ABB ACS880-04 drive modules Application Manual

ABB industrial drives

Application guide

ACS880-01 drives and ACS880-04 drive modules

Common DC systems

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 guides Code (English)

ACS880-01 hardware manual 3AUA0000078093

ACS880-01 quick installation guide for frames R1 to R3 3AUA0000085966

ACS880-01 quick installation guide for frames R4 and R5 3AUA0000099663

ACS880-01 quick installation guide for frames R6 to R9 3AUA0000099689

ACS880-01 assembly drawing for cable entry boxes of IP21

frames R5 to R9

3AUA0000119627

ACS880-04 drive modules (200 to 560 kW, 300 to 700 hp)

hardware manual

3AUA0000128301

ACS880-04 drive modules (200 to 560 kW, 300 to 700 hp)

quick installation guide

3AUA0000128301

ACS-AP assistant control panels user’s manual 3AUA0000085685

Drive firmware manuals and guides

ACS880 primary control program firmware manual 3AUA0000085967

Quick start-up guide for ACS880 drives with primary control

program

3AUA0000098062

Option manuals and quides

ACS880-01 drives and ACS880-04 drive modules Common

DC systems application guide

3AUA0000127818

Manuals and quick guides for I/O extension modules,

fieldbus adapters, etc.

ACS880-04 manuals

ACS880-01 manuals

Application guide

ACS880-01 drives and ACS880-04 drive modules

Common DC systems

3AUA0000127818 Rev B

EN

EFFECTIVE: 2014-04-17

Table of contents

5

Table of contents

List of related manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1. Introduction to the manual

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Applicability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Target audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Contents of the manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Related documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Categorization by frame size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Quick planning guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Terms and abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2. Operation principle and hardware description

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Operation basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Overview of the common DC system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Overview diagram of the common DC system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Benefits of the common DC system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Challenges of the common DC system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Overview diagram of the drive main circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Charging circuit types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Type A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Type B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Brake chopper types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

3. Planning – basics

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Defining the DC link duty cycle and key variables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Defining the DC link duty cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

DC link duty cycle diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

DC link key variables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Selecting the drives which are connected to AC power line . . . . . . . . . . . . . . . . . . . . . . 21

The selection rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Calculating the rectifier power capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Verifying the charging capacity of the common DC system . . . . . . . . . . . . . . . . . . . . 22

Checking the total charging resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Checking the peak AC current at charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Checking the charging energy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Handling the surplus energy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Background . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Defining the energy absorbing capacity of the common DC link . . . . . . . . . . . . . . . . 26

Defining the maximum DC link voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Selecting the brake choppers and resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Brake chopper selection formulas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

6

Brake resistor selection formulas - system with one brake chopper . . . . . . . . . . 28

Brake resistor selection formulas - system with several brake choppers and

resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

4. Planning – additional instructions

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Requirements for the AC input connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Constructing the DC link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Selecting the fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Selecting the AC input fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Selecting the DC fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Phase loss protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Selecting the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

DC contactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

DC link separation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Brake resistor protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Electromagnetic Compatibility (EMC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Connecting the Ready and Start enable signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Setting the drive parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

5. Technical data

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Rectifier power capacity (Prec,ave and Prec,max) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Power correction factor (k) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Frames R1 to R5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Frames R5 to R9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Frames R10 to R11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

DC contactors between the drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Frames R1 to R5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Frames R5 to R9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Frames R10 to R11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Charging resistance values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Charging circuit Er values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

DC link capacitance values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Brake chopper power ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

DC voltage limits of the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

DC fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Further information

Product and service inquiries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Product training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Providing feedback on ABB Drives manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Document library on the Internet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

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

Obey the safety instructions in the drive’s hardware manual.

Target audience

This manual is written for people who plan common DC systems. We expect the reader to

be a qualified electrical engineering professional.

Contents of the manual

The chapters in this manual are:

• Introduction to the manual

• Operation principle and hardware description

• Planning – basics

• Planning – additional instructions

• Technical data.

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 label of the drive shows the frame size. The frame size for each drive type is

given in the drive hardware manual.

Quick planning guide

No. Step

1. Define a duty cycle diagram for each motor (shaft power). Select the motors and drives as

usual with the DriveSize PC tool by ABB. Do not consider the common DC system yet.

2. Define a DC link duty cycle for the common DC system, and define the key variables

P

mot,ave

, P

mot,max

, P

gen,ave

and P

gen,max

.

