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ABB ACS880 Manual

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ABB INDUSTRIAL DRIVES
ACS880 multidrive for high-speed test
benches
Supplement

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Summary of Contents for ABB ACS880

  • Page 1 — ABB INDUSTRIAL DRIVES ACS880 multidrive for high-speed test benches Supplement...
  • Page 3 ACS880 multidrive for high-speed test benches Supplement Table of contents 3AXD50000818013 Rev A Original instructions EFFECTIVE: 2022-01-11...

  • Page 5: Table Of Contents

    BLHF-2x-7 layout and connections ............Terminal block X30 ................. Type designation label ..............Connection diagram ................Ordering information ................Cabinet-built ACS880 multidrives ............Restrictions and notes ..............Layout ..................ACS880 multidrive modules ..............4 Planning the drive system Dimensioning flowchart ................
  • Page 6 6 Table of contents Motor temperature protection ..............Motor ambient temperature ..............Motor model temperature adaptation ............Encoder settings ................... Encoder interface ................Example: EnDat absolute encoder ............Checking the encoder position signal ............Verifying that the rotor position is known by motor control ....... Motor parameter settings .................

  • Page 7: Safety

    Safety 7 Safety Electrical safety precautions These electrical safety precautions are for all personnel who do work on the drive, motor cable or motor. WARNING! Obey these instructions. If you ignore them, 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.

  • Page 8: Additional Instructions And Notes

    8 Safety • If you have a permanent magnet motor connected to the drive, disconnect the motor from the drive with a safety switch or by other means. • Disconnect all dangerous external voltages from the control circuits. • After you disconnect power from the drive, always wait 5 minutes to let the intermediate circuit capacitors discharge before you continue.

  • Page 9: Optical Components

    Safety 9 • ABB does not recommend attaching the cabinet by arc welding. If you have to, obey the welding instructions in the drive manuals. • Remove the code labels attached to mechanical parts such as busbars, shrouds and sheet metal parts before installation. They may cause bad electrical connections, or, after peeling off and collecting dust in time, cause arcing or block the cooling air flow.

  • Page 10: Additional Instructions For Permanent Magnet Motor Drives

    10 Safety Additional instructions for permanent magnet motor drives Safety in installation, start-up, maintenance ￭ These are additional warnings concerning permanent magnet motor drives. The other safety instructions in this chapter are also valid. WARNING! Obey these instructions. If you ignore them, injury or death, or damage to the equipment can occur.

  • Page 11: Introduction

    Introduction 11 Introduction This supplement describes the high-speed drive option available as part of the ACS880 multidrive product offering. The option is available for both cabinet-built ACS880 multidrive and ACS880 multidrive modules. The supplement includes a description of the option as well as additional dimensioning, start-up and maintenance instructions, and technical data.

  • Page 13: Description Of The High-Speed Option

    Description of the high-speed option 13 Description of the high-speed option The high-speed option is intended for test bench applications with high-speed permanent magnet motors rotating at up to 25000 rpm (with 3 pole pairs, corresponding to a maximum frequency of 1250 Hz). The option involves installing a BLHF-2x-7 filter to the drive output. High output frequencies inherently require high switching frequencies.
  • Page 14 In the diagram, "BLHF" denotes either +P967 • ACS880 cabinet-built multidrive option +E230, +E231 or +2E231, or • BLHF-2x-7 filter module(s) available in the ACS880 multidrive modules product offering. BLHF Inverter modules without +P967; BLHF filter when output filter is requested by motor data sheet OK for a maximum switching frequency of 10.5 kHz (with 400…500 V units) or...

  • Page 15: The Blhf-2X-7 Filter

    OK for a maximum switching frequency of 10.5 kHz (with 400…500 V units) or 7.5 kHz (with 690 V units) ACS880 The BLHF-2x-7 filter The filter module is an inductor-type filter that is available in two types: •...

  • Page 16: Blhf-2X-7 Layout And Connections

    16 Description of the high-speed option BLHF-2x-7 layout and connections ￭ Description AC connection AC connection Wheels Cooling fan Terminal block X55 (ready-connected) Type designation label. See Type designation label (page 17). Handle Unpainted grounding point (PE) Terminal block X30. See Terminal block X30 (page 17).

