ABB industrial drives

Application guide
ACS880-01 drives and ACS880-04 drive modules
Common DC systems
List of related manuals
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 3AUA0000119627
frames R5 to R9
ACS880-04 drive modules (200 to 560 kW, 300 to 700 hp) 3AUA0000128301
hardware manual
ACS880-04 drive modules (200 to 560 kW, 300 to 700 hp) 3AUA0000128301
quick installation guide
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 3AUA0000098062
program

Option manuals and quides

ACS880-01 drives and ACS880-04 drive modules Common 3AUA0000127818
DC systems application guide
Manuals and quick guides for I/O extension modules,
fieldbus adapters, etc.

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.

ACS880-01 manuals ACS880-04 manuals

 Application guide
ACS880-01 drives and ACS880-04 drive modules
Common DC systems

Table of contents

 2014 ABB Oy. All Rights Reserved. 3AUA0000127818 Rev B

EN
EFFECTIVE: 2014-04-17
 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
Pmot,ave, Pmot,max , Pgen,ave and Pgen,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

Term / Description
abbreviation
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.

Note: The symbols used in the equations and formulas are explained in the context of use.
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.
R-

UDC+
R+
UDC-

L1 U

L2 b V M
~3 ~3
L3 a c W

1 2 3 4 5

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
 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.

4 5

1 AC power line
2 Common DC link
3 Drive
4 Motor
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.

R1, …, R4

R-

UDC+
R+
UDC-
L1 U

L2 1 V
2
L3 W

R5, …, R11
BR-

UDC+
R+
UDC-

1
L1 U

L2 V
2
L3 W

1 Charging resistor
2 Brake chopper

 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).
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.

Inverter losses Pmot = keff × Pm

Motor losses Pm
Pmot Pgen =
k eff
Pm
T×n
Pm [kW] =
9550
keff Efficiency factor (1/efficiency) to include drive and motor losses.
If not known, value 1.25 can be used
n Motor shaft speed [rpm]
Pdc DC link power
Pmot Power that the motor takes from the DC link
Pgen Power that the motor supplies to the DC link
Pm Motor mechanical shaft power
T Torque [Nm] on motor shaft

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 Pmot,ave,
Pmot,max, Pgen,ave and Pgen,max for the whole system. See section DC link key
variables on page 19.
 Planning – basics 19

 DC link duty cycle diagram

~ ~ Pdc
Pmot
Drive a t
Pgen
Pdc
Pmot
Drive b t
a b c
Pgen
Pdc
Pmot
Pmot Pgen
Drive c t
M M M Pgen

Pdc
Pmot
Total
t
Pgen

 DC link key variables

c
M

b
~ M

a
~ M

Pbr Pgen

Prec Pmot
20 Planning – basics

Symbol Name Information

Pmot Motoring power Power that the motors take from the common DC link
Pmot,ave Average motoring Average power that the motors take from the common DC link. See the
power duty cycle diagram of the common DC link. Note: For long cycles
times, define Pmot,ave over the worst-case 3 minutes time window.
Pmot,max Maximum motoring Maximum power that the motors take from the common DC link. See
power the duty cycle diagram of the common DC link.
Pgen Generating power Power that the motors supply to the common DC link
Pgen,ave Average generating Average power that the motors feed to the common DC link when they
power 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 Pgen,ave over the worst-case 30
seconds time window.
Pgen,max Maximum Maximum power that the motors feed to the common DC link when they
generating power are in generating mode (braking the load). See the duty cycle diagram
of the common DC link.
Prec 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.
Prec,ave Average rectifier The drives that are connected to the AC power line can feed this
power capacity average power to the common DC link.
Prec,max Maximum rectifier The drives that are connected to the AC power line can feed this power
power capacity to the common DC link at the maximum.
Pbr 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.
Pbr,cont Continuous braking Continuous braking power that the brake resistors take from the
power common DC link. The braking is continuous if the braking time exceeds
30 seconds.
Pbr,max Maximum braking Maximum braking power that the brake resistors take from the common
power DC link. Brake choppers withstand this braking power for 5 second
within every minute.
 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, connect the drive with the highest power rating to the AC power line.
Then the second largest, etc. until both the rectifier power capacity and charging
capacity of the system are high enough.
2. Make sure that you connect only the allowed combination of drives to the AC power
line. See section Power correction factor (k) on page 41.
3. Make sure that you have enough rectifier power capacity in the system. See
subsection Calculating the rectifier power capacity on page 21.
4. Make sure that you have enough charging capacity in the system. See section
Verifying the charging capacity of the common DC system on page 22.

