ABB ACH480 Hardware Manual
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ABB ACH480 Hardware Manual

ABB ACH480 Hardware Manual

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  • Page 1 — ABB DRIVES FOR HVAC ACH480 drives Hardware manual...
  • Page 2 — List of related manuals Drive manuals and guides Code (English) ACH480 drives hardware manual 3AXD50000245949 ACH480 quick installation guide 3AXD50000247141 ACH480 drives firmware manual 3AXD50000247134 Option manuals and guides ACX-AP-x assistant control panel user’s manual 3AUA0000085685 DPMP-01 mounting platform for control panels...
  • Page 3 Hardware manual ACH480 drives Table of contents 1. Safety instructions 4. Mechanical installation 6. Electrical installation  2018 ABB Oy. All Rights Reserved. 3AXD50000245949 Rev A EFFECTIVE: 2018-11-22...

  • Page 5: Table Of Contents

    Table of contents 5 Table of contents 1. Safety instructions Contents of this chapter ............11 Use of warnings and notes in this manual .
  • Page 6 6 Table of contents Examining the installation site ..........36 Required tools .
  • Page 7 Table of contents 7 Measuring insulation ............56 Drive .
  • Page 8 8 Table of contents Altitude derating ............87 Fuses (IEC) .
  • Page 9 Table of contents 9 Frame R1 (400 V) (bottom & rear) ..........113 Frame R2 (400 V) (front &...
  • Page 10 10 Table of contents Abbreviations ............141 Declaration of conformity .

  • Page 11: Safety Instructions

    Safety instructions 11 Safety instructions Contents of this chapter This chapter contains the safety instructions which you must obey when you install and operate the drive and do maintenance on the drive. Obey the safety instructions to prevent injury or death, or damage to the equipment. Use of warnings and notes in this manual Warnings tell you about conditions which can cause injury or death, or damage to the equipment.

  • Page 12: General Safety In Installation, Start-Up And Maintenance

    12 Safety instructions General safety in installation, start-up and maintenance These instructions are for all personnel that install the drive and do maintenance work on it. WARNING! Obey these instructions. If you ignore them, injury or death, or damage to the equipment can occur. •...

  • Page 13: Electrical Safety In Installation, Start-Up And Maintenance

    Safety instructions 13 Electrical safety in installation, start-up and maintenance  Precautions before electrical work These warnings 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.

  • Page 14: Additional Instructions And Notes

    14 Safety instructions  Additional instructions and notes WARNING! Obey these instructions. If you ignore them, injury or death, or damage to the equipment can occur. • If you install the drive on an IT system (an ungrounded power system or a high- resistance-grounded [over 30 ohms] power system), disconnect the internal EMC filter;...

  • Page 15: Grounding

    Safety instructions 15  Grounding These instructions are for all personnel who are responsible for the electrical installation, including the grounding of the drive. WARNING! Obey these instructions. If you ignore them, injury or death, or equipment malfunction can occur, and electromagnetic interference can increase.

  • Page 16: Additional Instructions For Permanent Magnet Motor Drives

    16 Safety instructions Additional instructions for permanent magnet motor drives  Safety in installation, start-up and maintenance These are additional warnings that apply to 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 and damage to the equipment can occur.

  • Page 17: General Safety In Operation

    Safety instructions 17 General safety in operation These instructions are for all personnel that operate the drive. WARNING! Obey these instructions. If you ignore them, injury or death, or damage to the equipment can occur. • Do not control the motor with the disconnector at the drive power supply. Use the control panel start and stop keys or the start/stop commands from an external control device connected through the I/O or fieldbus interface.
  • Page 18 18 Safety instructions...

  • Page 19: Introduction To The Manual

    The chapter also has a flowchart for the delivery, installation and commissioning of the drive. Applicability The manual applies to ACH480 drives. Target audience The reader must know the fundamentals of electricity, wiring, electrical components and electrical schematic symbols.

  • Page 20: Contents Of This Manual

    20 Introduction to the manual Contents of this manual • Safety instructions (on page 11) gives the safety instructions that you must obey when you install, commission, operate and service the drive. • Introduction to the manual (on page 19) describes the applicability, target audience, purpose and contents of this manual.

  • Page 21: Quick Installation And Commissioning Flowchart

    Connect the control cables. Connecting the control cables on page 62. Examine the installation. Installation checklist on page 73. Commission the drive. Refer to the ACH480 drives quick installation guide (3AXD50000247141 [English]) and the ACH480 drives firmware manual (3AXD50000247134 [English]).
  • Page 22 22 Introduction to the manual Terms and abbreviations Term/abbreviation Explanation ACX-AP-X Assistant control panel. An advanced operator keypad for communication with the drive. BACnet™ BACnet™ is a registered trademark of American Society of Heating, Refrigerating and Air-Conditioning Engineers (ASHRAE). Brake chopper Conducts the surplus energy from the intermediate circuit of the drive to the brake resistor when necessary.
  • Page 23 Introduction to the manual 23 Term/abbreviation Explanation Frame (size) Refers to drive physical size, for example, R0 and R1. The type designation label attached to the drive shows the frame of the drive, refer to Type designation key on page 32. Input/Output IGBT Insulated gate bipolar transistor...
  • Page 24 24 Introduction to the manual...

