal overload and short circuit protections ..............................
30Protecting the input power cable against thermal overload .............................
30Diode supply unit ..........................................................................
30IGBT supply unit ...........................................................................
30Protecting the input power cable in short-circuits .........................................
30Diode supply unit ..........................................................................
30IGBT supply unit ...........................................................................
30Protecting the drive against thermal overload .............................................
30Cabinet-installed multidrives .............................................................
30Multidrive modules .........................................................................
31Protecting against short-circuit inside the drive ...........................................
31Cabinet-installed multidrives .............................................................
31Multidrive modules .........................................................................
31Protecting the motor and motor cable in short-circuits ...................................
31Protecting the motor cables against thermal overload ...................................
31Protecting the motor against thermal overload ...........................................
32Implementing a motor temperature sensor connection .....................................
32Connecting motor temperature sensor to the drive via an option module ............
33Connection of motor temperature sensor to the drive via a relay ......................
34Implementing a ground fault protecting function .............................................
34Cabinet-installed multidrives .................................................................
34Residual current device compatibility ...................................................
34Multidrives modules ...........................................................................
34Residual current device compatibility ...................................................
34Implementing the Emergency stop function ..................................................
34Cabinet-installed multidrives .................................................................
35Multidrive modules ............................................................................
35Implementing the Safe torque off function ....................................................
35Implementing the Prevention of unexpected start-up function .............................
35Cabinet-installed multidrives .................................................................
35Multidrive modules ............................................................................
35Implementing the Safely-limited speed function ..............................................
35Cabinet-installed multidrives .................................................................
36Multidrive modules ............................................................................
36Implementing the functions provided by the FSO-xx safety functions module ..........
36Cabinet-installed multidrives .................................................................
36Multidrive modules ............................................................................
6 Table of contents

36Supplying power for the auxiliary circuits ......................................................
36Cabinet-installed multidrives .................................................................
36Multidrive modules ............................................................................
37Using power factor compensation capacitors with the drive ................................
37Using a safety switch between the drive and the motor .....................................
37Implementing the Power-loss ride-through function .........................................
37Implementing the control of a contactor between drive and motor ........................
38Implementing a bypass connection ............................................................
38Protecting the contacts of relay outputs .......................................................
3 Standards and markings
41Contents of this chapter ..........................................................................
41Applicable standards .............................................................................
42Markings ...........................................................................................
43EMC compliance (IEC/EN 61800-3:2004 + A2012) .........................................
43Definitions ......................................................................................
43Category C3 ....................................................................................
43Category C4 ....................................................................................
45EU Declaration of Conformity (Machinery Directive) ........................................
45Multidrive modules ............................................................................
46Cabinet-installed multidrives .................................................................
46Approvals ..........................................................................................
47Disclaimers ........................................................................................
47Generic disclaimer ............................................................................
47Cybersecurity 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 ACS880 liquid-cooled multidrive cabinets and modules.
Safety instructions
WARNING!
Obey the safety instructions given in Safety instructions for ACS880
liquid-cooled multidrive cabinets and modules (3AXD50000048633
[English]). If you ignore the safety instructions, injury or death, or damage
to the equipment can occur.
If you are not a qualified electrician, do not do installation or maintenance
work.
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-x
Type of control unitBCU
Series of LCL-filters, for example BLCL-15-5BLCL
Brake chopper modules under control of one control board, and related accessoriesBrake 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
Charges or discharges an external energy storage (such as a battery or capacitor
bank) from or into the DC bus
DC/DC converter
Converter power electronics, related components and DC capacitors enclosed in a
metal frame or enclosure. Intended for cabinet installation.
DC/DC converter mod-
ule
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
Electromagnetic compatibilityEMC
Device through which the drive is connected to an external communication network,
that is, a fieldbus
Fieldbus adapter mod-
ule
Optional functional safety modulesFSO-12, FSO-21
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 board, 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
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 board, and related components. One
inverter unit typically controls one motor.
Inverter unit
Inductor-capacitor-inductor filterLCL 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
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 board, and related components.Supply unit
Type of control unitZCU
10 Introduction to the manual