 Calculating the rectifier power capacity

The drives which you connect to the AC power line must supply the rectifier power for the
common DC link, and further to the motors. Make sure that the system complies with these
formulas:
Prec,ave > Pmot,ave
Prec,max > Pmot,max
Use these equations to calculate Prec,ave and Prec,max:
Prec,ave = Prec,ave1 + k × (Prec,ave2 + Prec,ave3 +….)
Prec,max = Prec,max1+ 0.9 × k × (Prec,max2 + Prec,max3 +….)
k Power correction factor for a common DC system. See section Power correction factor (k)
on page 41.
Pmot,ave Average motoring power of the common DC system during the worst 3 minutes time
window. See section DC link key variables on page 19.
Pmot,max Maximum motoring power of the common DC system. See section DC link key variables on
page 19.
Prec, ave Average rectifier power capacity of the common DC system. See section DC link key
variables on page 19.
Prec, ave1 Average rectifier power capacity of drive 1. Drive 1 has the highest power rating of the
drives which are connected to AC power line. See section Rectifier power capacity
(Prec,ave and Prec,max) on page 40.
Prec,ave2 Average rectifier power capacity of drive 2. Drive 2 has the second highest power rating of
the drives which are connected to AC power line. See section Rectifier power capacity
(Prec,ave and Prec,max) on page 40.
Prec, max Maximum rectifier power of the common DC system allowed for 10 s. See section DC link
key variables on page 19.
Prec, max1 Maximum rectifier power capacity of drive 1. See section Rectifier power capacity
(Prec,ave and Prec,max) on page 40.
Prec,max2 Maximum rectifier power capacity of drive 2. See section Rectifier power capacity
(Prec,ave and Prec,max) on page 40.
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.
Calculating the rectifier power capacity
According to the table, k = 0.9 when two converters of frame size R3 are connected to the
AC power line, and Prec,ave becomes:
Prec,ave = 18.5 kW + (0.9 ×18.5 kW) = 35.15 kW
Example 2
Common DC system: The DC links of three converters ACS880-01-124A-5, 75 kW (frame
size R6), ACS880-01-180A-5, 110 kW (frame size R7) and ACS880-01-414A-5, 250 kW
(frame size R9) are connected together. All three converters are connected to the AC
power line.
Calculating the rectifier power capacity
According to the table, k = 0.9 when converters of frame size R6 and R7 are connected to
the AC power line, and k = 0.3 when converters of frame size R6 and R9 are connected to
the AC power line. The lowest factor is used in the calculations, that is, k = 0.3, and
Prec,ave becomes:
Prec,ave = 250 kW + (0.3 × 110 kW) + (0.3 × 75 kW) = 305.5 kW

 Verifying the charging capacity of the common DC system

After you select the drives that you will connect to the AC power line, you must verify that
there is enough charging capacity available.
Select the appropriate verification method and obey the related instructions:
1. If you only use drives with Type A charging circuit, make sure that both of these
conditions are true:
• The total charging resistance is high enough. See section Checking the total
charging resistance on page 23.
• The fuses, main contactor and other AC line-side components can withstand the
peak current during the charging. See section Checking the peak AC current at
charging on page 24.
2. If you use drives with Type B charging circuit, obey the instructions in subsection
Checking the charging energy on page 24.
Note: If you use both drives with Type A and Type B charging circuits and you connect
only Type B drives to the AC power line, select the verification method number 2 above.
Note: If you use both drives with Type A and Type B charging circuits AND you connect
both types of drives to the AC power line, you must separate the DC links of those drives
from each other during the charging. Then you actually have two (or several) separate DC
links from the charging capacity point of view, and you can verify the charging capacity of
each DC link separately. Select the appropriate verification method (number 1 or 2) above.
 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:
Rtot > Rmin
Rtot Calculated total charging resistance for the common DC system.
Rmin Minimum charging resistance allowed for the common DC system.

Calculate the value Rtot as follows:

1
Rtot =
1 1 1
+ + +
Ra Rb … Rn

Ra Charging resistance of drive a in the common DC system. See section Charging resistance
values on page 43.
Rb Charging resistance of drive b in the common DC system. See section Charging resistance
values on page 43.

Define the value Rmin as follows:

1. If you connect only one drive to the AC power line, Rmin is equal to the minimum
charging resistance defined for that drive. See section Charging resistance values on
page 43.
2. If you connect several drives to the AC power line, calculate Rmin. Use this equation:

1
Rmin =
1 1 1
+ + +
Rmin,1 Rmin,2 … Rmin,n

Rmin,1 Minimum charging resistance of drive 1 connected to the AC power line. See section
Charging resistance values on page 43.
Rmin,2 Minimum charging resistance of drive 2 connected to AC power line. See section Charging
resistance values on page 43.
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 peak current and compare it to
the allowed peak current data for the AC line-side components.
Rule of thumb: There can not be more than three drives which are not connected to the AC
power line per one connected drive.
Calculation: Calculate the peak current with this equation:

2 × U ac
I ac , peak =
Rtot

Iac,peak Peak AC current at charging.

U ac AC input voltage.
R tot Total charging resistance (see page 23).

Checking the charging energy

Use this method to verify the charging capacity if there are drives with Type B charging
circuit in the common DC system.
The drives that you connect to the AC power line must supply the total charging energy for
all of the DC capacitors in the common DC system at the power up. The charging capacity
must comply with this formula:
Erconnected > Etot
Erconnected Total energy pulse that the charging resistors of the drives connected to the AC power line
can withstand. See subsection Charging circuit Er values on page 43.
Etot Total charging energy of the DC capacitors of all drives in the common DC system.

