ABB ACS480-04-09A8-1 Hardware Manual
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ABB ACS480-04-09A8-1 Hardware Manual

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ABB GENERAL PURPOSE DRIVES
ACS480 drives
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Summary of Contents for ABB ACS480-04-09A8-1

  • Page 1 — ABB GENERAL PURPOSE DRIVES ACS480 drives Hardware manual...
  • Page 3 ACS480 drives Hardware manual Table of contents 1. Safety instructions 4. Mechanical installation 6. Electrical installation – IEC 7. Electrical installation – North America 3AXD50000047392 Rev E Original instructions EFFECTIVE: 2021-10-04...

  • Page 5: Table Of Contents

    Table of contents 5 Table of contents 1 Safety instructions Contents of this chapter ..................Use of warnings and notes ................. General safety in installation, start-up and maintenance ........General safety in operation ................Electrical safety in installation, start-up and maintenance ........Electrical safety precautions ................
  • Page 6 6 Table of contents Software information label ................Type designation key ..................Basic code ....................Option codes ....................4 Mechanical installation Contents of this chapter ..................Installation alternatives ..................Examining the installation site ................Required tools ..................... Unpacking the delivery ..................Installing the drive ....................
  • Page 7 Table of contents 7 Control panel to drive cable ................. PC tool cable ....................Routing the cables ....................General guidelines – IEC ................General guidelines – North America ............Continuous motor cable shield/conduit or enclosure for equipment on the motor cable ....................Separate control cable ducts ...............
  • Page 8 8 Table of contents Connection procedure .................. Connecting the control cables - IEC ..............Default I/O connection diagrams (ABB standard macro) ......Default fieldbus connection diagram ............Control cable connection procedure ............Additional information on the control connections ........Embedded EIA-485 fieldbus connection ..........
  • Page 9 Table of contents 9 Default fieldbus connection diagram ............Control cable connection procedure ............Additional information on the control connections ........Embedded EIA-485 fieldbus connection .......... PNP configuration for digital inputs ..........NPN configuration for digital inputs ..........Connection for obtaining 0 … 10 V from analog output 2 (AO2) ..Connection examples of two-wire and three-wire sensors ....
  • Page 10 10 Table of contents Output derating ....................Surrounding air temperature derating ............Altitude derating ................... Switching frequency derating ............... Fuses ........................IEC fuses ...................... gG fuses (IEC) .................. gR fuses (IEC) .................. UL (NEC) fuses .................... UL (NEC) fuse alternatives ............... Input chokes ......................
  • Page 11 Table of contents 11 Cybersecurity disclaimer ................11 Dimension drawings Contents of this chapter ..................Frame R0 ......................Frame R0 (front & side) - IP20 / UL open type ..........Frame R0 (bottom & rear) - IP20 / UL open type ......... Frame R1 ......................
  • Page 12 12 Table of contents Electrical installation ..................Measuring the insulation ..............Connecting power cables ..............Connection the control cables ............Start-up ....................... 13 The Safe torque off function Contents of this chapter ..................Description ......................Compliance with the European Machinery Directive and the UK Supply of Machinery (Safety) Regulations ..............
  • Page 13 Table of contents 13 Start-up ....................... Technical data ..................... 15 BIO-01 I/O extension module Contents of this chapter ..................Safety instructions ....................Hardware description ..................Product overview ..................Layout ......................Mechanical installation ..................Terminal configuration ..................Electrical installation ................... Start-up ....................... Technical data .....................

  • Page 15: Safety Instructions

    Safety instructions 15 Safety instructions Contents of this chapter This chapter contains the safety instructions which you must obey when you install, start-up, operate and do maintenance work on the drive. If you ignore the safety instructions, injury, death or damage can occur. Use of warnings and notes Warnings tell you about conditions which can cause injury or death, or damage to the equipment.

  • Page 16: General Safety In Installation, Start-Up And Maintenance

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

  • Page 17: General Safety In Operation

    Safety instructions 17 Note: • If you select an external source for the start command and it is on, the drive will start immediately after fault reset unless you configure the drive for pulse start. See the firmware manual. • If the drive is in remote control mode, you cannot stop or start the drive with the control panel.

  • Page 18: Electrical Safety In Installation, Start-Up And Maintenance

    18 Safety instructions Electrical safety in installation, start-up and maintenance ￭ Electrical safety precautions These electrical safety precautions are for all personnel who do work on the drive, motor cable or motor. WARNING! Obey these instructions. If you ignore them, injury or death, or damage to the equipment can occur.

  • Page 19: Additional Instructions And Notes

    Safety instructions 19 6. Install temporary grounding as required by the local regulations. 7. Ask for a permit to work from the person in control of the electrical installation work. ￭ Additional instructions and notes WARNING! Obey these instructions. If you ignore them, injury or death, or damage to the equipment can occur.

  • Page 20: Grounding

    20 Safety instructions ￭ Grounding These instructions are for all personnel who are responsible for 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. If you are not a qualified electrical professional, do not do grounding work.

  • Page 21: Safety In Operation

    Safety instructions 21 • If you cannot disconnect the motor, make sure that the motor cannot rotate during work. Make sure that no other system, like hydraulic crawling drives, can rotate the motor directly or through any mechanical connection like felt, nip, rope, etc. •...

  • Page 23: Introduction To The Manual

    Introduction to the manual 23 Introduction to the manual Contents of this chapter The chapter describes the applicability, target audience and purpose of the manual. The chapter contains a list of related manuals and a flowchart for installation and commissioning. Applicability This manual is applicable to ACS480 drives.

  • Page 24: Quick Installation And Commissioning Flowchart

    24 Introduction to the manual Quick installation and commissioning flowchart Task Identify the frame size: R0, R1, R2, etc. Type designation key (page 36) Plan the installation. Guidelines for planning the electrical installa- Check the ambient conditions, ratings and re- tion (page 45) quired cooling air flow.

  • Page 25: Terms And Abbreviations

    Introduction to the manual 25 Terms and abbreviations Term Description ACS-AP-I Industrial assistant non-Bluetooth control panel ACS-AP-S Standard assistant control panel ACS-AP-W Industrial assistant control panel with Bluetooth interface ACS-BP-S Basic control panel BAPO Optional auxiliary power extension module BCBL-01 Optional USB to RJ45 cable BIO-01 Optional I/O extension module.

  • Page 26: Related Manuals

    26 Introduction to the manual Term Description Macro A pre-defined set of default values of parameters in a drive control program. NETA-21 Remote monitoring tool Parameter In the drive control program, user-adjustable operation instruction to the drive, or signal measured or calculated by the drive. In some (for example fieldbus) contexts, a value that can be accessed as an object.
  • Page 27 Drive composer PC tool user's manual 3AUA0000094606 Converter module capacitor reforming instructions 3BFE64059629 You can find manuals and other product documents in PDF format on the Internet at www.abb.com/drives/documents. The code below opens an online listing of the manuals applicable to this product. ACS480 manuals...

  • Page 29: Operation Principle And Hardware Description

    This chapter briefly describes the operation principle and construction of the drive. Operation principle The ACS480 is a drive for controlling asynchronous AC induction motors, permanent magnet synchronous motors and ABB synchronous reluctance motors (SynRM motors). The drive is optimized for cabinet installation.