See section Defining the DC link duty cycle and key variables on page 18.

3. Select the drives that you will connect to the AC power line.

See section Selecting the drives which are connected to AC power line on page 21.

4. Define the means to handle the surplus DC link energy (motor braking energy).

See Handling the surplus energy on page 25.

5. Design the construction of the common DC link.

See section Constructing the DC link on page 31.

6. Select the fuses and phase loss guards.

See section Selecting the fuses on page 32 and section Phase loss protection on page 33.

7. Examine the need for DC contactors. If needed, select them.

See section DC contactors on page 34.

8. Plan the interlocking and safety.

•See Connecting the Ready and Start enable signals on page 36.

• Consider the use of safety circuits (such as emergency stop or Safe torque off) or control

signal interlocking for safe and reliable operation.

9. Select the measures necessary for the EMC. See section Electromagnetic Compatibility

(EMC) on page 35.

10. Repeat all design steps to verify the design.

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 rotates the load and takes power from

the drive DC link (normal operation).

Generating mode Motor operation mode in which the motor decelerates (brakes) the load and

generates energy back to the drive DC link.

This effect is also seen when the load is held at a fixed speed, but the

mechanical load is trying to “pull” the motor to a higher speed, sometimes

referred to as overhauling. Overhauling loads return energy to the DC link as

well.

10 Introduction to the manual

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.

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 smooth the ripple and form a steady energy

and power supply for the inverter. The inverter converts the intermediate circuit DC power

to AC power for the motor.

From a common DC system point of view, the motor has two main operation modes: the

motoring mode and the generating mode. In the motoring mode, the motor rotates the

machinery. The energy flows from the AC power line to the motor through the rectifier, DC

link and the inverter. In the generating mode, the machinery rotates the motor. This is the

case for example when a hoist motor of a crane lowers a load (overhauling load). To keep

the rotation speed steady, the motor brakes. During the braking, the motor generates

energy back to the inverter which then conveys the energy further to the DC link.

In the generating mode the DC capacitors are charged by the inverters and the DC link

voltage starts to rise. To prevent an excessive voltage rise, the drive must convey the

surplus energy away from the DC link. There are three options: to convey the energy to

the AC power line, to a brake resistor or to another drive. For the first option you need to

have a special type of drive in use, a regenerative drive. If you have an ordinary drive with

a rectifier (diode input bridge), regeneration is not possible so only the two other options

remain. If you connect a brake chopper and resistor to the DC link, you can dissipate the

energy in the resistor as heat. If you connect the DC link of the drive to another drive, you

can use the surplus energy for charging the DC capacitors of the other drive and use the

energy to rotate its motor. This is a common DC system.

No. Description

1. AC power line

2. Rectifier (input bridge)

3. DC link including DC capacitors (a), its charging circuit (b) and brake chopper (c)

4. Inverter

5. Motor

L1

L2

L3

U

V

W

R-

UDC+

R+

UDC-

M

~3

1 2 3 4 5

a

b

c

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 which you can affect the performance of the system. For

example, in certain applications you can:

• connect only one of the drives to the AC power line, and supply the other drives only

through the common DC link

• connect a shared brake chopper and resistor to the common DC link to absorb the

occasional surplus energy pulses that you cannot use in the drives

• connect one regenerative drive to a common DC link to convey the surplus motor

braking energy pulses to the AC power line instead of brake resistors

• supply the DC link from a separate DC source.

 Overview diagram of the common DC system

The diagram below shows an example of a common DC system.

1

2

3

4 5

1 AC power line

2 Common DC link

3Drive

4Motor

5 Brake resistor

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 energy storage that can absorb short

braking pulses of individual drives without a need for a brake chopper and resistor.

• If you need brake choppers and resistors, they can be optimized for the whole system.

You do not have to use the chopper of every drive.

• You do not necessarily need to connect every drive to the AC power line.

 Challenges of the common DC system

Challenges of the common DC system:

• You cannot operate any of the drives in the common DC system if one of the drives

connected to the AC power line has an active fault. See section Connecting the Ready

and Start enable signals on page 36.

• If you have drives with different type of charging circuits in the system, and you want to

connect them to AC power line, you must add extra contactors to the system and

arrange their control: For power up and charging, you must disconnect the DC links of

the drives which have different type of charging circuits. You can connect the DC links

together only after charging. See sections Charging circuit types on page 15 and

Charging resistance values on page 43.