Calculate the charging energy for a drive and the common DC system with these
equations:
Etot = Ea + …+ En = 1/2 × (CDCa +…+CDCn) × (1.35 × Unet)2
E1 = 1/2 × CDCa × (1.35 × Unet)2
C DC Capacitance of drive DC capacitors. CDCa is the capacitance of drive a. See subsection DC
link capacitance values on page 43.
Ea Charging energy of drive a.
U net Main voltage of the AC power line which the common DC system is connected to.
 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 sufficient for the whole common DC
system? Can you connect only the largest drive to the AC power line and leave the others
unconnected?
Calculations:
The total charging energy of the capacitors is:
Etot = 1/2 × (3800 μF + 5600 μF + 8800 μF) × (1.35 × 400 V)2 × 10-6 = 2653 J
The charging capacity of the ACS880-01-430A-3 (frame size R9) is sufficient since:
Er = 5600 J > 2653 J (Etot)
Conclusion: It is sufficient to connect only the largest drive to the AC power line.
Example 2
Common DC system: The DC links of two ACS880-01-240A-5 converters (frame size R8)
and three ACS880-01-361A-5 converters (frame size R9) are connected together. The
main supply voltage is 500 V.
Question: How many frame size R9 drives you must connect to the AC power line to
supply the charging energy for the whole system?
Calculations:
The total charging energy of the DC link capacitors is:
Etot = 1/2 × (2 ×5600 μF + 3 ×8800 μF) × (1.35 ×500 V)2 ×10-6 = 8566 J
The charging capacity of the ACS880-01-361A-5 (frame size R9):
One frame size R9 drive: Er = 5600 J < 8566 J (Etot)
Two frame size R9 drives: 2 × Er = 112 000 J > 8566 J (Etot)
Conclusion: It is sufficient to connect two frame size R9 drives to the AC power line.

Handling the surplus energy

 Background
When a motor brakes, it generates energy to the DC link. If the other drives in the common
DC system cannot use the energy at the same time, the DC link voltage starts to rise. The
capacitors in the DC link can absorb a small energy pulse. If that is not enough and the
voltage keeps rising, you must convey the surplus energy to the braking chopper and
resistors, or to the AC power line. For the latter case you need a special type of drive, a
regenerative drive. For more information of the electrical braking, see Technical guide
No. 8 Electrical braking in ABB Drives - Technical Guide Book (3AFE64514482 [English]).
This sections contains:
• instructions in defining the energy absorbing capacity of the common DC link
• instructions in dimensioning brake choppers and resistors.
This section does not contain instructions in selecting the regenerative drive.
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 chopper and a resistor to handle the surplus
energy.
Wdc > Egen (1)

(Cdca + Cdcb + Cdcc… + Cdcn)

Wdc = × (Udc,lim2 - Udc2)
2
T

Egen = ʃPgen(t) ×dt = Σ((Pg1 × t1) + … + (Pgn × tn))

0

Udc,lim = 2 × Uac

Drive a t
duty cycle

Drive b t
a b c duty cycle

M M M
Drive c t
duty cycle

Common DC t
duty cycle Pg1 Pg2
tg2
tg1
T

C dca Capacitance value of drive a

C dcb Capacitance value of drive b
Egen Generating energy of the common DC link during one duty cycle
Pg1 Generating power of the common DC link during time tg1
Pg2 Generating power of the common DC link during time tg2
Pgen(t) Generating power of the common DC link as a function of time over one duty cycle.
T Duty cycle time
tg1 Duration of generating power Pg1
tg2 Duration of generating power Pg2
U ac AC power line voltage
U dc Nominal DC link voltage. See section DC voltage limits of the drive on page 45.
U dc,lim Maximum DC link voltage. See section Defining the maximum DC link voltage on page 27.
Wdc Energy absorbing capacity of the common DC link
 Planning – basics 27

Defining the maximum DC link voltage

The table below shows how you can define the maximum DC link voltage Udc,lim. See
section DC voltage limits of the drive on page 45 for the explanation of the symbols.

Overvoltage control1) Brake choppers and Udc,lim

resistors

Enabled Not in use Udc,lim = UDC,ovc

Disabled Not in use Udc,lim < UDC,ovt 2)

Disabled In use Udc,lim = UDC,brcl 3)

1)
Parameter 30.30 Overvoltage control in the ACS880 primary control program.
2)
You must have some margin to the limit to avoid fault trips.
3)
The resistor braking starts when the voltage exceeds the limit.