  • Page 17: Terminal Block X30

    Description of the high-speed option 17 Terminal block X30 Control of DOL fan contactor N (230 V AC or 115 V AC) Control of DOL fan contactor L (230 V AC or 115 V AC) Normally-open feedback contact 14 from DOL fan contactor Normally-open feedback contact 13 from DOL fan contactor TP2, thermal cutoff circuit TP1, thermal cutoff circuit...

  • Page 18: Connection Diagram

    18 Description of the high-speed option Connection diagram Inverter unit BLHF filter Motor...

  • Page 19: Ordering Information

    Description of the high-speed option 19 Ordering information Cabinet-built ACS880 multidrives ￭ In a cabinet-built multidrive, the following option codes for high-speed filter units (HSFU) are selectable. Option code Filter type Cubicle width (mm) (µH) +E230 BLHF-21-7 1400 +E231 BLHF-22-7...

  • Page 20: Layout

    AC input from drive control cubicle (DCU) Cooling air intake Cooling air outlet Filter module AC output to common motor terminal cubicle (OPU), output disconnector cubicle (ODU) or output contactor cubicle (OCU) ACS880 multidrive modules ￭ Refer to ACS880-104 inverter modules hardware manual (3AUA0000104271 [English]).

  • Page 21: Planning The Drive System

    Dimensioning flowchart The following chart presents the basic dimensioning process. Consult your local ABB representative for dimensioning assistance. (ABB representatives can refer to a dimensioning tool using document code 3AXD10000595407.) Determine the nominal voltage of the drive according to the nominal voltage of the motor (see the motor data sheet).

  • Page 22: Loading Of Blhf Filters

    22 Planning the drive system Loading of BLHF filters Parameter Symbol BLHF-21-7 BLHF-22-7 Nominal current 1400 A 2000 A Overload current (60 seconds out of 10 minutes) 1700 A 2500 A ol,60s Overload current (10 seconds out of 10 minutes) 1900 A 2600 A ol,10s...

  • Page 23: Output Contactor

    Supply network An IT supply network system with a dedicated transformer is recommended. EMC compliance Drives with high-speed filters are always category C4 as per IEC/EN 61800-3. See ACS880 multidrive cabinets and modules electrical planning instructions (3AUA0000102324 [English]). Brake chopper...

  • Page 24: Encoder

    24 Planning the drive system Encoder The maximum pulse frequency of the encoder must be checked. With ACS880 encoder interface modules, the maximum pulse frequency is typically 500 kHz (see the technical data section of the appropriate interface manual). To calculate, first find out •...

  • Page 25: Igbt Supply Unit Dimensioning

    A brake chopper (BRC) and resistor can be fitted if the back-EMF voltage of the load motor is high enough to potentially cause damage if the inverter is coast-stopped at high speed. AC supply ACS880 DC bus – Active front end ACS880-207-…...
  • Page 26 (such as a brake chopper) are present. The ISU must also be able to supply enough power for the motors for a successful identification (ID) run. ACS880 DC bus –...

  • Page 27: Start-Up

    Start-up 27 Start-up This chapter contains settings that are specific to high-speed drives. For a general start-up sequence of the drive system, refer to the hardware manuals of the supply and inverter units. WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur.
  • Page 28 28 Start-up Add the following signals: • 1.02 Motor estimated speed • 1.04 Encoder 1 speed • 24.02 Used speed feedback • 1.07 Motor current • 1.10 Motor torque • 1.11 DC voltage • 24.01 Used speed reference • 26.02 Torque reference used •...

  • Page 29: Special Settings Related To High-Speed Drives

    Start-up 29 You can re-open the same monitoring configuration later by choosing Open… . Note that, in future sessions, you will have to enable service-level parameters again to be able to record those signals. Always start recording before you start the motor. Special settings related to high-speed drives Limits ￭...

