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ABB ACS880-04 drive modules Application Manual
Summary of ACS880-04 drive modules
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Abb industrial drives application guide acs880-01 drives and acs880-04 drive modules common dc systems.
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List of related manuals you can find manuals and other product documents in pdf format on the internet. See section document library on the internet on the inside of the back cover. For manuals not available in the document library, contact your local abb representative. Drive hardware manuals and g...
Page 3: Application Guide
Application guide acs880-01 drives and acs880-04 drive modules common dc systems 3aua0000127818 rev b en effective: 2014-04-17 2014 abb oy. All rights reserved. Table of contents.
Page 5: Table Of Contents
5 table of contents list of related manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 1. Introduction to the manual contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....
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6 brake resistor selection formulas - system with one brake chopper . . . . . . . . . . 28 brake resistor selection formulas - system with several brake choppers and resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 4. Planni...
Page 7: Introduction To The Manual
Introduction to the manual 7 1 introduction to the manual contents of this chapter this chapter contains information on this manual and a quick guide for planning a common dc system. Applicability this manual is applicable with the acs880-01 drives and acs880-04 drive modules. Safety instructions ob...
Page 8: Related Documents
8 introduction to the manual related documents see section list of related manuals on page 2 . Categorization by frame size some information in this manual is only valid for certain drive frame sizes. Such information includes the frame size indication, for example, frame r1. The type designation la...
Page 9: Terms And Abbreviations
Introduction to the manual 9 terms and abbreviations note: the symbols used in the equations and formulas are explained in the context of use. Term / abbreviation description avr automatic voltage regulator emc electromagnetic compatibility motoring mode motor operation mode in which the motor rotat...
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10 introduction to the manual.
Page 11: Operation Principle and
Operation principle and hardware description 11 2 operation principle and hardware description contents of this chapter this chapter contains a description of a common dc system. It also describes the drive features which are relevant in a common dc system..
Page 12: Operation Basics
12 operation principle and hardware description operation basics the main circuit of the drive consists of a rectifier, a dc link and an inverter. The rectifier (input bridge) converts the alternating current and voltage to direct current and voltage for the dc link. The dc capacitors in the dc link...
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Operation principle and hardware description 13 overview of the common dc system in a common dc system, you connect the dc links of several drives together in order to share their dc link energy storages. In addition to this basic configuration, there is a wide variety of additional choices with whi...
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14 operation principle and hardware description benefits of the common dc system benefits of the common dc system: • you can save energy by using the braking energy of one drive in the others - less energy needs to be taken from the ac power line. • dc capacitors of all drives form a high-capacity e...
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Operation principle and hardware description 15 overview diagram of the drive main circuit the overview diagrams below show the main circuits of the drive modules. The differences between the drive modules, in regards of the use of the drives in a common dc system, are the charging circuit and brake...
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16 operation principle and hardware description.
Page 17: Planning – Basics
Planning – basics 17 3 planning – basics contents of this chapter this chapter contains the basics of planning a common dc system. See section quick planning guide on page 8 for a summary of planning steps..
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18 planning – basics defining the dc link duty cycle and key variables defining the dc link duty cycle 1. Define the dc link duty cycle for each drive. See section dc link duty cycle diagram on page 19 . Use the duty cycle diagram of the motor shaft power and: • add the inverter and motor losses dur...
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Planning – basics 19 dc link duty cycle diagram dc link key variables p mot t drive a drive b drive c total m a b c m m ~ p dc p dc p dc ~ p gen p dc p mot t p gen p mot t p gen p mot t p gen p mot p gen m m m a b c ~ ~ p br p mot p gen p rec.
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20 planning – basics symbol name information p mot motoring power power that the motors take from the common dc link p mot,ave average motoring power average power that the motors take from the common dc link. See the duty cycle diagram of the common dc link. Note: for long cycles times, define p mo...
Page 21: Ac Power Line
Planning – basics 21 selecting the drives which are connected to ac power line this section contains instructions for selecting the drives which are connected to the ac power line. However, you can also connect more drives, for example, for backup reasons. The selection rules 1. At the very least, c...
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22 planning – basics example 1 common dc system: the dc links of three converters acs880-01-11a0-5, 5.5 kw (frame size r1), acs880-01-034a-5, 18.5 kw (frame size r3) and acs880-01-034a-5, 18.5 kw (frame size r3) are connected together. The input terminals of the 5.5 kw converter are left unconnected...
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Planning – basics 23 checking the total charging resistance use this method for verifying the charging capacity if there are only drives with type a charging circuits in the common dc system. The total charging resistance must comply with this formula: r tot > r min calculate the value r tot as foll...
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24 planning – basics checking the peak ac current at charging if you only have drives with type a charging circuits in the common dc system, make sure that the ac line-side components (fuses, contactors, etc.) can withstand the peak current at charging. Use the rule of thumb below, or calculate the ...
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Planning – basics 25 example 1 common dc system: the dc links of three converters acs880-01-169a-3 (frame size r7), acs880-01-246a-3 (frame size r8) and acs880-01-430a-3 (frame size r9) are connected together. The main supply voltage is 400 v. Questions: is the charging capacity of the largest drive...
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26 planning – basics defining the energy absorbing capacity of the common dc link use formula 1 below to examine if the common dc link capacitors can absorb the surplus energy of the common dc system. If the condition is true, the energy absorbing capacity is sufficient and you do not need a brake c...