 Selecting the brake choppers and resistors

You must use brake choppers and resistors in the common DC system if the DC link
capacitors cannot absorb the surplus energy, and there is no regenerative drive in the
system.
Depending on the drive frame size, the brake chopper is either a standard or optional
device. See section Brake chopper types on page 15. If the chopper is available as an
option, you can order it from ABB as factory-installed.
You must acquire and install the brake resistors separately. See the drive hardware
manual for ABB brake resistors for each drive. Use can use either the default ABB brake
resistors defined for each drive or other resistors that meet the selection criteria.
Select the choppers and resistors as follows:
1. Select the choppers:
• Examine if the chopper load capacity of the drive with the highest power rating is
high enough for the surplus power of the common DC link. See section Brake
chopper selection formulas on page 28.
• If the chopper load capacity of one drive is not enough, use also the chopper with
the second highest power rating, etc. until the total load capacity meets the
criteria.
2. Select the brake resistors:
• If you plan to use one chopper and resistor only, either verify the default ABB
brake resistor selection, or select a user-defined resistor. See section Brake
resistor selection formulas - system with one brake chopper on page 28. If the
resistor does not meet the criteria, try another resistor, or take the next biggest
chopper and its resistor in use as well.
• If you plan to use several choppers and resistors, verify each resistor selection.
See section Brake resistor selection formulas - system with several brake
choppers and resistors on page 29. If a resistor does not meet the criteria, try
another resistor, or take the next biggest chopper and its resistor in use as well.
Repeat the verification until each resistor meets the criteria.
28 Planning – basics

Brake chopper selection formulas

Use these formulas to select the choppers and verify the selection:
Pbr,cont > Pgen,ave
Pbr,max > Pgen,max
Pbr,cont = Pbr,cont1 + 0.8 × (Pbr,cont2 + Pbr,cont3 +…)
Pbr,max = Pbr,max1 + 0.7 × (Pbr,max2 + Pbr,max3 +…)
Pgen,ave Average generating power of the common DC link. See DC link duty cycle diagram on
page 19.
Pgen,max Maximum generating power of the common DC link. See DC link duty cycle diagram on
page 19.
Pbr,cont Continuous braking power of the common DC link. The braking is continuous if the braking
time exceeds 30 seconds.
Pbr,max Maximum braking power of the common DC link. Choppers withstand this braking power for
5 second within every minute.
Pbr,cont1 Continuous braking power of the chopper 1. See section Brake chopper power ratings on
page 44.
Pbr,max1 Maximum braking power of the chopper 1. See section Brake chopper power ratings on
page 44.

Brake resistor selection formulas - system with one brake chopper

Use these formulas to select the brake resistor, and to verify the resistor selection:

Rbr > Rmin

2
Udc,h
Rbr <
Pgen,max

Er > ʃPgen(t) ×dt = Σ((Pg1 × t1) + … + (Pgn × tn))

PN,r > Pgen,ave

Er Energy pulse that the resistor can withstand and dissipate during a predefined period. See
the drive hardware manual (ABB brake resistors) or resistor data sheet.
Pg1 Generating power of the common DC link during time tg1. See tg1 and the graph in section
Defining the energy absorbing capacity of the common DC link on page 22.
Pgen(t) Generating power of the common DC link as a function of time over one duty cycle.
Pgen,max Maximum generating power of the common DC link.
PN,r Nominal power of the brake resistor
R br Resistance of the brake resistor
R min Minimum resistance of the brake resistor that you can use with the drive. See the drive
hardware manual.
tg1 Duration for generating power Pg1. See the graph in section Defining the energy absorbing
capacity of the common DC link on page 22.
U ac AC power line voltage
U dc,h = 2.1 × U ac (high DC link voltage value but clearly below the trip level)
 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:
Rbr(i) > Rbr,min(i)

2
U dc
i) < Rbr ( i ) <
Pbr , max( i )
× Pgen ,max
( Pbr ,max 1 + Pbr ,max 2 + ...)

Pbr ,cont ( i )
×  Pgen dt < E R ( i )
(P br ,cont1 + Pbr ,cont 2 + ...)

Pbr ,cont ( i )
× Pgen ,ave < PN , R ( i )
(P
br ,cont1 + Pbr ,cont 2 + ...)

Er(i) Energy pulse that individual brake resistor i can withstand and dissipate during one load
cycle. See the drive hardware manual (ABB brake resistors) or resistor data sheet.
Rbr(i) Resistance of individual brake resistor i. See the drive hardware manual (ABB brake
resistors) or resistor data sheet.
Rbr,min(i) Minimum resistance of brake resistor i that you can use with individual drive (brake
chopper). See the drive hardware manual.
Pbr,cont(i) Continuous braking power of individual brake chopper. See the drive hardware manual
(ABB brake resistors) or resistor data sheet.
Pg1 Generating power of the common DC link during time tg1. See the graph in section Defining
the energy absorbing capacity of the common DC link on page 26.
Pgen(t) Generating power of the common DC link as a function of time over one duty cycle.
Pgen,max Maximum generating power of the common DC link.
PN,r(i) Nominal power of individual brake resistor i. See the drive hardware manual (ABB brake
resistors) or resistor data sheet.
Pbr,contr(i) Continuous power of brake chopper supplying the individual brake resistor i. See section
Brake chopper power ratings on page 44.
Pbr,max(i) Maximum power of brake chopper supplying the individual brake resistor i. See section
Brake chopper power ratings on page 44.
tg1 Duration for generating power Pg1. See graph in section Defining the energy absorbing
capacity of the common DC link on page 22.
Uac AC power line voltage
Udc,h = 2.1 × Uac High DC link voltage value but clearly below the trip level
30 Planning – basics
 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 of the drive.
Supply all drives which you connect to the AC power line from the same transformer. All
drives must have equal supply-side impedance. The supply-side impedance is an
important parameter which influences the current distribution.