  • Page 30: Simplified Main Circuit Diagram

    30 Operation principle and hardware description ￭ Simplified main circuit diagram T1/U T2/V T3/W UDC+ UDC- 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 31: Layout

    Operation principle and hardware description 31 Layout Type designation label Motor and brake resistor terminals Model information label Cooling fan (on frames R1…R4) Firmware information label Front cover Control panel connection Control terminals Control panel Cold configuration adapter connection (CCA-01) EMC filter grounding screw Front option slot Varistor grounding screw...

  • Page 32: Control Connections

    32 Operation principle and hardware description Control connections There are fixed control connections on the base unit and additional control connections on the installed option module. ￭ Standard unit (with RIIO-01) Connections of the base unit: 1. Auxiliary voltage output 2.

  • Page 33: Base Unit

    Operation principle and hardware description 33 ￭ Base unit Connections of the base unit: 1. Auxiliary voltage output 2. Digital inputs 3. Safe torque-off connections 4. Relay output connection 5. Cold configuration adapter connection for CCA-01 6. Front option module slot 1 +24V DGND RO1C...

  • Page 34: Control Panel Options

    34 Operation principle and hardware description Control panel options The drive supports these control panels: • ACS-AP-S assistant control panel • ACS-AP-W assistant control panel with Bluetooth • ACS-AP-I assistant control panel • ACS-BP-S basic control panel • RDUM-01 blank panel with RJ-45 connector •...

  • Page 35: Drive Labels

    Operation principle and hardware description 35 Drive labels The drive has these labels: • type designation label on the left side of the drive • model information label on the top of the drive • software information label under the control panel. Example labels are shown in this section.

  • Page 36: Software Information Label

    36 Operation principle and hardware description ￭ Software information label ACS480-04-07A3-4 3~ 400/480 V (Frame R1) Pld: 3 kW (3 hp) Phd: 2.2 kW (3 hp) S/N: 41940A0620 SW v2.14.0.0 Drive type Frame size and ratings Serial number and drive software version Type designation key The type designation key shows the specifications and the configuration of the drive.
  • Page 37 Operation principle and hardware description 37 Code Description I/O options L511 BREL-01 relay output extension module L515 BIO-01 I/O extension module (front option, can be used with fieldbus) L534 BAPO-01 external 24 V DC power extension module (side option) L540 RIIO-01 I/O &...

  • Page 39: Mechanical Installation

    Mechanical installation 39 Mechanical installation Contents of this chapter This chapter tells how to examine the installation site, unpack and examine the delivery and install the drive mechanically. Installation alternatives You can install the drive: • with screws on to a wall •...

  • Page 40: Examining The Installation Site

    40 Mechanical installation • You can install frames R1, R2, R3 and R4 tilted to a maximum of 90 degrees, from vertical to fully horizontal orientation. • Do not install the drive upside down. • Make sure that the hot exhaust air from a drive does not flow into the cooling inlet of other drives or equipment.

  • Page 41: Unpacking The Delivery

    Mechanical installation 41 Unpacking the delivery Keep the drive in its package until you are ready to install it. After unpacking, protect the drive from dust, debris and moisture. Make sure that these items are included: • drive • options, if ordered with an option code •...

  • Page 42: To Install The Drive To A Din Installation Rail

    42 Mechanical installation 5. Put the drive onto the mounting screws. 6. Tighten the mounting screws. ￭ To install the drive to a DIN installation rail Use an IEC/EN 60715 top hat type installation rail, width × height = 35 × 7.5 mm (1.4 ×...
  • Page 43 Mechanical installation 43 5. Release the locking button. 6. Move the locking part to the right. 7. Make sure that the drive is correctly installed. To remove the drive, use a flat-head screwdriver to open the locking part.

  • Page 45: Guidelines For Planning The Electrical Installation

    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 46: European Union And United Kingdom

    46 Guidelines for planning the electrical installation ￭ European Union and United Kingdom To meet the European Union Directives and United Kingdom Regulations, according to standard EN 60204-1, Safety of Machinery, the disconnecting device must be one of the following types: •...

  • Page 47: Checking The Compatibility Of The Motor And Drive

    Guidelines for planning the electrical installation 47 Checking the compatibility of the motor and drive Use asynchronous AC induction motor, permanent magnet synchronous motor or ABB synchronous reluctance motor (SynRM motors) with the drive. Multiple induction motors can be connected to the drive at a time when using the scalar motor control mode.

  • Page 48: Power Cable Types

    48 Guidelines for planning the electrical installation ￭ Power cable types Preferred power cable types This section presents the preferred cable types. Make sure that the selected cable type also complies with local/state/country electrical codes. Cable type Use as input power cabling Use as motor cabling Symmetrical shielded (or ar- mored) cable with three phase...

  • Page 49: Alternate Power Cable Types

    Guidelines for planning the electrical installation 49 Alternate power cable types Cable type Use as input power cabling Use as motor cabling Yes with phase conductor Yes with phase conductor smaller than 10 mm 2 (8 AWG) smaller than 10 mm 2 (8 AWG) Cu, or motors up to 30 kW (40 hp).

  • Page 50: Not Allowed Power Cable Types

    50 Guidelines for planning the electrical installation Cable type Use as input power cabling Use as motor cabling WARNING! A single-core cable system: If you use unshielded three phase conductors and single-core cables in an PE conductor on cable tray IT network, make sure that the non-conductive outer sheath (jacket) of...

  • Page 51: Additional Guidelines, North America

    ￭ Additional guidelines, North America ABB recommends the use of conduit for power wiring to the drive and between the drive and the motor(s). Due to the variety of application needs, metallic and non-metallic conduit can be used. ABB recommends the use of metallic conduit.

  • Page 52: Power Cable Shield

    52 Guidelines for planning the electrical installation resistor, and control wiring. Do not run motor wiring from more than one drive in the same conduit. ￭ Power cable shield If the cable shield is used as the sole protective earth (PE) conductor, make sure that its conductivity agrees with the PE conductor requirements.

  • Page 53: Additional Grounding Requirements - Iec

    Guidelines for planning the electrical installation 53 in a manner which produces a conductance equivalent to that which results from the application of this table. Cross-sectional area of the phase conduct- Minimum cross-sectional area of the corres- ponding protective earth conductor S (mm 2 ) S p (mm 2 ) S ≤...

  • Page 54: Additional Grounding Requirements - Ul (Nec)

    54 Guidelines for planning the electrical installation If the protective earth conductor is routed through a plug and socket, or similar means of disconnection, it must not be possible to disconnect it unless power is simultaneously removed. Note: You can use power cable shields as grounding conductors only when their conductivity is sufficient.

  • Page 55: Relay 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 RJ-45 connectors. The maximum length of the cable is 100 m (328 ft).

  • Page 56: General Guidelines - North America

    56 Guidelines for planning the electrical installation min. 300 mm (12 in) min. 300 mm (12 in) min. 500 mm (20 in) 90° min. 200 mm (8 in) min. 500 mm (20 in) Motor cable Input power cable Control cable Brake resistor or chopper cable (if any) ￭...

  • Page 57: Continuous Motor Cable Shield/Conduit Or Enclosure For Equipment On The Motor Cable

    Guidelines for planning the electrical installation 57 Input power cabling Motor cabling Conduit ￭ Continuous motor cable shield/conduit or enclosure for equipment on the motor cable To minimize the emission level when safety switches, contactors, connection boxes or similar equipment are installed on the motor cable between the drive and the motor: •...

