ABB ACS880 Series User manual

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

ACS880 liquid-cooled multidrives
cabinets and modules
Electrical planning
Table of contents
3AXD50000048634 Rev F
EN
Original instructions
EFFECTIVE: 2023-02-15

Table of contents
1 Introduction to the manual
9Contents of this chapter ........................................................................
9Applicability ........................................................................................
9Safety instructions ...............................................................................
9Target audience ...................................................................................
10Terms and abbreviations .......................................................................
11Related documents ..............................................................................
2 Electrical planning guidelines
13Contents of this chapter ........................................................................
13Limitation of liability .............................................................................
13Selecting the supply disconnecting device .................................................
13Cabinet-installed multidrives ...............................................................
13Multidrive modules ...........................................................................
14European Union and United Kingdom ................................................
14North America ..............................................................................
14Other regions ...............................................................................
14Selecting the main contactor (breaker) ......................................................
14Cabinet-installed multidrives ...............................................................
14Multidrive modules ...........................................................................
14North America ..............................................................................
14Other regions ...............................................................................
15Selecting the supply transformer .............................................................
15Cabinet-installed multidrives ...............................................................
15Basic guidelines ............................................................................
15Additional notes ...........................................................................
18Multidrive modules ...........................................................................
18
IGBT supply modules ACS880-204LC and diode supply modules
ACS880-304LC+A018 .....................................................................
18Diode supply modules ACS880-304LC+A019 ........................................
20Examining the compatibility of the motor and drive .....................................
20Protecting the motor insulation and bearings .........................................
20Requirements tables .........................................................................
21Requirements for ABB motors, P
n< 100 kW (134 hp) ..............................
22Requirements for ABB motors, P
n> 100 kW (134 hp) ..............................
23Requirements for non-ABB motors, P
n< 100 kW (134 hp) ........................
24Requirements for non-ABB motors, P
n> 100 kW (134 hp) ........................
24Abbreviations ..............................................................................
25Availability of d u /d t filter and common mode filter by drive or inverter type .
25Additional requirements for explosion-safe (EX) motors .........................
25
Additional requirements for ABB motors of types other than M2_, M3_, M4_,
HX_ and AM_ ................................................................................
25Additional requirements for braking applications .................................
25Additional requirements for drives with an IGBT supply unit ...................
25Additional requirements for ABB high-output and IP23 motors ................
26Additional requirements for non-ABB high-output and IP23 motors ..........
Table of contents 5

26Additional data for calculating the rise time and the peak line-to-line voltage .
27Additional note for sine filters ..........................................................
28Selecting the power cables .....................................................................
28General guidelines ............................................................................
28Typical power cable sizes ...................................................................
28Power cable types .............................................................................
28Preferred power cable types ............................................................
29Alternate power cable types ............................................................
30Not allowed power cable types .........................................................
30Power cable shield ............................................................................
32Grounding requirements ........................................................................
32Additional grounding requirements – IEC ...............................................
33Additional grounding requirements – UL (NEC) ........................................
34Selecting the control cables ....................................................................
34Shielding ........................................................................................
34Signals in separate cables ...................................................................
34Signals that can be run in the same cable ...............................................
34Relay cable ......................................................................................
34Control panel to drive cable ................................................................
34PC tool cable ...................................................................................
35Routing the cables ...............................................................................
35General guidelines – IEC .....................................................................
35
Continuous motor cable shield/conduit or enclosure for equipment on the
motor cable ....................................................................................
36Separate control cable ducts ...............................................................
36Roxtec cable entry option +H394 .............................................................
37Implementing thermal overload and short circuit protections .........................
37Protecting the drive and input power cables in short-circuits ......................
37Cabinet-installed multidrives ...........................................................
37Multidrive modules ........................................................................
37Protecting the motor and motor cable in short-circuits .............................
38Protecting the input power cable against thermal overload ........................
38Cabinet-installed multidrives ...........................................................
38Multidrive modules ........................................................................
38Protecting the drive against thermal overload .........................................
38Cabinet-installed multidrives ...........................................................
38Multidrive modules ........................................................................
38Protecting the motor cables against thermal overload ..............................
38Protecting the motor against thermal overload .......................................
39
Protecting the motor against overload without thermal model or temperature
sensors ..........................................................................................
40Implementing a motor temperature sensor connection .................................
40
Connecting a motor temperature sensor to the drive through an option mod-
ule ................................................................................................
41Implementing a ground fault protecting function ........................................
41Cabinet-installed multidrives ...............................................................
42Residual current device compatibility .................................................
42Multidrives modules ..........................................................................
42Residual current device compatibility .................................................
42Implementing the Emergency stop function ...............................................
42Cabinet-installed multidrives ...............................................................
42Multidrive modules ...........................................................................
6 Table of contents