Constructing the DC link

If the system consists of more than two drives, construct either common DC bus bars or
common DC terminals for the whole system. Connect the DC cabling of every drive to this
common connection point. Do not use the DC terminals of one of the drives for this
purpose, nor chain the DC link from one drive to another. This ensures that the drives
terminals do not overheat.
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 power line with fuses. The default AC fuses
for each drive are given in the drive hardware manual. Obey these guidelines if you select
other fuses:
• Fuse type: Only use the default fuse types (aR, T, etc.). See the drive hardware
manual.
• Voltage rating: According to the drive AC voltage rating, except use 500 V fuses for the
380 … 500 V AC supply.
• Nominal current of the fuses IF,N ≈ 1.6 × Irec,ave
• Irec,ave is the average rectifying current of the drive.
• Factor 1.6 covers the influence of cyclic load and ambient conditions.
• If you do not know the average rectifier current of the drive, use the rated input
current of the drive instead. See the drive hardware manual.
• Make sure that the operation time of the fuse is below the limit given for the default
fuses. See the drive hardware manual.

 Selecting the DC fuses

Equip every drive with DC fuses. Install a fuse on both DC+ and DC- cable that you
connect from the common DC link connection point to the drive.
Suitable fuses for each drive type are listed in section DC fuses on page 46. Obey these
guidelines if you select the fuses on your own:
• Fuse type: aR (ultra-rapid, fast)
• Voltage rating: Select according to the nominal DC voltage (UDC). See section DC
voltage limits of the drive on page 45.
• Nominal current: IF,N ≈ 1.6 x Idc,ave(i)
Make sure that the fuses also protect the DC cabling connected to the drive.

Pdc,ave(i)
Idc,ave =
Udc

1.6 Factor which covers the influence of the cyclic load and ambient conditions
Idc,ave Average DC link current
IF,N Nominal current of the fuse
Pdc,ave(i) Maximum average DC link power in the DC connection terminals of the
individual drive i. (during a worst case 3 min time window)
Udc actual DC link voltage = 1.35 x Uac
 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 protection. The internal
phase loss detection of the drive will not work, as the addition DC capacitors on the system
may prevent the DC ripple becoming large enough to be detected internally.

Selecting the power cables

• Obey the instructions in the drive hardware manual.
• Size the conductor cross-sectional area of the drive DC cable the same as the
conductors of the drive input power cable (AC).
• Use shielded DC cables, or only run them inside the cabinet. Ground the cable shield
at the other end only.
• Make sure that the lengths of the individual input power cables (AC) do not differ by
more than 15% from each other.
• Make sure that the total cable length of the DC cables between any two drives is no
longer than 50 m (164 ft).
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 drives with Type A charging circuit during
the charging. See the table in section Power correction factor (k) on page 41.
The contactor must be open during the power up until the separate DC links are charged
and the drives are in Ready state. Then you can close the contactor and connect the DC
links.
Select the DC contactor in the DC link using these values:
Udc_max = 1.21 × 1.35 × U1
IdcN = PDC / Udc
PDC ≈ Pcont.max
IdcN Nominal DC current in the DC link
Pcont.max Power rating of the larger drive to be separated (See the drive hardware manual.)
U1 AC input voltage of the drive
Udc_max Maximum voltage over the contactor in the DC link

 Brake resistor protection

If you use resistor braking, you must make sure that if the chopper fails and it cannot
switch off, the system will cut off the power supply for the brake resistor.
• If you use the chopper in a drive with Type B charging circuit, and that drive is the only
one that you connect to the AC power line, you do not need extra protection: The drive
detects the chopper fault, and its input bridge cuts off the power supply from the AC
power line to DC link and further to the resistor.
• If you use the chopper in a drive with Type A charging circuit, or connect several drives
to the AC power line, install a DC contactor between the chopper and brake resistor,
and wire the chopper fault relay to open the contactor control circuit after the chopper
fault.
Select the DC contactor for the chopper using these values:
Udc = 1.35 × U1
Ip = (1.25 x Udc) / Rbrake
Irms= (Pbr / Rbrake ) ½
Ip Peak current during the resistor braking
Irms Nominal rms current during the resistor braking
Pbr Motor braking power that the resistor must dissipate
Rbrake Resistance of the brake resistor
U1 AC input voltage of the drive
Udc Voltage over the contactor during the braking
 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 drive hardware manual.
• To minimize the conducted emissions, order a relevant EMC filter option for the drive
that will be connected to AC power line. See the drive hardware manual for the
possible EMC filter options.
• To minimize the radiated emissions:
• Keep the power cable runs as short as possible. Especially important is to keep
the DC cabling and the brake resistor cabling short.
• Make 360-degree grounding of the cable shields at the drive cable connection
box, using either a metal gland or the clamps supplied. If you install the drives
inside a cabinet, make the 360 degree earthing at the cabinet cable entry.
• Use shielded power cables.
For more information of the general EMC guidelines, see Technical guide, EMC compliant
installation and configuration for a power drive system (3AFE61348280 [English]).
Note: ABB has not tested the various common DC systems against the EMC product
standard (EN 61800-3:2004) requirements stated for drives. An EMC plan may be
required to gain CE compliance.
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 to the charging contactor or resistor.
To make sure that starting is not possible during the charging:
1. Connect the Ready signals of all drives with the AC power line connection in series
and supply the circuit with +24 V from one drive. This becomes the common Ready
signal for all drives.
Note: Relay output RO1 of the drive indicates the Ready signal in ACS880 primary
control program when the Factory macro is selected. If you have another macro or
control program in use, or want to use another relay output instead, see the drive
firmware manual for the parameter settings (parameter group 10 Standard DI, RO).
2. Connect the common Ready signal to digital input DI6 of all drives.
3. Connect the ground of the 24 V DC supply in all drives to each other (DICOM
terminals in ZCU control unit). We also recommend that you separate it from the digital
I/O ground (DIOGND terminal) in all drives. (Switch J6 in ZCU control unit.)
4. Set the digital input DI6 as the source for the Start enable signal in the drive control
program in all drives. (parameter 20.19 Enable start command in the ACS880 primary
control program.)
The diagram below shows the control connections with a solid line.