  • Page 58: Separate Control Cable Ducts

    58 Guidelines for planning the electrical installation ￭ Separate control cable ducts Put 24 V DC and 230 V AC (120 V AC) control cables in separate ducts, unless the 24 V DC cable is insulated for 230 V AC (120 V AC) or insulated with an insulation sleeving for 230 V AC (120 V AC).

  • Page 59: Protecting The Motor Against Thermal Overload

    Guidelines for planning the electrical installation 59 ￭ 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 60: Protecting The Drive Against Ground Faults

    60 Guidelines for planning the electrical installation 1. If there is double or reinforced insulation between the sensor and the live parts of the motor: You can connect the sensor directly to the analog/digital input(s) of the drive. See the control cable connection instructions. Make sure that the voltage does not exceed the maximum allowed voltage over the sensor.

  • Page 61: Implementing The Safe Torque Off Function

    203). 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 62 62 Guidelines for planning the electrical installation 230 V AC 230 V AC + 24 V DC Relay output Varistor RC filter Diode...

  • Page 63: Electrical Installation - Iec

    Electrical installation – IEC 63 Electrical installation – IEC Contents of this chapter This chapter describes how to: • measure the insulation • do the grounding system compatibility check • change the EMC filter or ground-to-phase varistor connection • connect the power and control cables •...

  • Page 64: Measuring The Insulation Resistance - Iec

    Use a measuring voltage of 1000 V DC. The insulation resistance of an ABB motor must be more than 100 Mohm (reference value at 25 °C [77 °F]). For the insulation resistance of other motors, refer to the manufacturer’s instructions.

  • Page 65: Measuring The Insulation Resistance Of The Brake Resistor Circuit

    Electrical installation – IEC 65 U1-PE, V1-PE, W1-PE 1000 V DC, > 100 Mohm ￭ Measuring the insulation resistance of the brake resistor circuit WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. If you are not a qualified electrical professional, do not do installation or maintenance work.

  • Page 66: Ground-To-Phase Varistor

    66 Electrical installation – IEC wye). For other systems, refer to Compatibility of EMC filter and ground-to-phase varistor with the grounding system (page 66). Note: If you disconnect the EMC filter, the electromagnetic compatibility of the drive decreases. WARNING! Do not install a drive with the internal EMC filter connected to a grounding system that the EMC filter is not compatible with (for example, an IT system).
  • Page 67 Electrical installation – IEC 67 you connect the drive to the input power, examine the screws and do the necessary actions shown in the table. Screw Screw material When to remove EMC screw or VAR screw label Symmetrically Corner-grounded IT systems (un- grounded TN-S delta (B1), mid- grounded or high-...

  • Page 68: Disconnecting The Emc Filter Or Ground-To-Phase Varistor

    68 Electrical installation – IEC ￭ Disconnecting the EMC filter or ground-to-phase varistor Before you continue, refer to Compatibility of EMC filter and ground-to-phase varistor with the grounding system (page 66). • To disconnect the EMC filter, remove the metal EMC screw. •...

  • Page 69: Guidelines For Installing The Drive To A Tt System

    Note: • ABB does not guarantee the EMC performance, because the internal EMC filter is disconnected. • ABB does not guarantee the functioning of the ground leakage detector built inside the drive.
  • Page 70 70 Electrical installation – IEC The table below shows the line-to-ground voltages in relation to the line-to-line voltage for each grounding system. U L-L U L1-G U L2-G U L3-G Electrical power system type Symmetrically grounded TN system (TN-S 0.58·X 0.58·X 0.58·X system)

  • Page 71: Connecting The Power Cables - Iec (Shielded Cables)

    PE conductor. Motor cable Note: ABB recommends to use a symmetrical shielded cable (VFD cable) as the motor cable. Separate PE cable (motor side). Use a separate grounding cable for the motor side, if the conductivity of the shield is not sufficient, or if there is no symmetrically constructed PE conductor in the cable.

  • Page 72: Connection Procedure

    72 Electrical installation – IEC ￭ Connection procedure WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. If you are not a qualified electrical professional, do not do installation or maintenance work. Refer to Terminal data for the power cables (page 156) for the tightening torques.
  • Page 73 Electrical installation – IEC 73 7. Connect the phase conductors of the motor cable to terminals T1/U, T2/V and T3/W. 8. If you use a brake resistor, connect the brake resistor cable to terminals R- and UDC+. Use shielded cable and ground the shield under the grounding clamp for 360-degree grounding.

  • Page 74: Connecting The Control Cables - Iec

    ￭ Default I/O connection diagrams (ABB standard macro) The connection diagrams below are applicable to the standard drive variant with the RIIO-01 I/O & EIA-485 module. ABB standard macro (parameter 96.04) is used with the default parameter settings. Description Connection...
  • Page 75 Electrical installation – IEC 75 Description Connection Terminal Relay outputs +24V Aux. voltage output +24 V DC, max. 250 mA +24 V +24 V DGND Aux. voltage output common DGND DGND DCOM DCOM DCOM Digital input common for all RO1C Common Ready run ×...

  • Page 76: Default Fieldbus Connection Diagram

    76 Electrical installation – IEC ￭ Default fieldbus connection diagram The connection diagrams are applicable to the base unit with an optional fieldbus adapter module. ABB standard macro (parameter 96.04) is used with its default parameter settings. Connection Description Terminal...

  • Page 77: Control Cable Connection Procedure

    Electrical installation – IEC 77 2) × = base unit, empty = fieldbus module ￭ Control cable connection procedure Do the connections according to the control macro (parameter 96.04) used. Keep the signal wire pairs twisted as near to the terminals as possible to prevent inductive coupling.

  • Page 78: Additional Information On The Control Connections

    78 Electrical installation – IEC ￭ Additional information on the control connections Embedded EIA-485 fieldbus connection The EIA-485 network uses shielded, twisted-pair cable with a characteristic impedance of 100 … 130 ohm for data signaling. The distributed capacitance between conductors is less than 100 pF per meter (30 pF per foot).
  • Page 79 Electrical installation – IEC 79 Connection examples are shown below. With signal ground reference terminal Without signal ground reference terminal 100 ohm Automation controller Drive Termination switch. The devices at the ends of the fieldbus must have termination on. All other devices must have termination off.

  • Page 80: Pnp Configuration For Digital Inputs

    80 Electrical installation – IEC PNP configuration for digital inputs Internal and external +24 V power supply connections for PNP (source) configuration are shown in the figures below. Internal +24 V power supply External +24 V power supply (with BAPO-01) +24 V +24 V 0 V DC...

  • Page 81: Connection For Obtaining 0

    Electrical installation – IEC 81 Connection for obtaining 0 … 10 V from analog output 2 (AO2) To obtain 0 … 10 V from analog output AO2, connect a 500 ohm resistor (or two 1 kohm resistors in parallel) between AO2 and AGND. Examples are shown in the figure below. 500 ohm 1 kohm 1 kohm...