  • Page 25: Hardware Description

    It shows a general diagram of the power connections and control interfaces. General description The ACH480 is a drive for controlling asynchronous AC induction motors, permanent magnet synchronous motors and ABB synchronous reluctance motors (SynRM motors). It is optimized for cabinet mounting.

  • Page 26: Hardware Overview

    26 Hardware description Hardware overview No. Description No. Description Type designation label Motor and braking resistor terminals Model information label Cooling fan (not on R0) Software information label Front cover Control panel connection Fixed control terminals Control panel Cold configuration connection (CCA-01) EMC filter grounding screw Slot for front option modules (I/O module or fieldbus module)

  • Page 27: Control Connections

    Hardware description 27 Control connections There are fixed control connections on the base unit and optional control connections based on the installed option module.  Standard unit Connections of the base unit: 1. Auxiliary voltage outputs 2. Digital inputs 3. Safe torque-off connections 4.

  • Page 28: Base Unit

    28 Hardware description  Base unit Connections of the base unit: 1. Auxiliary voltage outputs 2. Digital inputs 3. Safe torque-off connections 4. Relay output connection 5. Cold configuration connection for CCA-01 6. Front option module slot 1 +24V DGND RO C DCOM RO1A...

  • Page 29: Mounted Options

    (3AUA0000085685 [EN]). For information on how to start up the drive, and modify the settings and parameters, refer to the ACH480 drives firmware manual (3AXD50000247134 [English]). PC connection To connect a PC to the drive, there are two alternatives: 1.

  • Page 30: Drive Labels

    30 Hardware description Drive labels The drive has these labels: • Model information label on the top of the drive • Software information label on the front cover • Type designation label on the left side of the drive For label positions, refer to Hardware overview on page 26.

  • Page 31: Type Designation Label

    Hardware description 31  Type designation label This is a sample type designation label. IND.CONT.EQ. 1PDS ABB Oy 50/60 Hz FRAME IP20 No. Description Type designation, refer to Type designation key on page 32. Frame (size) Degree of protection Nominal ratings, refer to Ratings on page 84.

  • Page 32: Type Designation Key

    The type designation tells you the specifications and configuration of the drive. For more information on the ratings, refer to Technical data on page 83. Sample type code: ACH480-04-12A7-4+XXXX Segment ACH480 - 04 - 02A7 - 4 + Option codes...
  • Page 33 Hardware description 33 Code Description K475 FENA-21 Ethernet adapter module K491 FMBT-21 Modbus/TCP adapter module K492 FPNO-21 Profinet adapter module Documentation +R700 English +R707 French Full set of printed manuals in the selected language. An +R701 German +R708 Spanish English manual is included, if a +R702 Italian +R709 Portuguese translation is not available.

  • Page 34: Operation Principle

    34 Hardware description Operation principle The figure shows the simplified main circuit diagram of the drive. T1/U T2/V T3/W Description Rectifier. Converts alternating current and voltage to direct current and voltage. DC link. DC circuit between rectifier and inverter. Inverter. Converts direct current and voltage to alternating current and voltage. Brake chopper.

  • Page 35: Mechanical Installation

    Mechanical installation 35 Mechanical installation Contents of this chapter The chapter tells you how to examine the installation site, unpack, check the delivery and install the drive mechanically. Installation alternatives You can install the drive: • With screws on to a wall •...

  • Page 36: Examining The Installation Site

    36 Mechanical installation • Make sure that the hot exhaust air from a drive does not flow into the cooling inlet of other drives or equipment. • The drive has an IP20 ingress protection classification for cabinet installation. Examining the installation site Make sure that: •...

  • Page 37: Unpacking The Delivery

    Mechanical installation 37 Unpacking the delivery Make sure that all of the items are present and that there are no signs of damage. Standard drive package contents: • Drive • Assistant control panel (not installed) • I/O module RIIO-01 with EIA-485 (BACnet MS/TP, Modbus RTU, N2) (not installed) •...

  • Page 38: Installing The Drive

    38 Mechanical installation Installing the drive You can install the drive: • With screws to a suitable surface • To a DIN installation rail with the integrated lock  To install the drive with screws 1. Mark the surface for the mounting holes. Refer to Dimensions and weights page 92.

  • Page 39: To Install The Drive To A Din Installation Rail

    Mechanical installation 39  To install the drive to a DIN installation rail 1. Move the locking part to the left. 2. Push and hold the locking button down. 3. Put the top tabs of the drive onto the top edge of the DIN installation rail.
  • Page 40 40 Mechanical installation...

  • Page 41: Planning The Electrical Installation

    Make sure that the installation is designed and done according to the applicable local laws and regulations. ABB does not assume any liability whatsoever for any installation which breaches the local laws and/or other regulations. If the recommendations given by ABB are not followed, the drive may experience problems that the warranty does not cover.

  • Page 42: Other Regions

    42 Planning the electrical installation  Other regions The disconnecting device must conform to the applicable local safety regulations. Checking the compatibility of the motor and drive Use an asynchronous AC induction motor, permanent magnet motor or synchronous reluctance motor (SynRM) with the drive. Several induction motors can be connected to the drive at a time.