3 3

2 2 2

ZCU ZCU ZCU

Control unit Control unit Control unit

J6: OFF J6: OFF J6: OFF

DICOM

DICOM

DICOM
2 COM
2 +24V

2 +24V

2 +24V
2 COM

2 COM
DIIL

DIIL

DIIL
DI6

DI6

DI6
NO

NO

NO
1 NC

1 NC

1 NC
XRO1

XRO1

XRO1
XD24

XD24

XD24
XDI

XDI

XDI
1

3 3 3

M M M
~3 ~3 ~3
 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 program.
• Recommendation: Set parameter 99.04 Motor ctrl mode to DTC in all drives.
• Set parameter 30.26 Power motoring limit to the maximum motoring power of the drive
load cycle.
• Set parameter 30.27 Power generating limit to the maximum generating power of the
drive load cycle.
• When you use a brake chopper:
• Set parameter 30.30 Overvoltage control to Disable in all drives.
• Set parameter 43.06 Brake chopper to Enabled with thermal model or Enabled
without thermal model in those drives that you use the chopper.
• Set parameter 31.23 to No action in all drives to prevent unnecessary fault trips.
For more information, see the drive firmware manual.
38 Planning – additional instructions
 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.
40 Technical data

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

Frame Prec,ave Prec,max depending on Uac
208…240 V AC 380…415 V AC 380…500 V AC 600…690 V AC
(ACS880-01 (ACS880-01/-04 (ACS880-01/-04 (ACS880-01/-04
-xxxx-2) -xxxx-3) -xxxx-5) -xxxx-7)
R1 5.5 7 7 6 -
R2 11 13 13 10 -
R3 18.5 26 26 24 -
R4 30 37 37 32 -
R5a 15 - - - 24
R5b 45 63 63 59 54
R6 75 92 92 79 81
R7 110 153 153 144 150
R8 160 228 228 212 208
R9 250 - 317 262 304
R10a 250 - 340 420 -
R10b 355 - 420 500 510
R11 500/630 1) - 620 700 850

U ac: AC input voltage.

Prec,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)
Value 630 applies to 600…690 V AC.
Prec,max is the maximum rectifier power capacity of the drive allowed for max. 10 s. The instantaneous power
taken from AC power line must never exceed this limit.
R5a: ACS880-01 types -07A3-7, -09A8-7, -14A2-7 and -018A-7.
R5b: ACS880-01 types -022A-7, -026A-7, -035A-7, -042A-7 and -049A-7.
R10a: ACS880-04 types -505A-3 and -460A-5.
R10b: ACS880-04 types -585A-3, -650A-3, -583A-5, -635A-5, -330A-7 and -370A-7.
 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 may connect to the AC power
line. Connect only the drives visible in the same table. Connect only combinations which
are visible in the same table and which are not marked as prohibited. The other
combinations are not allowed.
Example for choosing the k:
If you connect frames R5, R4 and R2 to the AC power line, possible values for k are:
• 0.7 for combination of frames R5 and R4
• 0.8 for combination of frames R5 and R2
• 0.8 for combination of frames R4 and R2.
Choose the smallest value (0.7) and use it in the calculations.
The smaller drive may not be connected to the AC power line.