  • Page 82: Ai And Ao (Or Ai, Di And +10 V) As Ptc Motor Temperature Sensor Interface

    82 Electrical installation – IEC AI and AO (or AI, DI and +10 V) as PTC motor temperature sensor interface WARNING! IEC 61800-5-1 requires double or reinforced insulation between live parts and accessible parts when: • the accessible parts are not conductive, or •...

  • Page 83: Ai1 And Ai2 As Pt100, Pt1000, Ni1000, Kty83 And Kty84 Sensor Inputs

    Electrical installation – IEC 83 PTC connection 2 If no analog output is available for the PTC connection, it is possible to use a voltage divider connection. 1…3 PTC sensors are connected in series with 10 V reference and digital and analog inputs. The voltage over the digital input internal resistance varies depending on the PTC resistance.

  • Page 84: Safe Torque Off

    84 Electrical installation – IEC See the firmware manual for information on the related Motor thermal protection function. AGND AGND 1…3 × (Pt100 or Pt1000) or 1 × (Ni1000 or KTY83 or KTY84) Analog input. Set the analog input type to V (volt) in parameter group 12 Standard AI. Define the temperature sensor type, signal source, etc.

  • Page 85: Connecting A Pc

    Electrical installation – IEC 85 To connect an external auxiliary power supply to the drive: 1. Install a BAPO-01 power extension module to the drive. See Installing options (page 85). 2. Connect an external power supply to the +24V and DGND terminals of the base unit.

  • Page 86: Installing A Front Option

    86 Electrical installation – IEC • Side option: Multifunction extension module slot on the side of the drive. Refer also to the applicable fieldbus module manual for the installation instructions. For other option modules, refer to: • BREL-01 relay output extension module (page 233) •...

  • Page 87: Installing A Side Option

    Electrical installation – IEC 87 Note: If you have the BIO-01 option module, you can add one additional fieldbus module on top of it. ￭ Installing a side option WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur.
  • Page 88 88 Electrical installation – IEC 6. Attach the grounding bar to the bottom of the side option and to the front ground tab on the drive. Torque the screws to 1 N·m (8.8 lbf·in). 7. Connect the control cables. See the control cable connection instructions.

  • Page 89: Electrical Installation - North America

    Electrical installation – North America 89 Electrical installation – North America Contents of this chapter This chapter describes how to: • measure the insulation • do the grounding system compatibility check • change the EMC filter or ground-to-phase varistor connection •...

  • Page 90: Measuring The Insulation Resistance - North America

    Use a measuring voltage of 1000 V DC. The insulation resistance of an ABB motor must be more than 100 Mohm (reference value at 25 °C [77 °F]). For the insulation resistance of other motors, refer to the manufacturer’s instructions.

  • Page 91: Measuring The Insulation Resistance Of The Brake Resistor Circuit

    Electrical installation – North America 91 U1-PE, V1-PE, W1-PE 1000 V DC, > 100 Mohm ￭ Measuring the insulation resistance of the brake resistor circuit WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur.

  • Page 92: Emc Filter

    92 Electrical installation – North America ￭ EMC filter The drive has an internal EMC filter as standard. In the UL (NEC) drive types, the filter is disconnected by default. The filter is typically not necessary in North American installations. If you are concerned with EMC issues, and install the drive to a symmetrically grounded TN-S system (center-grounded wye), you can connect the internal EMC filter.
  • Page 93 Electrical installation – North America 93 you connect the drive to the input power, examine the screws and do the necessary actions shown in the table. Screw Screw material When to remove EMC screw or VAR screw label Symmetrically Corner-grounded IT systems (un- grounded TN-S delta (B1), mid-...

  • Page 94: Disconnecting The Ground-To-Phase Varistor, Or Connecting The Emc Filter

    94 Electrical installation – North America ￭ Disconnecting the ground-to-phase varistor, or connecting the EMC filter Before you continue, refer to Compatibility of EMC filter and ground-to-phase varistor with the grounding system (page 92). • To disconnect the ground-to-phase varistor, remove the metal VAR screw. •...

  • Page 95: Guidelines For Installing The Drive To A Tt System

    Note: • ABB does not guarantee the EMC performance, because the internal EMC filter is disconnected. • ABB does not guarantee the functioning of the ground leakage detector built inside the drive.
  • Page 96 96 Electrical installation – North America The table below shows the line-to-ground voltages in relation to the line-to-line voltage for each grounding system. U L-L U L1-G U L2-G U L3-G Electrical power system type Symmetrically grounded TN system (TN-S 0.58·X 0.58·X 0.58·X...

  • Page 97: Connecting The Power Cables - North America (Wiring In Conduits)

    ￭ Connection diagram UDC- UDC+ Drive Drive enclosure Supply disconnecting device and fuses Input power wiring Protective earth (ground) conductor(s) Motor wiring Note: ABB recommends to use a symmetrical shielded cable (VFD cable) as the motor cable. Brake resistor (optional)

  • Page 98: Connection Procedure

    98 Electrical installation – North America ￭ Connection procedure WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. If you are not a qualified electrical professional, do not do installation or maintenance work. Refer to Terminal data for the power cables (page 156) for the tightening torques.
  • Page 99 Electrical installation – North America 99 8. Connect the phase conductors of the motor wiring to terminals T1/U, T2/V and T3/W. 9. If you use a brake resistor, connect the brake resistor conductors to terminals R- and UDC+. 10. Make sure that the R- and UDC+ terminal screws are tightened. Do this step also if you do not connect cables to the terminals.

  • Page 100: Connecting The Control Cables - North America

    ￭ Default I/O connection diagrams (ABB standard macro) The connection diagrams below are applicable to the standard drive variant with the RIIO-01 I/O & EIA-485 module. ABB standard macro (parameter 96.04) is used with the default parameter settings. Description Connection...
  • Page 101 Electrical installation – North America 101 Description Connection Terminal Digital inputs and auxiliary voltage output +24V × Aux. voltage output +24 V DC, max. 250 mA +24 V +24 V DGND Aux. voltage output common × DGND DGND DCOM Digital input common for all ×...

  • Page 102: Default Fieldbus Connection Diagram

    5) See parameters 28.72, 28.73, 28.74 and 28.75. ￭ Default fieldbus connection diagram The connection diagrams are applicable to the base unit with an optional fieldbus adapter module. ABB standard macro (parameter 96.04) is used with its default parameter settings. Connection Description...

  • Page 103: Control Cable Connection Procedure

    Electrical installation – North America 103 Connection Description Terminal Safe torque off SGND Safe torque off. Factory connection. Both circuits × SGND must be closed for the drive to start. × × OUT1 OUT1 × Fieldbus connection DSUB9 +K457 FCAN-01 CANopen DSUB9 +K454 FPBA-01 Profibus DP RJ45×2...

  • Page 104: Additional Information On The Control Connections

    104 Electrical installation – North America 6. Connect the conductors to the correct control terminals. Torque the terminal connections to 0.5 … 0.6 N·m (4.4 … 5.3 lbf·in). 7. Connect the shields and grounding wires to the SCR terminal. Torque the terminal connection to 0.5 …...
  • Page 105 Electrical installation – North America 105 Connection examples are shown below. With signal ground reference terminal Without signal ground reference terminal 100 ohm Automation controller Drive Termination switch. The devices at the ends of the fieldbus must have termination on. All other devices must have termination off.