• You must make sure that the load imbalance between the drives that are connected to

the AC power line is as small as possible. There is always slightly unequal AC input

current distribution due to differences in the input cables, chokes and input bridges’

forward bias characteristics. If the voltage reduction over the input cable, rectifier and

chokes is not the same in all drives, more current will flow through the rectifier which

has the lowest voltage reduction.

• You must make sure that the common DC system complies with the relevant

regulations and directives. The compliance of individual drives does not guarantee or

cover the compliance of the common DC system.

• If you supply the drives from a totally separate DC source, the DC source:

• must be capable of powering the drives when motoring,

• must be protected to prevent regeneration onto the DC from causing any damage,

or from effecting the devices supplying the DC source (for example AVR systems

on generators).

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 chopper designs.

 Charging circuit types

Type A

Charging resistor is in the DC link (frame sizes R1 to R4).

Type B

Charging resistor is in parallel with the input bridge (frame sizes R5 and larger).

 Brake chopper types

• Brake chopper is included as standard in frame sizes R1 to R4.

• Brake chopper is a factory-installed option for frame sizes R5 and larger (option

+D150).

L1

L2

L3

U

V

W

R-

UDC+

R+

UDC-

L1

L2

L3

U

V

W

BR-

UDC+

R+

UDC-

R1, …, R4

R5, …, R11

1

2

1

2

1 Charging resistor

2 Brake chopper

16 Operation principle and hardware description

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.

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 during the motoring mode of the motor.

• Subtract the inverter and motor losses during the generating mode of the motor.

2. Sum the DC link duty cycle diagrams of the individual drives to one common DC link

duty cycle diagram for the common DC system. See section DC link duty cycle

diagram on page 19.

3. On basis of the common DC link duty cycle diagram, define the key variables P

mot,ave

,

P

mot,max

, P

gen,ave

and P

gen,max

for the whole system. See section DC link key

variables on page 19.

Inverter losses

Motor losses

P

m

P

mot

k

eff

Efficiency factor (1/efficiency) to include drive and motor losses.

If not known, value 1.25 can be used

n Motor shaft speed [rpm]

P

dc

DC link power

P

mot

Power that the motor takes from the DC link

P

gen

Power that the motor supplies to the DC link

P

m

Motor mechanical shaft power

T Torque [Nm] on motor shaft

P

mot

= k

eff

× P

m

P

gen

=

k

eff

P

m

P

m

[kW] =

9550

T × n

Planning – basics 19

 DC link duty cycle diagram

 DC link key variables

P

mot

t

Drive a

Drive b

Drive c

Total

M

abc

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

a

b

c

~

P

br

P

mot

P

gen

P

rec

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

mot,ave

over the worst-case 3 minutes time window.

P

mot,max

Maximum motoring

power

Maximum power that the motors take from the common DC link. See

the duty cycle diagram of the common DC link.

P

gen

Generating power Power that the motors supply to the common DC link

P

gen,ave

Average generating

power

Average power that the motors feed to the common DC link when they

are in generating mode (braking the load). See the duty cycle diagram

of the common DC link. Note: If you will use the brake choppers of the

drives in the system, determine P

gen,ave

over the worst-case 30

seconds time window.

P

gen,max

Maximum

generating power

Maximum power that the motors feed to the common DC link when they

are in generating mode (braking the load). See the duty cycle diagram

of the common DC link.

P

rec

Rectifier power Power that the drive input bridges (rectifiers) feed to the common DC

link. See section Selecting the drives which are connected to

AC power line on page 21 for the calculation instructions.

P

rec,ave

Average rectifier

power capacity

The drives that are connected to the AC power line can feed this

average power to the common DC link.

P

rec,max

Maximum rectifier

power capacity

The drives that are connected to the AC power line can feed this power

to the common DC link at the maximum.

P

br

Braking power Surplus power that the brake resistors take from the common DC link.

(Alternatively: Power that the drive feeds to the AC power line if a

regenerative type of drive is in use.) See section Handling the surplus

energy on page 25.

P

br,cont

Continuous braking

power

Continuous braking power that the brake resistors take from the

common DC link. The braking is continuous if the braking time exceeds

30 seconds.

P

br,max

Maximum braking

power

Maximum braking power that the brake resistors take from the common

DC link. Brake choppers withstand this braking power for 5 second

within every minute.

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ABB ACS880-04 drive modules Application Manual

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ABB ACS880-04 drive modules Application Manual

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