43Implementing theSafe torqueoff function .................................................
43Implementing the Prevention of unexpected start-up function ........................
43Cabinet-installed multidrives ...............................................................
43Multidrive modules ...........................................................................
43Implementing the Safely-limited speed function ..........................................
43Cabinet-installed multidrives ...............................................................
43Multidrive modules ...........................................................................
44Implementing the functions provided by the FSO safety functions module ........
44Cabinet-installed multidrives ...............................................................
44Multidrive modules ...........................................................................
44
Implementing the functions provided by the FSPS-21 PROFIsafe safety functions
module ..............................................................................................
44Cabinet-installed multidrives ...............................................................
44Multidrive modules ...........................................................................
45Supplying power for the auxiliary circuits ...................................................
45Cabinet-installed multidrives ...............................................................
45Multidrive modules ...........................................................................
45Using power factor compensation capacitors with the drive ..........................
45Using a safety switch between the drive and the motor .................................
46Implementing the control of a contactor between drive and motor ..................
46Implementing a bypass connection ..........................................................
46Protecting thecontacts ofrelay outputs ....................................................
3 Standards and markings
49Contents of this chapter ........................................................................
50Applicable standards (cabinets) ..............................................................
50Applicable standards (modules) ..............................................................
51Markings ............................................................................................
52EMC compliance (IEC/EN 61800-3:2004 + A2012) .........................................
52Definitions ......................................................................................
52Category C3 ....................................................................................
53Category C4 ....................................................................................
54Declarations of conformity .....................................................................
58UL and CSA checklist .............................................................................
59Approvals ...........................................................................................
59Disclaimers .........................................................................................
59Generic disclaimer ............................................................................
59Cybersecurity 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 to ACS880 liquid-cooled multidrives cabinets and modules.
Safety instructions
WARNING!
Obey the safety instructions given in ACS880 liquid-cooled multidrive
cabinets and modules safety instructions (3AXD50000048633 [English]).
If you ignore the safety instructions, 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.
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
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
The part in which the control program runs.Control unit
One section of a cabinet-installed drive. A cubicle is typically behind a door of
its own.
Cubicle
DC circuit between rectifier and inverter line-side converter and motor-side
converter
DC link
Diode rectifier and related components enclosed in a metal frame or enclosure.
Intended for cabinet installation.
Diode supply module
Diode supply modules under control of one control board, and related com-
ponents.
Diode supply unit
Frequency converter for controlling AC motorsDrive
Electromagnetic compatibilityEMC
Analog I/O extension moduleFAIO-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
Optional analog I/O extension moduleFIO-11
Optional thermistor protection moduleFPTC-01
Optional ATEX-certified thermistor protection module for potentially explosive
atmospheres
FPTC-02
Optional functional safety modulesFSO-12, FSO-21
Optional functional safety moduleFSPS-21
IGBT bridge and related components enclosed inside a metal frame or enclos-
ure. Intended for cabinet installation.
IGBT supply module
IGBT supply module(s) under control of one control unit, and related compon-
ents.
IGBT supply 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 unit, and related components.
One inverter unit typically controls one motor.
Inverter unit
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. For example, variable, constant, or signal.
Parameter
Performance level. Levels a...e correspond to SIL (EN ISO 13849-1)PL
Converts alternating current and voltage to direct current and voltageRectifier
Rectifier bridge and related components enclosed in a metal frame or enclos-
ure. Intended for cabinet installation.
Regenerative rectifier
module
Regenerative rectifier modules under control of one control board, and related
components
Regenerative rectifier
unit
Safety integrity level (1…3) (IEC 61508, IEC 62061, IEC 61800-5-2)SIL
Drive for controlling one motorSingle drive
Safe torque off (IEC/EN 61800-5-2)STO
10 Introduction to the manual

DescriptionTerm
Rectifier bridge and related components enclosed in a metal frame or enclos-
ure. Intended for cabinet installation.
Supply module
Supply module(s) under control of one control unit, and related components.Supply unit
Related documents
You can find manuals on the Internet. See below for the relevant code/link. For more
documentation, go to www.abb.com/drives/documents.
Manuals for ACS880 multidrives cabinets
Manuals for ACS880 multidrives modules
Introduction to the manual 11

12

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 13

European Union and United Kingdom
To comply with European Union directives and United Kingdom regulations related
to standard EN 60204-1, the disconnecting device must be one of these 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)
• 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 type and size, it is fitted with a main contactor or a main
breaker by default. With certain drive types, you can select either of the two.
￭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.
• 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.
14 Electrical planning guidelines

Selecting the supply transformer
￭Cabinet-installed multidrives
Basic guidelines
1. Define the apparent power of the transformer. You can use this rule of thumb:
if the drive is equipped with a diode supply unit, or a regenerative rectifier
unit:
•
S
N(kVA) = 1.32 × sum of the motor shaft powers (kW)
• if the drive is equipped with an IGBT supply unit:
S
N(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.
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. Alternatively, use a three-winding
transformer, and connect only drives to the same secondary winding. If it is necessary
to connect other equipment to the same transformer winding, obey these instructions
to prevent damage:
• Do not connect a direct online motor to the same transformer winding as the
drive unless the motor is designed for use with variable frequency drives.
• Do not connect capacitive loads (for example, lighting, PCs, PLCs, power factor
compensation capacitors) to the same transformer winding as the drive.
Electrical planning guidelines 15

