ABB ACS860 Electrical Planning Instructions
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ABB ACS860 Electrical Planning Instructions

ABB ACS860 Electrical Planning Instructions

Multidrives cabinets and modules
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ABB INDUSTRIAL DRIVES
ACS860 multidrives cabinets and modules
Electrical planning instructions

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  • Page 1 — ABB INDUSTRIAL DRIVES ACS860 multidrives cabinets and modules Electrical planning instructions...
  • Page 3 ACS860 multidrives cabinets and modules Electrical planning instructions Table of contents 3AXD50000034058 Rev B Original instructions EFFECTIVE: 2025-04-30...

  • Page 5: Table Of Contents

    Additional requirements for drives with an IGBT supply unit ....Additional requirements for ABB high-output and IP23 motors....
  • Page 6 ................Additional requirements for ABB high-output and IP23 motors....
  • Page 7 Table of contents 7 Implementing a ground fault detection function......... . Cabinet-installed multidrives.

  • Page 9: Introduction To Manual

    This chapter contains general information of the manual, a list of related manuals, and a list of terms and abbreviations. Applicability This manual is applicable with the air-cooled ACS860 multidrives cabinets and multidrive modules. Target audience This manual is intended for people who plan electrical installation of the drive. The reader is expected to know the fundamentals of electricity, wiring, electrical components and electrical schematic symbols.

  • Page 10: Terms And Abbreviations

    10 Introduction to manual Terms and abbreviations Term Description Brake unit Brake chopper modules and the necessary auxiliary equipment, such as control electronics, fusing and cabling Cabinet An enclosure that consists of one or more cubicles Common mode filtering Control unit Enclosure that contains the control board and related connector boards.
  • Page 11 Introduction to manual 11 Manual Code ACS860 multidrive cabinets and modules safety instructions 3AXD50000034060 ACS860 multidrive cabinets and modules Electrical planning instructions 3AXD50000034058 ACS860 multidrive modules cabinet design and construction instructions 3AXD50000034059 BCU-01/11 control units Hardware manual 3AXD50000034055 Supply module manuals...

  • Page 13: Electrical Planning Guidelines

    Limitation of liability The installation must always be designed and made according to applicable local laws and regulations. ABB does not assume any liability whatsoever for any installation which breaches the local laws and/or other regulations. Furthermore, if the recommendations given by ABB are not followed, the drive may experience problems that the warranty does not cover.

  • Page 14: Selecting The Main Contactor (Breaker)

    With certain drive types, you can select either of the two. Multidrive modules ￭ You can order a pre-selected main contactor (breaker) from ABB. See the appropriate drive or supply module hardware manual. Follow these guidelines when you select a customer-defined main contactor: •...

  • Page 15: Additional Notes

    Electrical planning guidelines 15 Additional notes ￭ A drive larger than 500 kVA with an IGBT supply unit or a regenerative rectifier unit Use a two-winding transformer dedicated to drives. Alternatively, use a three-winding transformer, and connect only drives to the same secondary winding. If it is necessary to connect other equipment to the same transformer winding, obey these instructions to prevent damage: •...
  • Page 16 16 Electrical planning guidelines Use a three-winding transformer, or two two-winding transformers: • Connection groups: three-winding transformer: Dy11d0 (or Dd0y1). Two two-winding transformers: Dy11 and Yy0. • Phase shift between secondaries: 30° electrical • Voltage difference between secondaries: < 0.5% •...

  • Page 17: Two Parallel-Connected Supply Units

    Examining the compatibility of the motor and drive Use asynchronous AC induction motors, permanent magnet synchronous motors or ABB synchronous reluctance motors (SynRM motors) with the drive. Select the motor size and drive type from the rating table on basis of the AC line voltage and motor load.

  • Page 18: Requirements Tables

    Nominal AC line Requirement for voltage Motor insula- ABB d u /d t and common mode filters, insulated tion system N-end motor bearings < 100 kW and frame size < IEC 315 < 134 hp and frame size < NEMA 500 Random-wound ≤...

  • Page 19: Requirements For Abb Motors, P

    21). Motor type Nominal AC line Requirement for voltage Motor insula- ABB d u /d t and common mode filters, insulated tion system N-end motor bearings 100 kW ≤ P < 350 kW ≥ 350 kW IEC 315 ≤ frame size <...

  • Page 20: Requirements For Non-Abb Motors, P

    Nominal AC line Requirement for voltage Motor insula- ABB d u /d t and common mode filters, insulated tion system N-end motor bearings < 100 kW and frame size < IEC 315 < 134 hp and frame size < NEMA 500 Random-wound and ≤...

  • Page 21: Requirements For Non-Abb Motors, P N > 100 Kw (134 Hp)

    21). Motor type Nominal AC line Requirement for voltage Motor insula- ABB d u /d t and common mode filters, insulated tion system N-end motor bearings 100 kW ≤ P < 350 kW ≥ 350 kW IEC 315 ≤ frame size <...