  • Page 43: Typical Power Cable Sizes

    Refer to the IEC/EN 61800-5-1 requirement on grounding on page 15.  Typical power cable sizes These are the typical cross-sectional area of the power cables at the nominal drive current. Type Frame (Cu) ACH480-04-… 1-phase U = 200…240 V 02A4-1 3×1.5 + 1.5 03A7-1 3×1.5 + 1.5 04A8-1 3×1.5 + 1.5...
  • Page 44 44 Planning the electrical installation Type Frame (Cu) ACH480-04-… 04A1-4 3×1.5 + 1.5 05A7-4 3×1.5 + 1.5 07A3-4 3×1.5 + 1.5 09A5-4 3×2.5 + 2.5 12A7-4 3×2.5 + 2.5 018A-4 3×6 + 6 026A-4 3×6 + 6 033A-4 3×10 + 10 039A-4 3×16 + 16...

  • Page 45: Recommended Power Cable Types

    Planning the electrical installation 45  Recommended power cable types Symmetrical shielded cable with three phase conductors and a concentric PE conductor as the shield. The shield must meet the requirements of IEC 61800-5-1 (refer to page 42). Make sure that local/state/country electrical codes permit this cable type.

  • Page 46: Motor Cable Shield

    46 Planning the electrical installation  Motor cable shield If the motor cable shield is the only protective earth conductor of the motor, make sure that the conductivity of the shield is sufficient. Refer to Selecting the power cables on page or to IEC 61800-5-1.
  • Page 47 Planning the electrical installation 47 Armored cable or shielded power cable Six-conductor (three phase and three ground conductors) type MC continuous corrugated aluminum armor cable with symmetrical grounds is available from the following suppliers (trade names in parentheses): • Anixter Wire & Cable (VFD) •...

  • Page 48: Selecting The Control Cables

     Relay cable The cable type with braided metallic screen (for example ÖLFLEX by LAPPKABEL, Germany) has been tested and approved by ABB.  Control panel to PC connection Use a USB type A (PC) – type B (control panel) cable. The maximum permitted length of the cable is 3 m (9.8 ft).

  • Page 49: Routing The Cables

    Planning the electrical installation 49 Routing the cables Select the cable routes as follows: • Put the input power cable (I), motor cable (M) and control cables (C) into separate trays. • Put the motor cable (M) away from the other cables. •...

  • Page 50: Separate Control Cable Ducts

    83. The fuses protect the input cable, restrict drive damage and prevent damage to adjoining equipment if there is a short-circuit. For information on circuit breakers, contact ABB for more information.  Protecting the motor and motor cable in short-circuits If the motor cable has the correct size for the nominal current, the drive protects the motor cable and motor if there is a short-circuit.

  • Page 51: Implementing Thermal Overload Protection

    Planning the electrical installation 51 Implementing thermal overload protection  Protecting the drive, and the input power and motor cables against thermal overload If the cables have the correct size for the nominal current, the drive protects itself and the input and motor cables against thermal overload. WARNING! If the drive is connected to several motors, use a separate circuit breaker or fuses to protect each motor cable and motor against overload.

  • Page 52: Implementing The Emergency Stop Function

    52 Planning the electrical installation Implementing the emergency stop function For safety reasons, install the emergency stop devices at each operator control station and at other operating stations where an emergency stop may be needed. Design the emergency stop according to the applicable standards. Note: The stop key on the control panel of the drive does not generate an emergency stop or separate the drive from dangerous potential.

  • Page 53: Protecting The Contacts Of Relay Outputs

    Planning the electrical installation 53 Protecting the contacts of relay outputs Inductive loads (relays, contactors and motors) cause voltage transients when switched off. The voltage transients can connect capacitively or inductively to other conductors and cause a malfunction in the system. Use a noise attenuating circuit (varistors, RC filters [AC] or diodes [DC]) to minimize the EMC emission of inductive loads at switch-off.
  • Page 54 54 Planning the electrical installation...

  • Page 55: Electrical Installation

    Electrical installation 55 Electrical installation Contents of this chapter The chapter describes how to check the insulation of the installation and the compatibility with IT (ungrounded) and corner-grounded TN systems. It shows how to connect the power and control cables, install optional modules and connect a PC. Warnings WARNING! Obey the instructions in Safety instructions...

  • Page 56: Measuring Insulation

    Use a measuring voltage of 1,000 V DC. The insulation resistance of an ABB motor must be more than 100 Mohm (reference value at 25 °C or 77 °F). For the insulation resistance of other motors, refer to the manufacturer’s instructions.

  • Page 57: Compatibility With It (Ungrounded) And Corner-Grounded Tn Systems

    Electrical installation 57 Compatibility with IT (ungrounded) and corner-grounded TN systems  EMC filter WARNING! Do not use the internal EMC filter of the drive in an IT system (an ungrounded power system or a high-resistance-grounded [over 30 ohms] power system). If you use the internal EMC filter, the system is connected to the ground potential through the EMC filter capacitors.

  • Page 58: Ground-To-Phase Varistor

    58 Electrical installation The EMC grounding screw is located on the bottom of the frame in R3 and R4 frames.  Ground-to-phase varistor The metallic varistor screw (VAR) connects the varistor protection circuit to electrical ground. To disconnect the varistor protection circuit from ground, remove the varistor screw.