1
22
33
4
5
56
1
2
3
4
5
6
Medium voltage network1
Transformer2
Low voltage network3
Drive4
Other drives5
Other load (not drives)6
A drive with a 12-pulse diode supply unit
A 12-pulse diode supply unit cannot control the load sharing between its diode bridges.
The load sharing depends on factors such as the transformer selection, actual state
of the transformer (voltages, harmonics), supply network and cables. Load unbalance
reduces the load capacity of the drive. To avoid it, and to achieve the optimal drive
system performance, obey the guidelines in this section on the transformer selection
and on other factors.
Use a three-winding transformer, or two two-winding transformers:
• Connection groups: three-winding transformer: 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: < 3%
• No grounding of the secondary windings.
• Static shield is recommended.
16 Electrical planning guidelines

M
3
M
3
M
3
5
6
7a7b
1
3
2
4
Medium voltage network1
Three-winding transformer2
12-pulse drive3
No grounding of transformer secondary windings is permitted4
No load unbalance between transformer secondary windings is permitted5
Large 6-pulse drives (possible sources of harmonics)6
No (or only minimal) voltage distortion in medium voltage network is permitted.7
a. Path of harmful effect (harmonics) to one leg of the 12-pulse supply unit through transformer
delta-delta connections
b. Path of harmful effect (harmonics) to one leg of the 12-pulse supply unit through transformer
delta-wye connections.
Use identical supply cables between the transformer secondary windings and the
drive (type, size, length, quantity).
Make sure that there is no (or only minimal) voltage distortion in the medium voltage
system. The distortion has a negative effect on the operation of the transformer and
the 12-pulse drive. Especially 5th and 7th order harmonics are harmful. They can
decrease the DC output voltage of either 12-pulse leg of the supply unit. This causes
load unbalance and decreases the load capacity of the drive. Similar transformer
connection of the source drive and the 12-pulse drive tend to convey the harmful effect
more effectively. This strengthens the load unbalance between the two legs of the
12-pulse drive. Refer to the illustration above. Loads such as large 6-pulse drives can
cause 5th and 7th harmonics.
If you must connect a load other than a 12-pulse drive to the transformer, make sure
that the load is identically shared between the secondary windings.
Electrical planning guidelines 17

If the three-winding transformer supplies power to multiple 12-pulse drives, derate
the drive power rating from the nominal value according to the table below.
Drive power rating (%)Number of 12-pulse drives
1001
902
853
824
805
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).
￭Multidrive modules
IGBT supply modules ACS880-204LC and diode supply modules ACS880-304LC+A018
See the instructions given for the cabinet-installed multidrives.
Diode supply modules ACS880-304LC+A019
The supply modules do not have input chokes. Thus, the supply transformer (or
generator) must be dimensioned according to the apparent power of the supply unit
( S
n) and the supply transformer impedance
Z
k(trafo). The supply nominal impedance
Z
kmust be at least 5% calculated with nominal apparent power of the supply modules.
In a 6-pulse system, the transformer's nominal short-circuit impedance must be
according to the following equation. The same impedance requirement also applies
to a generator when used as the supply.
× Z (trafo) > 5%
S
S(trafo)
n
nk
Definitions
S
nACS880 liquid-cooled multidrives cabinets and modules nominal apparent
power
S
n(trafo) Transformer or generator nominal apparent power
Z
k(trafo) Transformer or generator nominal short-circuit impedance
Example:
Diode supply unit: ACS880-304LC-1540A-7+A019 → S
n= 1840 kVA
Transformer nominal power is, for example, 2500 kVA
(trafo) > 2500 kVA
1840 kVA × 5%
k
Z
→ Z
k(trafo) ≥ 6.8%
18 Electrical planning guidelines

The same rule also applies to 12-pulse transformers when the nominal values are
calculated based on the total power of the 12-pulse transformer. If the nominal values
are calculated per 6-pulse windings (power per winding is half of the power of the
12-pulse transformer), then half of the reactance (≥ 2.5%) is sufficient.
If the necessary transformer impedance Z
kcannot be fulfilled, it is also possible to
install a separate 3-phase AC choke in addition to transformer (or generator) impedance
to reach the necessary minimum impedance of 5%. Separate chokes are not available
from ABB.
Note: Since the supply modules do not have input chokes, the THD currents and
voltages have to be taken into account when dimensioning the system. If necessary,
it is also possible to install a separate 3-phase AC choke to reach lower THD levels.
The diagram below shows the typical current THD at nominal current in relation to
supply transformer impedance in a 6-pulse connection.
50%
45%
40%
35%
30%
25%
20%
4% 5% %8%7%6
Supply transformer reactance
Current THD
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
tables (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 with nominal voltage that
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 to 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.
d u /d t filters 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 tables
These tables show how to select the motor insulation system and when a drive d u /d t
and 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