Related documents
￭Cabinet-installed multidrive manuals
CodeManual
General manuals
3AXD50000048633
ACS880 liquid-cooled multidrive cabinets and modules safety instructions
3AXD50000048634
ACS880 liquid-cooled multidrive cabinets and modules electrical planning instructions
3AXD50000048635
ACS880 liquid-cooled multidrive cabinets mechanical installation instructions
3AXD50000126880
CIO-01 I/O module for distributed I/O bus control user's manual
Supply unit manuals
3AXD50000174782
ACS880-207LC IGBT supply units hardware manual
3AUA0000131562
ACS880 IGBT supply control program firmware manual
Inverter unit manuals
3AXD50000196111
ACS880-107LC 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
3AXD50000481491
ACS880-607LC 1-phase brake units hardware manual
3AXD50000020967
ACS880 (3-phase) brake control program firmware manual
3AXD50000431342
ACS880-1607LC DC/DC converter units hardware manual
3AXD50000024671
ACS880 DC/DC converter control program firmware manual
Option manuals
3AXD50000129607
ACS880-1007LC liquid cooling unit user's manual
3AXD50000039629
ACS880 +C132 marine type-approved cabinet-built drives supplement
3AUA0000085685
ACS-AP-x assistant control panels user’s manual
3AUA0000094606
Drive composer start-up and maintenance PC tool user’s manual
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
3AXD50000048633
ACS880 liquid-cooled multidrive cabinets and modules safety instructions
3AXD50000048634
ACS880 liquid-cooled multidrive cabinets and modules electrical planning instructions
3AUA0000107668
Drive modules cabinet design and construction instructions
3AUA0000113605
BCU-02/12/22 control units hardware manual
3AXD50000126880
CIO-01 I/O module for distributed I/O bus control user's manual
Supply module manuals
3AXD50000284436
ACS880-204LC IGBT supply modules hardware manual
3AUA0000131562
ACS880 IGBT supply control program firmware manual
Introduction to the manual 11

CodeManual
3AXD50000045157
ACS880-304LC+A019 diode supply modules hardware manual
3AUA0000103295
ACS880 diode supply control program firmware manual
Inverter module manuals and guides
3AXD50000045610
ACS880-104LC 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
3AXD50000184378
ACS880-604LC 1-phase brake chopper modules hardware manual
3AXD50000371631
ACS880-1604LC DC/DC converter modules hardware manual
3AXD50000024671
ACS880 DC/DC converter control program firmware manual
Option manuals
3AXD50000037752
ACS880 +C132 marine type-approved drive modules and module packages supplement
3AXD50000129607
ACS880-1007LC liquid cooling unit user's manual
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
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.
12 Introduction to the manual

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.
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:
2
Electrical planning guidelines 13

• switch-disconnector, with or without fuses, in accordance with IEC 60947-3, utilization
category AC-23B or DC-23B
• 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 meet the requirements of UL (UL 508C) and/or CSA C22.2 No. 14 and
be compliant with NFPA 70 (NEC) and/or Canadian Electrical Code (CE) along with state
and local codes for your location and application. (NFPA 70 (NEC) = 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.
Obey 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 ambient temperature.
• 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.
14 Electrical planning guidelines

Selecting the supply transformer
￭Cabinet-installed multidrives
Basic guidelines
1. Define the apparent power of the transformer:
• if the drive is equipped with a diode 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 (IEC), or short-circuit current protection (UL or CSA)
• etc.
4. Consider the additional notes below.
5. Contact the transformer manufacturer for more information on the transformer selection.
Electrical planning guidelines 15

Additional notes
A drive larger than 500 kVA with an IGBT supply 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.
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).
16 Electrical planning guidelines

￭Multidrive modules
IGBT supply modules ACS880-204LC
See the instructions given for the cabinet-installed multidrives.
Diode supply modules ACS880-304LC+A019
The supply modules do not have input chokes. For this reason, dimension the supply
transformer according to the supply unit apparent power (Sn), and make sure that the supply
transformer impedance is suitable for the supply unit. The transformer reactance Xkhas to
be at least 4% and the transformer nominal apparent power (Sn) must not be more than 2
times the nominal apparent power (Sn) of the supply unit in question.
Electrical planning guidelines 17

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 drive or inverter unit hardware
manual. You can also use the DriveSize PC tool.
Make sure that the motor withstands the maximum peak voltage in the motor terminals. See
Requirements table (page 18). For basics of protecting the motor insulation and bearings
in drive systems, see Protecting the motor insulation and bearings (page 18).
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.
• If the motor and drive are not of the same size, consider the operation limits of the drive
control program for the motor nominal voltage and current. See the appropriate
parameters in the firmware manual.
￭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.
18 Electrical planning guidelines