  • Page 59: Connecting The Power Cables

    Electrical installation 59 Connecting the power cables  Connection diagram a. Two grounding conductors. Use two conductors, if the cross-section of grounding conductor is less than 10 mm Cu or 16 mm Al (IEC/EN 61800-5-1). For example, use the cable shield in addition to the fourth conductor. b.

  • Page 60: Connection Procedure

    60 Electrical installation  Connection procedure WARNING! Obey the Safety instructions on page 11. If you ignore them, injury or death, or damage to the equipment can occur. WARNING! If the drive is connected to an IT (non-grounded) system or to a corner-grounded TN system, disconnect the EMC filter grounding screw.
  • Page 61 Electrical installation 61 7. Strip the input power cable. 8. If the input power cable has a shield, twist it into a bundle, mark it with yellow-green insulation tape, fit a cable lug, and connect it to the grounding terminal. 9.

  • Page 62: Connecting The Control Cables

    Refer to I/O connections (HVAC default) on page for the default I/O connections of the ABB standard macro. For other macros and information, refer to ACH480 drives firmware manual (3AXD50000247134 [English]). Connect the cables as shown in Control cable connection procedure on page 67.

  • Page 63: I/O Connections (Hvac Default)

    Electrical installation 63  I/O connections (HVAC default) This connection diagram is valid for drives with the standard I/O extension module RIIO-01 with EIA-485. Refer to Type designation key on page 32. The fixed terminals in the base unit are marked in the table. Terminal Description Terminals in...
  • Page 64 64 Electrical installation Fieldbus connection diagram This connection diagram is valid for drives with a fieldbus adapter module. Refer to Type designation key on page 32. Terminal Description Aux. voltage output and digital connections +24 V Aux. voltage output +24 V DC, max. 200 mA DGND Aux.

  • Page 65: Connecting Eia-485 Embedded Fieldbus Terminal To The Drive

    Electrical installation 65  Connecting EIA-485 embedded fieldbus terminal to the drive Connect the fieldbus to the EIA-485 terminal on the RIIO-01 module. The connection diagram is shown below. Fieldbus controller Termination ON Data flow Fieldbus Control Word (CW) References Process I/O (cyclic) Status Word (SW) Actual values...
  • Page 66 66 Electrical installation Connection examples of two-wire and three-wire sensors The figures give examples of connections for a two-wire or three-wire sensor/transmitter that is supplied by the auxiliary voltage output of the drive. Note: Do not exceed the maximum capability of the auxiliary 24 V (200 mA) output. Two-wire sensor/transmitter 4…20 mA Process actual value measurement or reference,...

  • Page 67: Control Cable Connection Procedure

    Control cable connection procedure Do the connections according to the macro in use. The default macro connections are valid with the I/O module (refer to page 63), except for the ABB 2-wire limited macro. Keep the signal wire pairs twisted as near to the terminals as possible to prevent inductive coupling.

  • Page 68: Auxiliary Voltage Connection

    24 V DC and an output voltage of 5 V DC. It supplies the drive control board to keep its processor and the communication links on at all times. ACH480 External supply BAPO-01 24VDC (+)

  • Page 69: Option Modules

    Electrical installation 69 outputs of the auxiliary power source or by multiple auxiliary power sources with a single +24 V DC output. Option modules WARNING! Obey the Safety instructions on page 11. If you ignore them, injury or death, or damage to the equipment can occur. The drive has two option module slots: •...

  • Page 70: To Install A Front Option

    70 Electrical installation  To install a front option 1. Open the locking screw of the front cover and lift the front cover up. 2. If the option module has a locking tab, pull it up. 3. Carefully align the option module with the option module slot in the front of the drive.

  • Page 71: To Remove A Front Option

    Electrical installation 71  To remove a front option 1. Disconnect the control cables from the option module. 2. Loosen the locking screw. 3. If the option module has a locking tab, pull it out. 4. Carefully pull the option module to disconnect and remove it. Note that the option module can be tight.
  • Page 72 72 Electrical installation...

  • Page 73: Installation Checklist

    Installation checklist 73 Installation checklist Contents of this chapter This chapter contains an installation checklist which you must complete before you start up the drive. Warnings WARNING! Obey the instructions in Safety instructions on page 11. If you ignore them, injury or death, or damage to the equipment can occur. Checklist Refer to Precautions before electrical work...
  • Page 74 74 Installation checklist Make sure that … There is an adequately sized protective earth (ground) conductor between the drive and the switchboard. There is an adequately sized protective earth (ground) conductor between the motor and the drive. All protective earth (ground) conductors are connected to the correct terminals and the terminals are tightened (pull the conductors to check).

  • Page 75: Maintenance

    Maintenance 75 Maintenance Contents of this chapter The chapter contains the preventive maintenance instructions.

  • Page 76: Maintenance Intervals

    Long term operation near the specified maximum ratings or ambient conditions may require shorter maintenance intervals for certain components. ABB recommends annual drive inspections to ensure the highest reliability and optimum performance.

  • Page 77: Cleaning The Heat Sink

    Maintenance 77 Cleaning the heat sink The fins of the drive heat sink become dusty from the cooling air. If the heat sink is not clean, this can cause the drive to give overtemperature warnings and faults. WARNING! Obey the instructions in Safety instructions on page 11.