  • Page 30: Voltage Reserve

    30 Start-up Voltage reserve ￭ Use parameter 97.04 Voltage reserve to apply a +2% voltage reserve. This is recommended with permanent magnet motors to prevent instability in the field weakening area. Switching frequency reference ￭ To enable a custom switching frequency reference setting, set parameter 97.09 Switching freq mode to Custom.

  • Page 31: Motor Model Temperature Adaptation

    Start-up 31 Motor model temperature adaptation ￭ Enable adaptation of temperature-dependent parameters, and select a suitable source, using parameter 97.15 Motor model temperature adaptation. If Pt100 sensors in the stator windings are used as temperature feedback, set service-level parameter 97.17 Rotor temperature factor to an initial value of 50%.
  • Page 32 32 Start-up Insert the FEN-11 module into a free slot (1…3) on the control unit. Connect the encoder cable according to the encoder data sheet and the FEN-11 manual. Connect the cable plug to X42 on the FEN-11. Switch on the power to the inverter control unit. Activate the encoder interface module in parameter 91.11 Module 1 type.

  • Page 33: Checking The Encoder Position Signal

    Start-up 33 When parameter 92.30 Serial link mode is set to Initial position, the position of the motor is updated only at power-on. The encoder used in this example indicates the position in the serial link message and separate sine-cosine hardware signals. Note: Validate any parameter changes using parameter 91.10 Encoder parameter refresh.

  • Page 34: Verifying That The Rotor Position Is Known By Motor Control

    34 Start-up Verifying that the rotor position is known by motor control ￭ When parameter 21.13 Autophasing mode is set to Turning with Z-pulse, and the motor is started for the first time after power-on, it will rotate slowly until a zero pulse is detected. After that, the control is released internally and starts to follow the reference.

  • Page 35: Identification (Id) Run

    Start-up 35 reference value of 100% in the drive corresponds to the nominal torque at operating point Operating point Parameter Speed 500 rpm 4600 rpm 9173 rpm 10000 rpm Torque 1250.0 N·m 1250.0 N·m 626.8 N·m 575.0 N·m Power 65.4 kW 602.1 kW 602.1 kW 602.1 kW...

  • Page 36: Activating Encoder Feedback

    36 Start-up Start the drive again to a slow speed. Check that the motor rotates in the correct (forward) direction with a positive speed reference. Activating encoder feedback ￭ With the motor running at a slow speed (eg. 100 rpm), check that parameters 1.02 Motor estimated speed and 24.02 Used speed feedback are equal both in value and sign.

  • Page 37: Autophasing

    Start-up 37 If 98.08 is greater than 1.2 or smaller than 0.8, a new value can be calculated for 99.07 Motor nominal voltage, and the ID run repeated. The following image shows the user motor parameters as calibrated by the ID run. Autophasing Autophasing is a measurement routine that determines the angular position of the magnetic flux of a permanent magnet synchronous motor.

  • Page 38: Starting The Drive

    38 Start-up Perform autophasing a few times to be sure that you get consistent results. For example, if you perform autophasing three times and the offset is detected as 61.2°, 61.4° and 61.4°, set 98.15 manually to 61.3°. To make the drive use the newly-determined offset, set 98.01 User motor model mode to Motor parameters &...
  • Page 39 Start-up 39 As an overall indicator of the validity of motor parameter settings, service-level parameters 227.01 Moderr and 227.02 Moderr2 should remain close to zero (in practice, between -0.3 and +0.3) in a static situation. After finishing the test runs, switch the drive from local to remote mode to be controlled by the PLC.

  • Page 41: Maintenance

    Maintenance 41 Maintenance This chapter describes the maintenance actions specifically related to the BLHF filter. For other maintenance actions, see ACS880-107 inverter units hardware manual (3AUA0000102519 [English]) or ACS880-104 inverter modules hardware manual (3AUA0000104271 [English]).

  • Page 42: Fans

    See the firmware manual for the actual signal which indicates the running time of the cooling fan. Reset the running time signal after fan replacement. Replacement fans are available from ABB. Do not use other than ABB specified spare parts. Replacing the fan of the filter ￭...