 Frames R1 to R5
Frame R1 R2 R3 R4 R5
R1 0.9 0.4 0.9
R2 0.4 0.9 0.7 0.8 0.8
R3 0.9 0.7 0.9 0.6 0.4
R4 0.8 0.6 0.9 0.7
R5 0.8 0.4 0.7 0.9

 Frames R5 to R9
Uac = 208…240, 380…415, 380…500

Frame R5 R6 R7 R8 R9
R5 0.9 0.3
R6 0.3 0.9 0.9 0.5 0.3
R7 0.9 0.9 0.7 0.6
R8 0.5 0.7 0.9 0.9
R9 0.3 0.6 0.9 0.9

Uac = 600…690
Frame R5a R5b R6 R7 R8 R9
R5a 0.9 0.9 1 1 0.7 0.9
R5b 0.9 0.9 0.7 0.5 0.2
R6 1 0.7 0.9 1 0.8 0.7
R7 1 0.5 1 0.9 0.9 0.8
R8 0.7 0.2 0.8 0.9 0.9 1
R9 0.4 0.7 0.8 1 0.9

R5a: ACS880-01 types -07A3-7, -09A8-7, -14A2-7 and -018A-7.

R5b: ACS880-01 types -022A-7, -026A-7, -035A-7, -042A-7 and -049A-7.
42 Technical data

 Frames R10 to R11

Frame R10a R10b R11
R10a 0.9 0.7 0.5
R10b 0.7 0.9 0.9
R11 0.5 0.9 0.9

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 frame sizes exist in the common DC system, and both of them are connected to the
AC power line, you must have a DC contactor between the DC terminals of these drives.
The DC contactor must isolate the drives until charging is complete.
Contactor is not needed.
X Contactor is needed.
The smaller drive may not be connected to the AC power line.

 Frames R1 to R5
Frame R1 R2 R3 R4 R5
R1
R2 X
R3 X
R4 X
R5 X X X

 Frames R5 to R9
Frame R5 R6 R7 R8 R9
R5
R6
R7
R8
R9

 Frames R10 to R11

Frame R10a R10b R11
R10a
R10b
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.
 Technical data 43

Charging resistance values

Frame R [ohm] Rmin [ohm]
R1, R2, R3 50 16
R4 25 6
R5 20 N/A
R6, R7 36 N/A
R8, R9 18 N/A
R10 3.3 N/A
R11 10 N/A

R: Charging resistance of the drive module.

Rmin : Minimum resistance that the charging circuit can supply (in case the circuit must supply charging current
of several drives).

Charging circuit Er values

Frame Er [J]
R5 411
R6 1400
R7 1400
R8 5600
R9 5600
R10 5600
R11 7400

Er: Maximum energy pulse that the charging circuit of the drive can withstand.

DC link capacitance values

Frame CDC [microF] depending on Uac
208…240 V AC 380…415 V AC 380…500 V AC 600…690 V AC
(ACS880-01 (ACS880-01/-04 (ACS880-01/-04 (ACS880-01/-04
-xxxx-2) -xxxx-3) -xxxx-5) -xxxx-7)
R1 300 300 300 -
R2 500 500 500 -
R3 1000 1000 1000 -
R4 4100 1000 1000 -
R5a - - - 350
R5b 6200 1500 1500 700
R6 10500 2600 2600 1200
R7 15300 3800 3800 1700
R8 22500 5600 5600 2500
R9 - 8800 8800 3900
R10 - 15800 15800 5267
R11 - 23700 23700 10533

Uac : AC input voltage.

R5a: ACS880-01 types -07A3-7, -09A8-7, -14A2-7 and -018A-7.
R5b: ACS880-01 types -022A-7, -026A-7, -035A-7, -042A-7 and -049A-7.
44 Technical data

Brake chopper power ratings

Drive type Pbr, Rbr, Drive type Pbr, Rbr, Drive type Pbr, Rbr, Drive type Pbr, Rbr,
ACS880- cont min
ACS880- cont min
ACS880- cont min
ACS880- cont min
01- [kW] [ohm] 01- [kW] [ohm] 01- [kW] [ohm] 01- [kW] [ohm]
04A6-2 0.75 65 02A4-3 0.75 78 02A1-5 0.75 78 07A3-7 6 18
06A6-2 1.1 65 03A3-3 1.1 78 03A0-5 1.1 78 09A8-7 8 18
07A5-2 1.5 65 04A0-3 1.5 78 03A4-5 1.5 78 14A2-7 11 18
10A6-2 2.2 65 05A6-3 2.2 78 04A8-5 2.2 78 018A-7 17 18
16A8-2 4.0 18 07A2-3 3.0 78 05A2-5 3.0 78 022A-7 23 18
24A3-2 5.5 18 09A4-3 4.0 78 07A6-5 4.0 78 026A-7 28 18
031A-2 7.5 13 12A6-3 5.5 78 11A0-5 5.5 78 035A-7 33 18
046A-2 11 12 017A-3 7.5 39 014A-5 7.5 39 042A-7 45 18
061A-2 11 12 025A-3 11 39 021A-5 11 39 049A-7 45 18
075A-2 18.5 6 032A-3 15 19 027A-5 15 19 061A-7 55 13
087A-2 22 6 038A-3 18.5 19 034A-5 18.5 19 084A-7 65 13
115A-2 30 3.5 045A-3 22 13 040A-5 22 13 098A-7 90 8
145A-2 37 3.5 061A-3 22 13 052A-5 22 13 119A-7 110 8
170A-2 45 2.4 072A-3 37 8 065A-5 37 8 142A-7 132 6
206A-2 55 2.4 087A-3 45 8 077A-5 45 8 174A-7 160 6
274A-2 75 1.8 105A-3 55 5.4 096A-5 55 5.4 210A-7 200 4
145A-3 75 5.4 124A-5 75 5.4 271A-7 250 4
169A-3 90 3.3 156A-5 90 3.3
206A-3 110 3.3 180A-5 110 3.3
246A-3 132 2.3 240A-5 132 2.3
293A-3 132 2.3 260A-5 132 2.3
363A-3 160 2 302A-5 160 2.3
430A-3 160 2 361A-5 160 2.3
414A-5 160 2.3