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Planning – basics 27 defining the maximum dc link voltage the table below shows how you can define the maximum dc link voltage u dc,lim . See section dc voltage limits of the drive on page 45 for the explanation of the symbols. 1) parameter 30.30 overvoltage control in the acs880 primary control pro...
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28 planning – basics brake chopper selection formulas use these formulas to select the choppers and verify the selection: p br,cont > p gen,ave p br,max > p gen,max p br,cont = p br,cont1 + 0.8 × (p br,cont2 + p br,cont3 +…) p br,max = p br,max1 + 0.7 × (p br,max2 + p br,max3 +…) brake resistor sele...
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Planning – basics 29 brake resistor selection formulas - system with several brake choppers and resistors use these formulas to select the brake resistor for each chopper, and to verify the resistor selection: r br(i) > r br,min(i) e r(i) energy pulse that individual brake resistor i can withstand a...
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30 planning – basics.
Page 31: Planning – Additional
Planning – additional instructions 31 4 planning – additional instructions contents of this chapter this chapter contains some additional instructions for planning a common dc system. Requirements for the ac input connection see the drive hardware manual for the electric power network specification ...
Page 32: Selecting The Fuses
32 planning – additional instructions selecting the fuses there must be fuses both at the ac supply side of the drive and at the dc connection. They protect the cabling and limit the drive damage in case of a short circuit. Selecting the ac input fuses equip every drive which you connect to the ac p...
Page 33: Phase Loss Protection
Planning – additional instructions 33 phase loss protection we recommend that you use phase loss guard in the ac supplies of the drives which you connect to the ac power line. If one ac fuse blows, the semiconductors of the drives can be overloaded and be damaged if you do not have the phase loss pr...
Page 34: Dc Contactors
34 planning – additional instructions dc contactors dc link separation if you connect drives with different type of charging circuits to the ac power line, you must separate their dc link with a dc contactor. The dc links of drives with type b charging circuit may not be connected to the dc link of ...
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Planning – additional instructions 35 electromagnetic compatibility (emc) to ensure that the common dc link system complies with electromagnetic compatibility (emc) rules and does not interfere with other systems, obey the following guidelines: • obey the electrical installation instructions in the ...
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36 planning – additional instructions connecting the ready and start enable signals all drives which you connect to the ac power line must be ready (charging complete) before you can start to load any of the drives. If a drive on the common dc system starts its motor too early, it can cause damage t...
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Planning – additional instructions 37 setting the drive parameters check the settings of the drive parameters against the recommendations below. This is not the complete list of settings, just settings for the common dc system to work effectively. The list is valid for the acs880 primary control pro...
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38 planning – additional instructions.
Page 39: Technical Data
Technical data 39 5 technical data contents of this chapter this chapter contains the technical data that you need in the planning of a common dc system..
Page 40: And P
40 technical data rectifier power capacity (p rec,ave and p rec,max ) u ac : ac input voltage. P rec,ave is the average rectifier power capacity of the drive over a 3-minutes time window. The average power taken from ac power line must be lower than this value during any 3-minutes time window. 1) va...
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Technical data 41 power correction factor (k) the tables below shows the power correction factor (k) for calculating the sum rectifying capacity of the drives connected to the ac power line. Choose the lowest k factor of the possible choices. The tables also show the combinations of drives that you ...
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42 technical data frames r10 to r11 r10a: acs880 types -505a-3 and -460a-5. R10b: acs880 types -585a-3, -650a-3, -583a-5, -635a-5, -330a-7 and -370a-7. U ac : ac input voltage. Dc contactors between the drives tables below show when you need a dc contactor between the drives in the dc link. If both ...
Page 43: Charging Resistance Values
Technical data 43 charging resistance values r: charging resistance of the drive module. R min : minimum resistance that the charging circuit can supply (in case the circuit must supply charging current of several drives). Charging circuit e r values e r : maximum energy pulse that the charging circ...
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44 technical data brake chopper power ratings p br,cont : continuous braking power of the chopper. The braking is considered continuous if the braking time exceeds 30 seconds. R br,min : the minimum allowed resistance of the brake resistor used with the brake chopper. Note: p br,max = u dc,brcl 2 / ...
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Technical data 45 dc voltage limits of the drive u ac : ac input voltage. Set also parameter 95.01 supply voltage in the drive control program to this value. All drives on the common dc system must have the same setting. Set parameter 95.02 adaptive voltage limits to disabled. U dc : nominal dc link...
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46 technical data dc fuses drive type acs880-01- fuse [a] drive type acs880-01- fuse [a] drive type acs880-01- fuse [a] drive type acs880-01- fuse [a] 04a6-2 10 02a4-3 10 02a1-5 10 07a3-7 16 06a6-2 16 03a3-3 10 03a0-5 10 09a8-7 20 07a5-2 16 04a0-3 10 03a4-5 10 14a2-7 32 10a6-2 20 05a6-3 10 04a8-5 10...
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Further information product and service inquiries address any inquiries about the product to your local abb representative, quoting the type designation and serial number of the unit in question. A listing of abb sales, support and service contacts can be found by navigating to www.Abb.Com/searchcha...
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Contact us www.Abb.Com/drives www.Abb.Com/drivespartners 3aua0000127818 rev b (en) 2014-04-17.