  • Page 78: Replacing The Cooling Fans

    After you replace the fan, reset the fan counter. Refer to the ACH480 drives firmware manual (3AXD50000247134 [English]). You can get replacement fans from ABB. Use only ABB specified spare parts.  To replace the cooling fan for frame sizes R1, R2 and R3...
  • Page 79 Maintenance 79 7. Free the fan clips and remove the fan from the fan cover. 8. Install the new fan into the fan cover. Make sure that the air flow is in the correct direction. The air flows in from the bottom of the drive and out from the top of the drive.

  • Page 80: To Replace The Cooling Fan For Frame R4

    80 Maintenance  To replace the cooling fan for frame R4 WARNING! Obey the instructions in Safety instructions on page 11. If you ignore them, injury or death, or damage to the equipment can occur. 1. Stop the drive and do the steps in section Precautions before electrical work...

  • Page 81: Servicing The Capacitors

    Capacitor failure can cause damage to the drive and an input cable fuse failure, or a fault in the drive. Contact ABB if you think that a capacitor failed.  Capacitor reforming You must reform the capacitors if the drive is stored for a year or more.
  • Page 82 82 Maintenance...

  • Page 83: Technical Data

    Technical data 83 Technical data Contents of this chapter The chapter contains the technical specifications of the drive, such as ratings, sizes and technical requirements as well as provisions for fulfilling the requirements for CE, UL and other approval marks.

  • Page 84: Ratings

    84 Technical data Ratings  IEC ratings Type Input Input Output ratings Frame ACH480- rating with size Max. Nominal use Light-duty use Heavy-duty use 04-… choke current 3-phase U = 380…480 V 02A7-4 0.75 0.75 0.55 03A4-4 0.75 04A1-4 05A7-4 07A3-4 11.5...

  • Page 85: Definitions

    The derating factor for 1500 m is 1 - 1/10 000 m · (1500 - 1000) m = 0.95. The minimum size required becomes then I = 9.4 A / 0.95 = 9.9 A. Referring to I in the ratings tables (starting from page 84), drive type ACH480-04-12A7-4 exceeds the I requirement of 9.9 A.

  • Page 86: Surrounding Air Temperature Derating, Ip20

    +122 +140 °F +50…+60 °C Output current is decreased by 1% for every additional 1 °C on: +122…+140 °F • ACH480-04-033A-4 • ACH480-04-046A-4 Output current is decreased by 2% for every additional 1 °C on: • ACH480-04-039A-4 • ACH480-04-050A-4 • ACH480-04-055A-2 ...

  • Page 87: Altitude Derating

    Technical data 87  Altitude derating At 1000…4000 m (3300…13120 ft) above sea level, the derating is 1% for every 100 m (330 ft). An altitude of up to 4000 m is permitted for 400 V units when the following boundary conditions are taken into account: •...

  • Page 88: Fuses (Iec)

     gG fuses Make sure that the operating time of the fuse is less than 0.5 seconds. Obey the local regulations. Type Input Min. short- Nominal Voltage ABB type IEC 60269 ACH480-04-… current circuit current rating size current 3-phase U = 380…480 V...

  • Page 89: Gr Fuses

    Technical data 89  gR fuses Type Input Min. short- Nominal Voltage Bussmann IEC 60269 ACH480-04-… current circuit current rating type size current 3-phase U = 380…480 V 02A7-4 170M2694 03A4-4 170M2694 04A1-4 170M2695 05A7-4 170M2695 07A3-4 11.5 170M2696 09A5-4 15.0...

  • Page 90: Alternate Short-Circuit Protection

    The protective characteristics of the circuit breakers depend on their type, construction and settings. There are also limitations pertaining to the short-circuit capacity of the supply network. Your local ABB representative can help you to select the circuit breaker when the supply network characteristics are known.

  • Page 91: Self-Protected Combination Manual Controller - Type Eusa (Ul) Environment

    2CDC131085M0201 – Manual Motor Starters – North American Applications for complete technical data on the ABB Type E manual motor protectors. In order for these manual motor protectors to be used for branch circuit protection, they must be UL listed Type E manual motor protectors, otherwise they can be used only as an At Motor Disconnect.

  • Page 92: Dimensions And Weights

    92 Technical data Dimensions and weights Frame Dimensions and weights (IP20 / UL type open) size Weight 8.07 8.78 6.93 2.87 8.19 1.97 7.52 1.70 3.74 8.07 8.78 6.93 2.87 8.19 1.97 7.52 1.77 3.90 8.07 8.78 6.93 3.80 8.19 2.95 7.52 2.35...

  • Page 93: Free Space Requirements

    (all digital inputs in the on state and the panel, fieldbus and fan in use). The total heat dissipation is the sum of the heat dissipation in the main and control circuits. Heat dissipation Air flow Noise Frame Type ACH480-04-… Main Control Control Main and size circuit at...

  • Page 94: Terminal Data For The Power Cables

    94 Technical data Terminal data for the power cables Type U1, V1, W1 / U2, V2, W2 / BRK+, BRK- / DC+, DC- terminals PE terminal ACH480-04-… Torque Min (solid/stranded) Max (solid/stranded) Torque N·m lbf·in N·m lbf·in 3-phase U = 380…480 V 02A7-4 0.2/0.2...