Pbr,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: Pbr,max= UDC,brcl2 / Rbr, min: This is the theoretical maximum braking power which
the brake chopper can withstand for a short time. Thermal protection of the brake chopper
can limit the available braking power to a lower value.
 Technical data 45

DC voltage limits of the drive

Symbol DC voltage value depending on Uac
208…240 V AC 380…415 V AC 440…480 V AC 500 V AC 525…600 V AC 660…690 V AC
R1-R3 R4-R8
UDC 281…324 V DC 513…560 V DC 594…648 V DC 675 V DC 709…810 V DC 891…932 V DC
UDC,chr 225 V DC 410 V DC 475 V DC 540 V DC 567 V DC 713 V DC
UDC,ovc 389 V DC 700 V DC 778 V DC 810 V DC 1013 V DC 1118 V DC
UDC,uvc 239 V DC 436 V DC 505 V DC 574 V DC 602 V DC 757 V DC
UDC,ovt 489 440 800 V DC 878 V DC 880 V DC 1113 V DC 1218 V DC
UDC,uvt 168 V DC 308 V DC 356 V DC 405 V DC 425 V DC 535 V DC
UDC,brcl 375 V DC 648 V DC 749 V DC 780 V DC 936 V DC 1077 V DC
UDC,brch 403 V DC 697 V DC 806 V DC 806 V DC 1008 V DC 1159 V DC
3AXD10000114906 - 2013-10-24

Uac : 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.
Udc : Nominal DC link voltage = 1.35 × Uac in normal motoring operation mode of the drive.
UDC,chr: Charging limit. Drive opens the charging circuit when the DC voltage reaches this limit at power up.
UDC,ovc, UDC,uvc: Overvoltage control limit and Undervoltage control limit. The overvoltage and undervoltage
control of the DC link voltage level are enabled by default. The drive limits the motoring and generating torque
when necessary to keep the DC link voltage within the control limits. When a brake chopper and resistor are in
use, you must disable the overvoltage control.
UDC,ovt, U DC,uvt: DC overvoltage trip limit and DC undervoltage trip limit. The drive trips and gives a fault
message if the DC link voltage reaches these levels.
UDC,brcl, UDC,brch: Brake chopper limit low and Brake chopper limit high. The brake chopper starts operation
when the DC link voltage reaches the low level and you have enabled the chopper with the drive parameter. If
the DC link voltage level reaches the high level, the brake chopper will be at its maximum load.
46 Technical data

DC fuses
Drive type Fuse [A] Drive type Fuse [A] Drive type Fuse [A] Drive type Fuse [A]
ACS880-01- ACS880-01- ACS880-01- ACS880-01-
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 018A-7 40
16A8-2 32 07A2-3 16 05A2-5 10 022A-7 40
24A3-2 50 09A4-3 20 07A6-5 16 026A-7 50
031A-2 63 12A6-3 25 11A0-5 20 035A-7 63
046A-2 100 017A-3 32 014A-5 32 042A-7 80
061A-2 125 025A-3 50 021A-5 40 049A-7 100
075A-2 160 032A-3 63 027A-5 50 061A-7 125
087A-2 160 038A-3 80 034A-5 63 084A-7 160
115A-2 250 045A-3 100 040A-5 80 098A-7 200
145A-2 315 061A-3 125 052A-5 100 119A-7 250
170A-2 315 072A-3 160 065A-5 125 142A-7 315
206A-2 400 087A-3 160 077A-5 160 174A-7 350
274A-2 500 105A-3 200 096A-5 200 210A-7 400
145A-3 315 124A-5 250 271A-7 500
169A-3 315 156A-5 315
206A-3 400 180A-5 350
246A-3 450 240A-5 450
293A-3 550 260A-5 500
363A-3 700 302A-5 550
430A-3 800 361A-5 700
414A-5 800
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.

Product training
For information on ABB product training, navigate to www.abb.com/drives and select
Training courses.

Providing feedback on ABB Drives manuals

Your comments on our manuals are welcome. Go to www.abb.com/drives and select
Document Library – Manuals feedback form (LV AC drives).

Document library on the Internet

You can find manuals and other product documents in PDF format on the Internet. Go to
www.abb.com/drives and select Document Library. You can browse the library or enter
selection criteria, for example a document code, in the search field.
Contact us

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3AUA0000127818 Rev B (EN) 2014-04-17