  • Page 106: Pnp Configuration For Digital Inputs

    106 Electrical installation – North America PNP configuration for digital inputs Internal and external +24 V power supply connections for PNP (source) configuration are shown in the figures below. Internal +24 V power supply External +24 V power supply (with BAPO-01) +24 V +24 V 0 V DC...

  • Page 107: Connection For Obtaining 0

    Electrical installation – North America 107 Connection for obtaining 0 … 10 V from analog output 2 (AO2) To obtain 0 … 10 V from analog output AO2, connect a 500 ohm resistor (or two 1 kohm resistors in parallel) between AO2 and AGND. Examples are shown in the figure below. 500 ohm 1 kohm 1 kohm...

  • Page 108: Ai And Ao (Or Ai, Di And +10 V) As Ptc Motor Temperature Sensor Interface

    108 Electrical installation – North America AI and AO (or AI, DI and +10 V) as PTC motor temperature sensor interface WARNING! IEC 61800-5-1 requires double or reinforced insulation between live parts and accessible parts when: • the accessible parts are not conductive, or •...

  • Page 109: Ai1 And Ai2 As Pt100, Pt1000, Ni1000, Kty83 And Kty84 Sensor Inputs

    Electrical installation – North America 109 PTC connection 2 If no analog output is available for the PTC connection, it is possible to use a voltage divider connection. 1…3 PTC sensors are connected in series with 10 V reference and digital and analog inputs.

  • Page 110: Safe Torque Off

    110 Electrical installation – North America See the firmware manual for information on the related Motor thermal protection function. AGND AGND 1…3 × (Pt100 or Pt1000) or 1 × (Ni1000 or KTY83 or KTY84) Analog input. Set the analog input type to V (volt) in parameter group 12 Standard AI. Define the temperature sensor type, signal source, etc.

  • Page 111: Connecting A Pc

    Electrical installation – North America 111 To connect an external auxiliary power supply to the drive: 1. Install a BAPO-01 power extension module to the drive. See Installing options (page 85). 2. Connect an external power supply to the +24V and DGND terminals of the base unit.

  • Page 112: Installing A Front Option

    112 Electrical installation – North America • Side option: Multifunction extension module slot on the side of the drive. Refer also to the applicable fieldbus module manual for the installation instructions. For other option modules, refer to: • BREL-01 relay output extension module (page 233) •...

  • Page 113: Installing A Side Option

    Electrical installation – North America 113 Note: If you have the BIO-01 option module, you can add one additional fieldbus module on top of it. ￭ Installing a side option WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur.
  • Page 114 114 Electrical installation – North America 6. Attach the grounding bar to the bottom of the side option and to the front ground tab on the drive. Torque the screws to 1 N·m (8.8 lbf·in). 7. Connect the control cables. See the control cable connection instructions.

  • Page 115: Installation Checklist

    Installation checklist 115 Installation checklist Contents of this chapter This chapter contains a checklist of the mechanical and electrical installation of the drive. Checklist Examine the mechanical and electrical installation of the drive before start-up. Go through the checklist together with another person. WARNING! Obey the safety instructions of the drive.
  • Page 116 116 Installation checklist Make sure that … The insulation resistance of the input power cable, motor cable and motor is measured according to local regulations and the manuals of the drive. The drive is attached securely on an even, vertical and non-flammable wall. The cooling air flows freely in and out of the drive.
  • Page 117 Installation checklist 117 Make sure that … The area in front of the drive is clean: the drive cooling fan cannot draw any dust or dirt inside. Drive covers and cover of the motor connection box are in place. The motor and the driven equipment are ready for power-up.

  • Page 119: Maintenance

    Maintenance intervals The tables below show the maintenance tasks which can be done by the end user. The complete maintenance schedule is available on the Internet (www.abb.com/drivesservices). For more information, consult your local ABB Service representative (www.abb.com/searchchannels). ￭ Description of symbols...

  • Page 120: Recommended Maintenance Intervals After Start-Up

    20 years Note: • Maintenance and component replacement intervals are based on the assumption that the equipment is operated within the specified ratings and ambient conditions. ABB recommends annual drive inspections to ensure the highest reliability and optimum performance. • Long term operation near the specified maximum ratings or ambient conditions may require shorter maintenance intervals for certain components.

  • Page 121: Cleaning The Heatsink

    The remaining mission time of the whole circuit is however determined by its oldest component. Contact your local ABB service representative for more information. Cleaning the heatsink The drive module heatsink fins pick up dust from the cooling air. The drive runs into overtemperature warnings and faults if the heatsink is not clean.

  • Page 122: Replacing The Cooling Fan, Frames R1

    122 Maintenance You can get replacement fans from ABB. Use only ABB specified spare parts. ￭ Replacing the cooling fan, frames R1…R3 WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. If you are not a qualified electrical professional, do not do installation or maintenance work.
  • Page 123 Maintenance 123 7. 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. 8.

  • Page 124: Replacing The Cooling Fan, Frame R4

    124 Maintenance ￭ Replacing the cooling fan, frame R4 WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. If you are not a qualified electrical professional, do not do installation or maintenance work. 1.

  • Page 125: Capacitors

    Capacitor failure is usually followed by damage to the unit and an input cable fuse failure, or a fault trip. If you think that any capacitors in the drive have failed, contact ABB. ￭...

  • Page 127: Technical Data

    CE, UL and other approval marks. Note: 230 V drive types were not available at the time of publication of this manual. For more information, contact ABB. Electrical ratings ￭...
  • Page 128 128 Technical data IEC type Input current Output ratings ACS480- With Max. Nominal use Light-duty use Heavy-duty 04-… choke choke cur- Frame rent I 1N I 1N I max I Ld P Ld I Hd P Hd 3-phase U N = 230 V 02A4-2 0.37 0.37...

  • Page 129: Ul (Nec) Ratings

    Technical data 129 ￭ UL (NEC) ratings UL (NEC) Input current Output ratings Frame type With Max. Light-duty use Heavy-duty use ACS480- choke choke current 04-… I 1Ld I 1Ld I max I Ld P Ld I Hd P Hd 1-phase U N = 230 V 02A3-1 0.33...

  • Page 130: Definitions

    NEMA 4-pole motors. ￭ Sizing ABB recommends the DriveSize tool for selecting the drive, motor and gear combination (https://new.abb.com/drives/software-tools/drivesize). You can also use the ratings tables. The minimum recommended nominal current of the motor is 40% of the drive nominal output current (I ) .

  • Page 131: Output Derating

    Technical data 131 Output derating The load capacity (I ) decreases in some situations. In such situations, where full motor power is required, oversize the drive so that the total derated output current is sufficient for the motor to reach the full power. In an environment where more than one type of derating is necessary (for example, high altitude and high temperature), the effects of derating are cumulative.
  • Page 132 132 Technical data Multiply the drive output current by all the applicable derating factors. In this example, the derated output current becomes Example 2, IEC: How to calculate the required drive The application requires a nominal motor current of 6.0 A at a switching frequency of 8 kHz.

  • Page 133: Surrounding Air Temperature Derating

    Technical data 133 ￭ Surrounding air temperature derating Frame Temperature Derating Less than 50 °C No derating (122 °F) R1…R3 50 … 60 °C Output current decreases by 1% for each additional 1 °C (122 … 140 °F) (1.8 F). 50 …...