  • Page 95: External Emc Filters

    EMC category that is met with the external EMC filter. For information on the maximum permitted motor cable length, refer to Motor cable length on page 97. Type EMC filter type Category ACH480-04-… ABB order code Schaffner order code 3-phase U = 380…480 V 02A7-4 RFI-32 FN 3268-16-44 03A4-4...

  • Page 96: Electric Power Network Specification

    96 Technical data Electric power network specification Voltage (U 200/208/220/230/240 V AC 1-phase for 200 V AC drives 200/208/220/230/240 V AC 3-phase for 200 V AC drives 380/400/415/440/460/480 V AC 3-phase for 400 V AC drives +10%/-15% variation from converter nominal voltage is allowed as default.

  • Page 97: Motor Cable Length

    Technical data 97 Motor connection data Motor type Asynchronous induction motor or permanent magnet synchronous motor Voltage (U 0 to U , 3-phase symmetrical, U at the field weakening point Short-circuit protection The motor output is short-circuit proof by IEC 61800-5-1 and (IEC 61800-5-1, UL 61800-5-1.
  • Page 98 98 Technical data EMC compatibility and motor cable length To comply with the EMC limits in the European EMC Directive (standard IEC/EN 61800-3), use these maximum motor cable lengths for the 4 kHz switching frequency. Frame Maximum motor cable length, 4 kHz size With internal EMC filter 3-phase 380...480 V...

  • Page 99: Control Connection Data

    Technical data 99 Control connection data Analog inputs Voltage signal, 0…10 V DC (10% overrange, 11 V DC max.) (AI1, AI2) single-ended = 221.6 kohm Current signal, 0…20 mA (10% overrange, 22 mA max.) single-ended = 137 ohm Inaccuracy ≤ 1.0%, of full scale Overvoltage up to 30 V DC protection...

  • Page 100: Brake Resistor Connection

    The brake resistor output is conditionally short-circuit proof by (IEC 61800-5-1, IEC/EN 61800-5-1 and UL 61800-5-1. For correct fuse selection, IEC 60439-1, contact your local ABB representative. Rated conditional short-circuit UL 61800-5-1) current as defined in IEC 60439-1. Efficiency Approximately 98% at nominal power level.

  • Page 101: Ambient Conditions

    Technical data 101 Ambient conditions Environmental limits for the drive are given below. The drive is to be used in a heated indoor controlled environment. Operation Storage Transportation installed for in the protective in the protective stationary use package package Installation site altitude 0 to 4000 m above sea level (with derating above...

  • Page 102: Materials

    IEC 62635 guidelines. To aid recycling, plastic parts are marked with an appropriate identification code. Contact your local ABB distributor for further information on environmental aspects and recycling instructions for professional recyclers. End of life treatment must follow international and local...

  • Page 103: Applicable Standards

    Technical data 103 Applicable standards The drive complies with the following standards: EN ISO 13849-1:2015 Safety of machinery – Safety related parts of the control systems – Part 1: general principles for design EN ISO 13849-2:2012 Safety of machinery – Safety-related parts of the control systems – Part 2: Validation EN 60204-1:2006 + Safety of machinery.

  • Page 104: Ce Marking

    104 Technical data CE marking A CE mark is attached to the drive to verify that the drive follows the provisions of the European Low Voltage, EMC, RoHS and WEEE Directives.The CE marking also verifies that the drive, in regard to its safety functions (such as Safe torque off), conforms with the Machinery Directive as a safety component.

  • Page 105: Compliance With The European Machinery Directive

    Technical data 105  Compliance with the European Machinery Directive The drive includes the Safe torque off function and can be equipped with other safety functions for machinery which, as safety components, are in the scope of the Machinery Directive. These functions of the drive comply with European harmonized standards such as EN 61800-5-2.

  • Page 106: Compliance With En 61800-3:2004 + A1:2012

    Category C1 The conducted emission limits are complied with the following provisions: 1. The optional EMC filter is selected according to the ABB documentation and installed as specified in the EMC filter manual. 2. The motor and control cables are selected as specified in this manual.

  • Page 107: Category C3

    Technical data 107 If it is used in a residential or domestic environment, the drive can cause radio- frequency interference. If it is necessary, take measures to prevent interference, in addition to the requirements for the CE compliance. WARNING! Do not install a drive with the internal EMC filter connected on IT (ungrounded).

  • Page 108: Ul Marking

    108 Technical data UL marking If the drive type label has the UL marking, the drive has UL certification.  UL checklist • Make sure that the drive type designation label includes the cULus Listed marking. • CAUTION - Risk of electric shock. After you disconnect the input power, always wait for 5 minutes to let the intermediate circuit capacitors discharge before you start working on the drive, motor or motor cable.

  • Page 109: Csa Marking

    Technical data 109 CSA marking If the drive type label has the CSA marking, the drive has CSA certification. The CSA marking indicates that a product has been tested to a Canadian or U.S. standard and meets the requirements of an applicable CSA standard or another recognized document used as a basis for certification.

  • Page 110: Tüv Marking

    ABB and its affiliates are not liable for damages and/or losses related to such security breaches, any unauthorized access,...

  • Page 111: Dimension Drawings

    Dimension drawings 111 Dimension drawings The dimension drawings of the ACH480 drive in frame sizes R0, R1, R2, R3 and R4. The dimensions are in millimeters and inches.