  • Page 43: Replacing The Filter Module

    Maintenance 43 Replacing the filter module Note: The equipment pictured may differ from the actual hardware, but the filter replacement procedure will apply. Refer to the drawings below. WARNING! Obey the safety instructions. If you ignore them, injury or death, or damage to the equipment can occur.
  • Page 44 44 Maintenance WARNING! • Do not use the module extraction/installation ramp with plinth heights which exceeds the maximum allowed height. • Secure the module extraction/installation ramp carefully. • Push the module into the cabinet and pull it from the cabinet carefully preferably with help from another person.
  • Page 45 Maintenance 45 Note: As an alternative to using the extraction/installation ramp, a lifter is available from ABB Service. For more information, contact ABB Service, or see Lifter for air-cooled drive modules user's guide (3AXD50000332588 [English]). Stop the drive (if running) and do the steps in section...
  • Page 46 46 Maintenance...
  • Page 47 Maintenance 47...

  • Page 49: Technical Data

    Code +C188 denotes a 3-phase direct-on-line fan (400 V AC 50/60 Hz or 320 V AC 60 Hz), which is the default. Option +C188+G427 (3-phase 208 V AC direct-on-line cooling fan) is available in the ACS880 multidrive modules product range. Option +C183 (heating element) is available for both filter types.

  • Page 50: Current Derating

    50 Technical data Current derating ￭ See section Loading of BLHF filters (page 22). Power loss ￭ Power loss at f Filter type (Hz) BLHF-21-7 (filter module only) 5830 BLHF-22-7 (filter module only) 5090 +E230 6060 (HSFU cabinet with BLHF-21-7) +E231 5550 (HSFU cabinet with BLHF-22-7)

  • Page 51: Auxiliary Circuit Current Consumption

    Options +C183 (heating element) and +G304 (single-phase 115 V AC fan supply voltage) are available for all listed types. Output ratings Inverter unit type Input ratings No-overload Light-over- Heavy-duty load use Frame size as modules cabinet-built ACS880- ACS880- 104-… 107-… = 400 V 1250A-3+E205+P967 2×R8i 1406 1250 1200 1860A-3+E205+P967 3×R8i...

  • Page 52: Definitions

    Continuous rms output current allowing 50% overload for 1 minute every 5 minutes Switching frequency and output frequency derating ￭ Contact your local ABB representative for information. Ambient temperature and altitude derating ￭ See ACS880-107 inverter units hardware manual (3AUA0000102519 [English]) or ACS880-104 inverter modules hardware manual (3AUA0000104271 [English]).

  • Page 53: Inverter Modules Used

    Technical data 53 Inverter modules used ￭ Inverter unit type Modules used as modules cabinet-built Module type ACS880-104-… ACS880-107-… ACS880-104-… = 400 V 1250A-3+E205+P967 0640A-3+E205+P967 1860A-3+E205+P967 0640A-3+E205+P967 2450A-3+E205+P967 0640A-3+E205+P967 3050A-3+E205+P967 0640A-3+E205+P967 3640A-3+E205+P967 0640A-3+E205+P967 4250A-3+E205+P967 0640A-3+E205+P967 4860A-3+E205+P967 0640A-3+E205+P967 = 500 V...

  • Page 54: Protection Classes

    Enclosure types (UL50) Cabinet-built filter units (HSFU): Type 1 (standard), Type 1 (option +B054). For in- door use only. BLHF-2x-7 filter modules and ACS880-104 inverter modules: Type Open Overvoltage category III, except for auxiliary power connections (fan, control, heating, lighting etc) which (IEC/EN 60664-1) are category II.

  • Page 55: Filter Module

    Technical data 55 Filter module ￭...

  • Page 56: Blfh-2X-7 Internal Circuit Diagram

    56 Technical data BLFH-2x-7 internal circuit diagram...
  • Page 57 Technical data 57...

  • Page 59: 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/searchchannels.
  • Page 60 3AXD50000818013A © Copyright 2022 ABB. All rights reserved. Specifications subject to change without notice.

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