  • Page 134: Switching Frequency Derating

    134 Technical data ￭ Switching frequency derating Derating the drive output current is necessary when using high minimum switching frequencies. If you change parameter 97.02 Minimum switching frequency, calculate the derated current. Multiply the drive output current with the applicable derating factor from the table.
  • Page 135 Technical data 135 IEC type Derating factor ACS480- < 4 kHz 8 kHz 12 kHz 04-… 07A3-4 0.65 0.48 09A5-4 0.65 0.48 12A7-4 0.68 0.51 018A-4 0.68 0.51 026A-4 0.67 0.51 033A-4 0.65 0.49 039A-4 0.65 0.49 046A-4 0.66 0.49 050A-4 0.66 0.49...

  • Page 136: Fuses

    Make sure that the operating time of the fuse is less than 0.5 seconds. Obey the local regulations. IEC type Drive input gG fuses Min. ACS480-04- current I 2 t short-circuit Nominal Voltage ABB type current current rating 60269 size A 2 s 1-phase U N = 230 V 02A4-1 OFAF000H10 03A7-1 OFAF000H10 04A8-1 10.1...

  • Page 137: Gr Fuses (Iec)

    Technical data 137 IEC type Drive input gG fuses Min. ACS480-04- current I 2 t short-circuit Nominal Voltage ABB type current current rating 60269 size A 2 s 3-phase U N = 230 V 02A4-2 OFAF000H6 03A7-2 OFAF000H10 04A8-2 OFAF000H10 06A9-2 10.4...
  • Page 138 138 Technical data IEC type Drive input gR fuses Min. ACS480-04- current short-circuit Nominal Voltage Bussmann I 2 t current current rating type 60269 size A 2 s 03A7-1 170M2695 04A8-1 10.1 170M2696 06A9-1 14.5 1000 170M2697 07A8-1 16.4 1800 170M2698 09A8-1 20.6...

  • Page 139: Ul (Nec) Fuses

    Technical data 139 ￭ UL (NEC) fuses UL (NEC) Drive in- Fuses type put cur- Nomin- Max. fuse rating ACS480- rent Voltage al cur- for group install- Bussmann/ 04-… rating Type rent ation Edison type 1-phase U N = 230 V 02A3-1 JJN/TJN10 UL class T...

  • Page 140: Ul (Nec) Fuse Alternatives

    2. Fuses with a higher current rating than specified must not be used. 3. The UL listed fuses recommended by ABB are the required branch circuit protection per NEC. 4. The recommended size or smaller UL listed 248 fast acting, time delay, or high speed fuses must be used to maintain the UL listing of the drive.
  • Page 141 Technical data 141 UL (NEC) Drive Fuse UL 248-15 Class T Fast Acting Fuses type input Max. Voltage Mersen / Edison ACS480-04- current current rating Ferraz Bussmann Littelfuse Shawmut 07A5-2 11.7 JJS-20 JLLS020 A6T20 TSJ20 11A6-2 18.3 JJS-25 JLLS025 A6T25 TSJ25 017A-2 24.6...
  • Page 142 142 Technical data UL (NEC) Drive Fuse UL 248-8 Fast Acting Class J Fuses type input Max. Voltage Mersen / Edison ACS480-04- current current rating Ferraz Bussmann Littelfuse Shawmut 053A-2 60.0 JKS-100 JLS100 A4J100 JFL100 3-phase U N = 480 V 02A1-4 JKS-6 JLS6...
  • Page 143 Technical data 143 UL (NEC) Drive Fuse UL 248-8 High Speed Class J Fuses type input Max. Voltage Mersen / Edison ACS480-04- current current rating Ferraz Bussmann Littelfuse Shawmut 06A0-4 11.5 DFJ-20 LDFJ020 HSJ20 JHL20 07A6-4 15.0 DFJ-20 LDFJ020 HSJ20 JHL20 011A-4 20.2...

  • Page 144: Input Chokes

    The tables that follow give the input chokes that you can use. The maximum surrounding air temperature for the chokes is 40 °C (104 °F). IEC type Input choke Frame ACS480- 04-… 1-phase U N = 230 V 02A4-1 ABB CHK-A1 03A7-1 ABB CHK-B1 04A8-1 ABB CHK-B1 06A9-1 ABB CHK-C1...
  • Page 145 Technical data 145 IEC type Input choke Frame ACS480- 04-… 07A8-1 ABB CHK-C1 09A8-1 ABB CHK-D1 12A2-1 ABB CHK-D1 3-phase U N = 230 V 02A4-2 Contact ABB 03A7-2 Contact ABB 04A8-2 Contact ABB 06A9-2 Contact ABB 07A8-2 Contact ABB...

  • Page 146: Alternative Short-Circuit Protection

    146 Technical data UL (NEC) Input choke Frame type ACS480- 04-… 06A6-1 ABB CHK-C1 07A4-1 ABB CHK-C1 09A3-1 ABB CHK-D1 11A6-1 ABB CHK-D1 3-phase U N = 230 V 02A3-2 Contact ABB 03A5-2 Contact ABB 04A6-2 Contact ABB 06A6-2 Contact ABB...
  • Page 147 Obey the manufacturer’s instructions. You can use the circuit breakers specified by ABB. You can also use other circuit breakers with the drive if they provide the same electrical characteristics. ABB does not assume any liability whatsoever for the correct function and protection of the circuit breakers not specified by ABB.

  • Page 148: Manual Self-Protected Combination Motor Controller - Type E Usa (Ul (Nec))

    This is in accordance with the National Electrical Code (NEC). When the correct ABB Type E manual motor protector is selected from the table and used for branch circuit protection, the drive is suitable for use in a circuit capable of delivering no more than 65 kA rms symmetrical amperes at the maximum rated voltage of the drive.
  • Page 149 50 kA. See the ABB manual motor starter catalog (1SBC100214C0201) 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 150: Dimensions And Weights

    Refer to the technical data. For UL only: The minimum enclosure volume is specified in the UL listing when applied with the ABB Type E MMP shown in the table. Fuses must be used for wall-mounted drives installed with a UL Type 1 kit.

  • Page 151: Free Space Requirements

    Technical data 151 Ø 5 [.21] Ø 10 [.40] Ø 5 [.21] Height back Height Height front Width Depth Mounting hole distance Mounting hole distance Free space requirements Frame Free space requirement Below Above Sides 1) Drives with the optional UL Type 1 kit: 50 mm (2 in), measured from the top of the hood. 2) A side-mounted option module requires 20 mm (0.8 in) of free space on the right side of the drive.
  • Page 152 152 Technical data IEC type Air flow Noise Frame Typical power loss ACS480-04- size m 3 /h BTU/h dB(A) 07A8-1 09A8-1 12A2-1 3-phase U N = 230 V 02A4-2 03A7-2 04A8-2 06A9-2 07A8-2 09A8-2 12A2-2 17A5-2 25A0-2 1358 032A-2 1194 048A-2 1914 055A-2...