  • Page 112: Frame R1 (400 V) (Front & Side)

    112 Dimension drawings Frame R1 (400 V) (front & side)

  • Page 113: Frame R1 (400 V) (Bottom & Rear)

    Dimension drawings 113 Frame R1 (400 V) (bottom & rear)

  • Page 114: Frame R2 (400 V) (Front & Side)

    114 Dimension drawings Frame R2 (400 V) (front & side)

  • Page 115: Frame R2 (400 V) (Bottom & Rear)

    Dimension drawings 115 Frame R2 (400 V) (bottom & rear)

  • Page 116: Frame R3 (Front & Side)

    116 Dimension drawings Frame R3 (front & side)

  • Page 117: Frame R3 (Bottom & Rear)

    Dimension drawings 117 Frame R3 (bottom & rear)

  • Page 118: Frame R4 (Front & Side)

    118 Dimension drawings Frame R4 (front & side)

  • Page 119: Frame R4 (Bottom & Rear)

    Dimension drawings 119 Frame R4 (bottom & rear)
  • Page 120 120 Dimension drawings...

  • Page 121: Resistor Braking

    Resistor braking 121 Resistor braking Contents of this chapter The chapter describes how to select the brake resistor and cables, protect the system, connect the brake resistor and enable resistor braking. Operation principle and hardware description The brake chopper handles the energy generated by a decelerating motor. The chopper connects the brake resistor to the intermediate DC circuit whenever the voltage in the circuit exceeds the limit defined by the control program.
  • Page 122 122 Resistor braking Equations for selecting the resistor: 150000 Eq. 1. U = 200…240 V: Rmax Rmax 450000 Rave = 380…415 V: Rmax 615000 = 415…480 V: R = Rmax Eq. 2. · Rpulse Rmax Eq. 3. · For conversion, use 1 hp = 746 W. Rave Rmax where...

  • Page 123: Reference Brake Resistors

    Resistor braking 123  Reference brake resistors Type Example resistor types Braking time BRcont BRmax ACH480- ohm ohm Danotherm 04-… 1-phase U = 200…240 V 02A4-1 32.5 0.25 0.33 0.38 0.50 CBH 360 C T 406 210R Refer to braking...

  • Page 124: Selecting And Routing The Brake Resistor Cables

    The maximum length of the resistor cable(s) is 10 m (33 ft).  EMC compliance of the complete installation ABB has not verified that the EMC requirements are fulfilled with external user- defined brake resistors and cabling. The EMC compliance of the complete installation must be considered by the customer.

  • Page 125: Protecting The System In Brake Circuit Fault Situations

    Resistor braking 125 Protecting the system in brake circuit fault situations  Protecting the system in cable and brake resistor short-circuit situations The input fuses also protect the resistor cable when it is identical with the input cable.  Protecting the system against thermal overload Equipping the drive with a main contactor is highly recommended for safety reasons.

  • Page 126: Electrical Installation

    126 Resistor braking Electrical installation  Measuring the insulation of the assembly Refer to Measuring insulation on page 56.  Connection diagram Refer to Connecting the power cables on page 59.  Connection procedure Refer to Connecting the power cables on page 59.

  • Page 127: Start-Up

    Resistor braking 127 Start-up Set the following parameters: 1. Disable the overvoltage control of the drive with parameter 30.30 Overvoltage control. 2. Set the source of parameter 31.01 External event 1 source to point to the digital input where the thermal switch of the brake resistor is wired. 3.
  • Page 128 128 Resistor braking...

  • Page 129: Safe Torque Off Function

    Safe torque off function 129 Safe torque off function Contents of this chapter This chapter describes the Safe torque off (STO) function of the drive and gives instructions for its use. Description The Safe torque off function can be used, for example, as the final actuator device of safety circuits that stop the drive in case of danger (such as an emergency stop circuit).

  • Page 130: Compliance With The European Machinery Directive

    130 Safe torque off function The Safe torque off function of the drive complies with these standards: Standard Name IEC 60204-1:2016 Safety of machinery – Electrical equipment of machines – Part 1: General requirements EN 60204-1:2006 + A1:2009 + AC:2010 IEC 61000-6-7:2014 Electromagnetic compatibility (EMC) –...

  • Page 131: Connection Principle

    Safe torque off function 131 Connection principle  Connection with internal +24 V DC power supply Drive Control board + 24 V DC OUT1 SGND UDC+ T1/U, Control logic T2/V, T3/W UDC-  Connection with external +24 V DC power supply 24 V DC Drive Control board...

  • Page 132: Wiring Examples

    132 Safe torque off function Wiring examples An example of a Safe torque off wiring with internal +24 V DC power supply is shown below. Safety PLC Drive OUT1 SGND Safety relay An example of a Safe torque off wiring with external +24 V DC power supply is shown below.

  • Page 133: Cable Types And Lengths

    Safe torque off function 133  Cable types and lengths • Double-shielded twisted-pair cable is recommended. • Maximum cable length: • 100 m (328 ft) between activation switch (K) and drive • 60 m (200 ft) between external power supply and drive Note: A short-circuit in the wiring between the switch and an STO terminal causes a dangerous fault and therefore it is recommended to use a safety relay (including wiring diagnostics), or a wiring method (shield grounding, channel separation) which...