  • Page 22: Availability Of D U /D T Filter And Common Mode Filter By Drive Or Inverter Type

    If you use an explosion-safe (EX) motor, obey the rules in the requirements table above. In addition, consult the motor manufacturer for any further requirements. Additional requirements for ABB motors of types other than M2_, M3_, M4_, HX_ and Use the selection criteria given for non-ABB motors.

  • Page 23: Additional Requirements For Non-Abb High-Output And Ip23 Motors

    The rated output power of high-output motors is higher than what is stated for the particular frame size in EN 50347 (2001). If you plan to use a non-ABB high-output motor or an IP23 motor, consider these additional requirements for protecting the motor insulation and bearings in drive systems: •...

  • Page 24: Additional Note For Sine Filters

    24 Electrical planning guidelines peak voltage and voltage rise time considering the actual cable length, proceed as follows: Peak line-to line voltage: Read the relative Û • value from the diagram below and multiply it by the nominal supply voltage ( U •...

  • Page 25: Protecting The Motor Insulation And Bearings

    Electrical planning guidelines 25 Use asynchronous AC induction motors, permanent magnet synchronous motors or ABB synchronous reluctance motors (SynRM motors) with the drive. Select the motor size and drive type from the rating table on basis of the AC line voltage and motor load.

  • Page 26: Requirements For Abb Motors, P

    Nominal AC line Requirement for voltage Motor insulation ABB d u /d t and common mode filters, insulated system N-end motor bearings < 100 kW and frame size < IEC 315 < 134 hp and frame size < NEMA 500 Random-wound ≤...

  • Page 27: Requirements For Abb Motors, P

    21). Motor type Nominal AC line Requirement for voltage Motor insulation ABB d u /d t and common mode filters, insulated system N-end motor bearings 100 kW ≤ P < 350 kW ≥ 350 kW or frame size ≥ IEC 400 IEC 315 ≤...

  • Page 28: Requirements For Non-Abb Motors, P

    For motor dimensioning and selection, refer to IEC 60034-18-41, IEC 60034-18-42, IEC/TC 60034-25 and IEC/TS 61800-8. ABB strongly recommends to do a detailed network study for proper cable and motor selection.

  • Page 29: Requirements For Non-Abb Motors, P

    For motor dimensioning and selection, refer to IEC 60034-18-41, IEC 60034-18-42, IEC/TC 60034-25 and IEC/TS 61800-8. ABB strongly recommends to do a detailed network study for proper cable and motor selection.

  • Page 30: Availability Of D U /D T Filter And Common Mode Filter By Drive Or Inverter Type

    If you use an explosion-safe (EX) motor, obey the rules in the requirements tables above. In addition, consult the motor manufacturer for any further requirements. Additional requirements for ABB motors of types other than M2_, M3_, _XR, AM_, Use the selection criteria given for non-ABB motors.

  • Page 31: Additional Requirements For Non-Abb High-Output And Ip23 Motors

    For motor dimensioning and selection, refer to IEC 60034-18-41, IEC 60034-18-42, IEC/TC 60034-25 and IEC/TS 61800-8. ABB strongly recommends to do a detailed network study for proper cable and motor selection.

  • Page 32: Additional Data For Calculating The Rise Time And The Peak Line-To-Line Voltage

    32 Electrical planning guidelines Additional data for calculating the rise time and the peak line-to-line voltage The diagrams below show the relative peak line-to-line voltage and rate of change of voltage as a function of the motor cable length. If you need to estimate the peak voltage and voltage rise time considering the actual cable length, proceed as follows: Peak line-to line voltage: Read the relative Û...

  • Page 33: Additional Note For Sine Filters

    Electrical planning guidelines 33 Additional note for sine filters A sine filter also protects the motor insulation system. The peak phase-to-phase voltage with a sine filter is approximately 1.5 · U Selecting the power cables General guidelines ￭ Select the input power and motor cables according to local regulations. •...

  • Page 34: Alternate Power Cable Types

    34 Electrical planning guidelines Cable type Use as input power cabling Use as motor cabling and as brake resistor cabling Symmetrical shielded (or ar- mored) cable with three phase conductors and symmetrically constructed PE conductor and a shield (or armor) Symmetrical shielded (or ar- mored) cable with three phase conductors and a shield (or ar-...

  • Page 35: Not Allowed Power Cable Types

    Electrical planning guidelines 35 Cable type Use as input power cabling Use as motor cabling and as brake resistor cabling WARNING! If you use unshielded single- A single-core cable system: three core cables in an IT network, phase conductors and PE conduct- make sure that the non- or on cable tray conductive outer sheath...

  • Page 36: Grounding Requirements

    36 Electrical planning guidelines Insulation jacket Helix of copper tape or copper wire Copper wire shield Inner insulation Cable core Grounding requirements This section gives general requirements for grounding the drive. When you plan the grounding of the drive, obey all the applicable national and local regulations. The conductivity of the protective earth conductor(s) must be sufficient.

  • Page 37: Additional Grounding Requirements - Iec

    ￭ Only use shielded control cables. Use a double-shielded twisted pair cable for analog signals. ABB recommends this type of cable also for the pulse encoder signals. Use one individually shielded pair for each signal. Do not use common return for different analog signals.