  • Page 153: Typical Power Cable Sizes

    Technical data 153 UL (NEC) Air flow Noise Frame Typical power loss type size m 3 /h BTU/h dB(A) ACS480-04- 04A6-1 06A6-1 07A4-1 09A3-1 11A6-1 3-phase U N = 230 V 02A3-2 03A5-2 04A6-2 06A6-2 07A5-2 11A6-2 017A-2 024A-2 1358 031A-2 1194 046A-2...
  • Page 154 154 Technical data Cable size, Cu (mm 2 ) Conductor size, Cu (AWG) Frame type ACS480- 04-… 1-phase U N = 230 V 02A4-1 3×1.5 + 1.5 03A7-1 3×1.5 + 1.5 04A8-1 3×1.5 + 1.5 06A9-1 3×1.5 + 1.5 07A8-1 3×1.5 + 1.5 09A8-1 3×2.5 + 2.5...
  • Page 155 Technical data 155 Cable size, Cu (mm 2 ) Conductor size, Cu (AWG) Frame (NEC) type ACS480- 04-… 1-phase U N = 230 V 02A3-1 3×1.5 + 1.5 03A5-1 3×1.5 + 1.5 04A6-1 3×1.5 + 1.5 06A6-1 3×1.5 + 1.5 07A4-1 3×1.5 + 1.5 09A3-1...

  • Page 156: Terminal Data For The Power Cables

    156 Technical data Terminal data for the power cables IEC type L1, L2, L3, T1/U, T2/V, T3/W, R-, R+/ ACS480- UDC+ 04-… Minimum Maximum Tightening Minimum Maximum Tightening (solid/stran- (solid/stran- torque (solid/stran- (solid/stran- torque ded) ded) ded) ded) mm 2 mm 2 mm 2 mm 2...
  • Page 157 Technical data 157 IEC type L1, L2, L3, T1/U, T2/V, T3/W, R-, R+/ ACS480- UDC+ 04-… Minimum Maximum Tightening Minimum Maximum Tightening (solid/stran- (solid/stran- torque (solid/stran- (solid/stran- torque ded) ded) ded) ded) mm 2 mm 2 mm 2 mm 2 N·m N·m 046A-4...

  • Page 158: Terminal Data For The Control Cables

    EMC compliance (IEC/EN 61800-3:2004 + A1:2012) (page 168). For compliance information, see Category C1 (page 169). IEC type EMC filter type ACS480- ABB type code Schaffner order code 04-… 1-phase U N = 230 V 02A4-1 RFI-11 FS 21754-6.1-07 03A7-1 RFI-12 FS 21754-16.1-07...
  • Page 159 Technical data 159 IEC type EMC filter type ACS480- ABB type code Schaffner order code 04-… 07A8-1 RFI-12 FS 21754-16.1-07 3-phase U N = 230 V 02A4-2 RFI-32 FN 3258-16-44 03A7-2 RFI-32 FN 3258-16-44 04A8-2 RFI-32 FN 3258-16-44 06A9-2 RFI-32...

  • Page 160: Electrical Power Network Specification

    ACS480-04-xxxx-2 drives: 3-phase 200 … 240 V AC -15% … +10%. ACS480-04-xxxx-4 drives: 3-phase 380 … 480 V AC -15% … +10%. Network type Public low voltage networks. Symmetrically grounded TN-S system, IT (ungrounded), corner-grounded delta. Consult ABB before connecting to other systems (for example, TT, or midpoint grounded delta).

  • Page 161: Motor Connection Data

    (cos phi) Motor connection data Motor type Asynchronous AC induction motors, permanent magnet synchronous motors or ABB synchronous reluctance motors (SynRM motors) Voltage (U2) 0 … U1, 3-phase symmetrical Short-circuit protec- The motor output is short-circuit proof by IEC 61800-5-1 and UL 61800- tion (IEC 61800-5-1, 5-1.

  • Page 162: Emc Compatibility And Motor Cable Length

    162 Technical data Frame Maximum motor cable length Standard drive, without external options R0…R4 Note: In multimotor systems, the calculated sum of all motor cable lengths must not exceed the maximum motor cable length given in the table. EMC compatibility and motor cable length To comply with the EMC requirements of IEC/EN 61800-3, do not exceed these maximum motor cable lengths.

  • Page 163: Brake Resistor Connection Data

    Technical data 163 Frame Maximum motor cable length, 4 kHz 1) Category C1 with conducted emissions only. Radiated emissions are not compatible when measured with the standard emission measurement setup and must be measured on cabinet and machine installations for each case.

  • Page 164: Energy Efficiency Data (Ecodesign)

    Energy efficiency data (ecodesign) Energy efficiency data according to IEC 61800-9-2 is available from the ecodesign tool (https://ecodesign.drivesmotors.abb.com/). Energy efficiency data is not provided for the 1~230 V drives. The drives with one phase input are not in the scope of the EU ecodesign requirements (Regulation EU/2019/1781)

  • Page 165: Protection Classes

    Technical data 165 Protection classes Degree of protection IP20. The drive must be installed in a cabinet to fulfill the requirements (IEC/EN 60529) for shielding from contact. Enclosure types UL open type. For indoor use only. UL Type 1 kit is available as an option. (UL 61800-5-1) Overvoltage category (IEC 60664-1)

  • Page 166: Materials

    166 Technical data Requirement Operation installed Storage in the protect- Transportation in the for stationary use ive package protective package Contamination levels IEC 60721-3-3: 2002 IEC 60721-3-1: 1997 IEC 60721-3-2: 1997 (IEC 60721-3-x) - Chemical gases Class 3C2 Class 1C2 Class 2C2 - Solid particles Class 3S2.

  • Page 167: Applicable Standards

    Technical data 167 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 regulations. Applicable standards The drive complies with the following standards: EN ISO 13849-1:2015 Safety of machinery –...

  • Page 168: Emc Compliance (Iec/En 61800-3:2004 + A1:2012)

    168 Technical data TÜV Safety Approved mark (functional safety) Product contains Safe Torque Off and possibly other (optional) safety functions which are certified by TÜV according to the relevant functional safety standards. Applicable to drives and inverters; not applicable to supply, brake or DC/DC converter units or modules.

  • Page 169: Category C1

    Technical data 169 Drive of category C1: drive of rated voltage less than 1000 V and intended for use in the first environment. Drive of category C2: drive of rated voltage less than 1000 V and intended to be installed and started up only by a professional when used in the first environment.

  • Page 170: Category C3

    170 Technical data This product can cause radio-frequency inference. In a residential or domestic environment, supplementary mitigation measures may be required in addition to the requirements listed above for the CE compliance. WARNING! Do not install a drive with the internal EMC filter connected to a grounding system that the EMC filter is not compatible with (for example, an IT system).

  • Page 171: Ul Checklist

    Technical data 171 Equipment Supply transformer Static screen Drive 2. 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]). 3.

  • Page 172: Disclaimers

    • The cables located within the motor circuit must be rated for at least 75 °C in UL-compliant installations. • The input cable must be protected with UL-rated fuses, or the ABB Type E manual motor protectors (MMP) listed in this manual. The fuses or the manual motor protectors provide branch circuit protection in accordance with the National Electrical Code (NEC) and Canadian Electrical Code.
  • Page 173 Notwithstanding any other provision to the contrary and regardless whether the contract is terminated or not, ABB and its affiliates are under no circumstances liable for damages and/or losses related to such security breaches, any unauthorized access, interference,...

  • Page 175: Dimension Drawings

    Dimension drawings 175 Dimension drawings Contents of this chapter The chapter contains the dimension drawings of the drive. The dimensions are in millimeters and inches.