  • Page 134: Start-Up Including Acceptance Test

    134 Safe torque off function Start-up including acceptance test To ensure the safe operation of a safety function, validation is required. The final assembler of the machine must validate the function by performing an acceptance test. The acceptance test must be performed •...

  • Page 135: Acceptance Test Procedure

    Safe torque off function 135  Acceptance test procedure After wiring the Safe torque off function, validate its operation as follows. Action WARNING! Obey the Safety instructions (page 11). If you ignore them, injury or death, or damage to the equipment can occur. Ensure that the drive can be run and stopped freely during start-up.

  • Page 136: Use

    136 Safe torque off function Action Test the operation of the failure detection of the drive. The motor can be stopped or running. • Open the 1st channel of the STO circuit (wire coming to IN1). If the motor was running, it should coast to a stop.
  • Page 137 Safe torque off function 137 WARNING! (With permanent magnet motors or synchronous reluctance motors [SynRM] only) In case of a multiple IGBT power semiconductor failure, the drive can produce an alignment torque which maximally rotates the motor shaft by 180/p degrees (with permanent magnet motors) or 180/2p degrees (with synchronous reluctance [SynRM] motors) regardless of the activation of the Safe torque off function.

  • Page 138: Maintenance

    If any wiring or component change is needed after start up, or the parameters are restored, do the test in Acceptance test procedure (page 135). Use only ABB approved spare parts. Record all maintenance and proof test activities in the machine logbook.  Competence...

  • Page 139: Fault Tracing

    See the drive firmware manual for the indications generated by the drive, and for details on directing fault and warning indications to an output on the control unit for external diagnostics. Any failures of the Safe torque off function must be reported to ABB.

  • Page 140: Safety Data

    140 Safe torque off function Safety data The safety data for the Safe torque off function is given below. Note: The safety data is calculated for redundant use, and does not apply if both STO channels are not used. Frame MTTF Cat.

  • Page 141: Abbreviations

    Safe torque off function 141  Abbreviations Abbr. Reference Description Cat. EN ISO 13849-1 Classification of the safety-related parts of a control system in respect of their resistance to faults and their subsequent behavior in the fault condition, and which is achieved by the structural arrangement of the parts, fault detection and/or by their reliability.

  • Page 142: Declaration Of Conformity

    142 Safe torque off function  Declaration of conformity Refer to Compliance with the European Machinery Directive on page 130.  TÜV certificate The TÜV certificate is available on the internet. Refer to Document library on the Internet on the inner back cover.

  • Page 143: Bapo-01 Power Extension Module

    BAPO-01 power extension module 143 BAPO-01 power extension module Contents of this chapter This chapter contains a description and technical data of the optional BAPO-01 auxiliary power extension module. The chapter also contains references to the relevant other content elsewhere in the manual. Safety instructions WARNING! Obey the instructions in Safety instructions...

  • Page 144: Hardware Description

    144 BAPO-01 power extension module Hardware description  Product overview The BAPO-01 auxiliary power extension module (option +L534) enables the use of an external auxiliary power supply with the drive. You need an external auxiliary power supply to keep the drive on during a power outage. Connect the auxiliary voltage supply to the +24V and DGND terminals on the drive.

  • Page 145: Mechanical Installation

    BAPO-01 power extension module 145 Mechanical installation Refer to Option modules on page 69. Electrical installation Connect the auxiliary voltage supply to the +24V and DGND terminals on the drive. Refer to Option modules on page 69. The BAPO module has internal connections to provide back-up power to the control board (I/O, fieldbus).

  • Page 146: Technical Data

    146 BAPO-01 power extension module Technical data  Voltage and current rating for the auxiliary power supply Refer to Option modules on page 69.  Power loss Power losses with maximum load 4 W.  Dimensions 3AXD50000031166 rev. A...

  • Page 147: Bio-01 I/O Extension Module

    BIO-01 I/O extension module 147 BIO-01 I/O extension module Contents of this chapter This chapter contains a description and technical data of the optional BIO-01 I/O extension module. The chapter also contains references to the relevant other content elsewhere in the manual. Safety instructions WARNING! Obey the instructions in Safety instructions...

  • Page 148: Hardware Description

    148 BIO-01 I/O extension module Hardware description  Product overview The BIO-01 front option module (Option +L515) is an I/O extension module that can be used with an optional fieldbus module. The optional fieldbus module is installed on top of the BIO-01 option module. The BIO-01 has three additional digital inputs (DI3, DI4 and DI5), one analog input (AI1) and one digital output (DO1) that is referred as DIO1 in the firmware (but works only in output mode).

  • Page 149: Electrical Installation

    SGND Safe torque off. Factory connection. Both circuits must be closed for the drive to start. OUT1 Start-up The BIO-01 module is automatically identified by the drive firmware. To configure the inputs refer to the ACH480 firmware manual (3AXD50000247134 [English])

  • Page 150: Technical Data

    150 BIO-01 I/O extension module Technical data  Control connection data For BIO-01 electrical data, refer to Technical data on page 83.  Dimensions Note: BIO-01 is supplied with a high cover part (part no. 3AXD50000190188) that increases the drive depth by 15 mm (0.6 in).
  • Page 151 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 abb.com/searchchannels. Product training For information on ABB product training, navigate to new.abb.com/service/training.
  • Page 152 © Copyright 2018 ABB. All rights reserved. Specifications subject to change without notice.

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