This table shows the requirements when an ABB motor is in use.
Requirement forNominal AC supply
voltage
Motor
type ABB du/dtand common mode filters, insulated N-end
motor bearings
Motor insula-
tion system
PN≥ 350 kW
or
frame size ≥ IEC 400
100 kW ≤ PN< 350
kW
or
IEC 315 ≤ frame size
< IEC 400
PN< 100 kW
and frame
size <
IEC 315
PN≥ 469 hp
or
frame size >
NEMA 580
134 hp ≤ PN< 469 hp
or
NEMA 500 ≤ frame
size ≤ NEMA 580
PN< 134 hp
and frame
size <
NEMA 500
+ N + CMF+ N-Standard
UN≤ 500 V
Random-
wound
M2_, M3_
and M4_
+ N + du/dt+ CMF+ N + du/dt+ du/dt
Standard
500 V < UN≤ 600 V
or
+ N + CMF+ N-Reinforced
+ N + du/dt+ CMF+ N + du/dt+ du/dt
Reinforced
600 V < UN≤ 690 V
(cable length ≤
150 m)
+ N + CMF+ N-Reinforced
600 V < UN≤ 690 V
(cable length >
150 m)
PN< 500 kW:
+N + CMF
+ N + CMFn.a.Standard
380 V < UN≤ 690 V
Form-
wound
HX_ and
AM_ PN≥ 500 kW:
+N + du/dt+ CMF
+ N + du/dtwith voltages over 500 V + CMF
Check with the
motor manu-
facturer.
380 V < UN≤ 690 V
Old1)
form-
wound
HX_ and
modular
+ N + CMFEnamelled
wire with fiber
glass taping
0 V < UN≤ 500 V
Random-
wound
HX_ and
AM_ 2)
+ N + du/dt+ CMF500 V < UN≤ 690 V
Consult the motor manufacturer.HDP
1) manufactured before 1.1.1998
2) For motors manufactured before 1.1.1998, check for additional instructions with the motor manufacturer.
Electrical planning guidelines 19

This table shows the requirements when a non-ABB motor is in use.
Requirement forNominal AC supply
voltage
Motor
type ABB du/dtand common mode filters, insulated N-end
motor bearings
Motor insula-
tion system
PN≥ 350 kW
or
frame size ≥ IEC 400
100 kW ≤ PN< 350
kW
or
IEC 315 ≤ frame size
< IEC 400
PN< 100 kW
and frame
size <
IEC 315
PN≥ 469 hp
or
frame size >
NEMA 580
134 hp ≤ PN< 469 hp
or
NEMA 500 ≤ frame
size ≤ NEMA 580
PN< 134 hp
and frame
size <
NEMA 500
+ N + CMF+ N or CMF-Standard:
ÛLL = 1300 V
UN≤ 420 V
Random-
wound
and form-
wound + N + du/dt+ CMF+ du/dt+ (N or CMF)+ du/dt
Standard:
ÛLL = 1300 V
420 V < UN≤ 500 V
or
+ N + CMF+ N or CMF-Reinforced:
ÛLL = 1600 V,
0.2 micro-
second rise
time
+ N + du/dt+ CMF+ du/dt+ (N or CMF)+ du/dt
Reinforced:
ÛLL = 1600 V
500 V < UN≤ 600 V
or
+ N + CMF+ N or CMF-Reinforced:
ÛLL = 1800 V
+ N + du/dt+ CMF+ du/dt+ N+ du/dt
Reinforced:
ÛLL = 1800 V
600 V < UN≤ 690 V
+ N + CMF+ N + CMF-
Reinforced:
ÛLL = 2000 V,
0.3 micro-
second rise
time1)
1) If the intermediate DC circuit voltage of the drive is increased from the nominal level due to long term resistor braking
cycles, check with the motor manufacturer if additional output filters are needed in the applied drive operation range.
The abbreviations used in the tables are defined below.
DefinitionAbbr.
Nominal AC line voltage
UN
Peak line-to-line voltage at motor terminals which the motor insulation must withstand
ÛLL
Motor nominal power
PN
du/dtfilter at the output of the drivedu/dt
Common mode filterCMF
N-end bearing: insulated motor non-drive end bearingN
Motors of this power range are not available as standard units. Consult the motor manufacturer.n.a.
20 Electrical planning guidelines