  • Page 38: Signals That Can Be Run In The Same Cable

    Relay cable ￭ The cable type with braided metallic shield (for example ÖLFLEX by LAPPKABEL, Germany) has been tested and approved by ABB. Control panel to drive cable ￭ Use EIA-485, Cat 5e (or better) cable with male RJ45 connectors. The maximum length of the cable is 100 m (328 ft).

  • Page 39: Routing The Cables

    Electrical planning guidelines 39 Routing the cables General guidelines – IEC ￭ • Route the motor cable away from other cables. Motor cables of several drives can be run in parallel installed next to each other. • Install the motor cable, input power cable and control cables on separate trays. •...

  • Page 40: Separate Control Cable Ducts

    In addition, drive with ACS880-307…+A003 diode supply unit equipped with supply module frame D6D or D7D: Protect the input power cable with the ABB-specified fuses. See the supply unit hardware manual. The fuses protect the cable, and limit the short-circuit current of the drive.

  • Page 41: Protecting The Input Power Cable Against Thermal Overload

    Electrical planning guidelines 41 • the cable length does not exceed the allowed maximum length specified for the drive • the setting of parameter 99.10 Motor nominal power in the drive is equal with the value given on the motor rating plate. The electronic power output short-circuit protection circuitry meets the requirements of IEC 60364-4-41:2005 + AMD1:2017.

  • Page 42: Protecting The Motor Against Thermal Overload

    42 Electrical planning guidelines Protecting the motor against thermal overload ￭ According to regulations, the motor must be protected against thermal overload and the current must be switched off when overload is detected. The drive includes a motor thermal protection function that protects the motor and switches off the current when necessary.

  • Page 43: Implementing A Motor Temperature Sensor Connection

    Electrical planning guidelines 43 Implementing a motor temperature sensor connection WARNING! IEC 61800-5-1 requires double or reinforced insulation between the live parts and accessible parts when: • the accessible parts are not conductive, or • the accessible parts are conductive, but not connected to the protective earth.

  • Page 44: Implementing The Emergency Stop Function

    44 Electrical planning guidelines Note: As standard, the drive contains capacitors connected between the main circuit and the frame. These capacitors and long motor cables increase the ground leakage current and may cause fault current circuit breakers to function. Implementing the Emergency stop function Cabinet-installed multidrives ￭...

  • Page 45: Multidrive Modules

    Using a safety switch between the drive and the motor ABB recommends to install a safety switch between the permanent magnet motor and the drive output. The switch is needed to isolate the motor from the drive during maintenance work on the drive.

  • Page 46: Implementing A Bypass Connection

    IEC/EN/UL 61800-5-1, subclause 6.5.3, for example, “THIS MACHINE STARTS AUTOMATICALLY”. Bypass connection is available as a factory-installed option for some cabinet-installed drive types. Consult ABB for more information. WARNING! Do not connect the drive output to the electrical power network. The connection can damage the drive.
  • Page 47 Electrical planning guidelines 47 230 V AC 230 V AC + 24 V DC Relay output Varistor RC filter Diode...

  • Page 49: Standards And Markings

    Standards and markings 49 Standards and markings Contents of this chapter The chapter contains a list of applicable standards, a list of markings, compliance information, and disclaimers.

  • Page 50: Applicable Standards (Cabinets)

    Product is compliant with the People’s Republic of China Electronic Industry Standard (SJ/T 11364-2014) about hazardous substances. The EFUP is 20 years. China RoHS II Declaration of Conformity is available from https://library.abb.com. WEEE mark At the end of life the product should enter the recycling system at an appropriate collection...

  • Page 51: Emc Compliance (Iec/En 61800-3)

    Standards and markings 51 EMC compliance (IEC/EN 61800-3) Definitions ￭ EMC stands for Electromagnetic Compatibility. It is the ability of electrical/electronic equipment to operate without problems within an electromagnetic environment. Likewise, the equipment must not disturb or interfere with any other product or system within its locality.

  • Page 52: Category C3

    52 Standards and markings The drive is installed according to its installation instructions. The EMC recommendations are obeyed. Motor cable length (for any inverter unit) does not exceed 100 m (328 ft). WARNING! The drive may cause radio interference. The installer is required to take measures to prevent interference, in addition to the requirements for CE compliance listed above, if necessary.
  • Page 53 Standards and markings 53 Medium voltage network Equipment Neighboring network Supply transformer Point of measurement Static screen Low voltage Drive Equipment (victim) An EMC plan for preventing disturbances is drawn up for the installation. A template is available in Technical guide No. 3 EMC compliant installation and configuration for a power drive system (3AFE61348280 [English]).

  • Page 54: Approvals

    ABB and its affiliates are not liable for damages and/or losses related to such security breaches, any unauthorized access, interference, intrusion, leakage and/or theft of data or information.

  • Page 55: 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 new.abb.com/contact-centers.
  • Page 56 3AXD50000034058B © Copyright 2025 ABB. All rights reserved. Specifications subject to change without notice.

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