  • Page 176: Frame R0

    176 Dimension drawings Frame R0 ￭ Frame R0 (front & side) - IP20 / UL open type...

  • Page 177: Frame R0 (Bottom & Rear) - Ip20 / Ul Open Type

    Dimension drawings 177 ￭ Frame R0 (bottom & rear) - IP20 / UL open type...

  • Page 178: Frame R1

    178 Dimension drawings Frame R1 ￭ Frame R1 (front & side) - IP20 / UL open type...

  • Page 179: Frame R1 (Bottom & Rear) - Ip20 / Ul Open Type

    Dimension drawings 179 ￭ Frame R1 (bottom & rear) - IP20 / UL open type...

  • Page 180: Frame R1 (Front & Side) - Ul Type 1 Kit Installed

    180 Dimension drawings ￭ Frame R1 (front & side) - UL Type 1 kit installed...

  • Page 181: Frame R1 (Bottom & Rear) - Ul Type 1 Kit Installed

    Dimension drawings 181 ￭ Frame R1 (bottom & rear) - UL Type 1 kit installed...

  • Page 182: Frame R2

    182 Dimension drawings Frame R2 ￭ Frame R2 (front & side) - IP20 / UL open type...

  • Page 183: Frame R2 (Bottom & Rear) - Ip20 / Ul Open Type

    Dimension drawings 183 ￭ Frame R2 (bottom & rear) - IP20 / UL open type...

  • Page 184: Frame R2 (Front & Side) - Ul Type 1 Kit Installed

    184 Dimension drawings ￭ Frame R2 (front & side) - UL Type 1 kit installed...

  • Page 185: Frame R2 (Bottom & Rear) - Ul Type 1 Kit Installed

    Dimension drawings 185 ￭ Frame R2 (bottom & rear) - UL Type 1 kit installed...

  • Page 186: Frame R3

    186 Dimension drawings Frame R3 ￭ Frame R3 (front & side) - IP20 / UL open type...

  • Page 187: Frame R3 (Bottom & Rear) - Ip20 / Ul Open Type

    Dimension drawings 187 ￭ Frame R3 (bottom & rear) - IP20 / UL open type...

  • Page 188: Frame R3 (Front & Side) - Ul Type 1 Kit Installed

    188 Dimension drawings ￭ Frame R3 (front & side) - UL Type 1 kit installed...

  • Page 189: Frame R3 (Bottom & Rear) - Ul Type 1 Kit Installed

    Dimension drawings 189 ￭ Frame R3 (bottom & rear) - UL Type 1 kit installed...

  • Page 190: Frame R4

    190 Dimension drawings Frame R4 ￭ Frame R4 (front & side) - IP20 / UL open type...

  • Page 191: Frame R4 (Bottom & Rear) - Ip20 / Ul Open Type

    Dimension drawings 191 ￭ Frame R4 (bottom & rear) - IP20 / UL open type...

  • Page 192: Frame R4 (Front & Side) - Ul Type 1 Kit Installed

    192 Dimension drawings ￭ Frame R4 (front & side) - UL Type 1 kit installed...

  • Page 193: Frame R4 (Bottom & Rear) - Ul Type 1 Kit Installed

    Dimension drawings 193 ￭ Frame R4 (bottom & rear) - UL Type 1 kit installed...

  • Page 195: Resistor Braking

    Resistor braking 195 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. Safety WARNING! Do not do work on the brake resistor or the resistor cable when the drive is energized.
  • Page 196 196 Resistor braking 2. Calculate resistance R with Equation 1. 3. Calculate energy E with Equation 2. Rpulse 4. Select the resistor so that the following conditions are met: • The rated power of the resistor must be greater than or equal to P Rmax •...

  • Page 197: Reference Brake Resistors

    Resistor braking 197 Braking cycle time (s) WARNING! Do not use a brake resistor with a resistance below the minimum value specified for the particular drive. The drive and the internal chopper are not able to handle the overcurrent caused by the low resistance. ￭...
  • Page 198 198 Resistor braking IEC type Example resistor R min R max P BRcont P BRmax 1) 2) ACS480- types 04-… Danotherm 018A-4 5.50 7.50 8.25 11.00 CBR-V 560 D HT 406 39R UL 026A-4 7.50 10.00 11.25 15.00 033A-4 11.00 15.00 22.00 CBT-H 560 D HT 406...

  • Page 199: Definitions

    Resistor braking 199 UL (NEC) Example resistor R min R max P BRcont P BRmax 1) 2) type types ACS480- Danotherm 04-… 3-phase U N = 480 V 02A1-4 0.55 0.75 0.83 1.10 CBH 360 C T 406 210R 03A0-4 0.75 1.00 1.13...

  • Page 200: Maximum Cable Length

    IGBT semiconductors of the brake chopper. Note: ABB has not verified that the EMC requirements are fulfilled with custom brake resistors and cabling. The customer must consider the EMC compliance of the complete installation.

  • Page 201: Protecting The System Against Thermal Overload

    (1) inside the resistor assembly. The switch indicates overtemperature. ABB recommends that you also wire the thermal switch to a digital input of the drive, and configure the input to cause a fault trip at resistor overtemperature indication.

  • Page 202: Mechanical And Electrical Installation Of Brake Resistor

    202 Resistor braking Mechanical and electrical installation of brake resistor WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. If you are not a qualified electrical professional, do not do installation or maintenance work. WARNING! Stop the drive and do the steps in section Electrical safety precautions (page 18)

  • Page 203: The Safe Torque Off Function

    The Safe torque off function 203 The 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 204: Compliance With The European Machinery Directive And The Uk Supply Of Machinery (Safety) Regulations

    204 The Safe torque off function Standard Name IEC 61000-6-7:2014 Electromagnetic compatibility (EMC) – Part 6-7: Generic stand- ards – Immunity requirements for equipment intended to perform functions in a safety-related system (functional safety) in indus- trial locations IEC 61326-3-1:2017 Electrical equipment for measurement, control and laboratory use –...

  • Page 205: Wiring

    The Safe torque off function 205 Wiring For the electrical specifications of the STO connection, see the technical data of the control unit. ￭ Connection principle Single ACS480 drive, internal power supply + 24 V DC OUT1 SGND UDC+ UDC- Drive Control unit Control logic...

  • Page 206: Single Acs480 Drive, External Power Supply

    206 The Safe torque off function Single ACS480 drive, external power supply 24 V DC OUT1 + 24 V DC SGND UDC+ UDC- Drive Control unit Control logic To motor Activation switch...

  • Page 207: Wiring Examples

    The Safe torque off function 207 ￭ Wiring examples Single ACS480 drive, internal power supply OUT1 SGND Drive Safety PLC Safety relay Single ACS480 drive, external power supply 24 V DC OUT1 SGND ÍN2 Drive Safety PLC Safety relay...

  • Page 208: Multiple Acs480 Drives, Internal Power Supply

    208 The Safe torque off function Multiple ACS480 drives, internal power supply OUT1 +24 V SGND OUT1 SGND OUT1 SGND Drive Control unit Activation switch...

  • Page 209: Multiple Acs480 Drives, External Power Supply

    The Safe torque off function 209 Multiple ACS480 drives, external power supply 24 V DC – OUT1 +24 V SGND OUT1 SGND OUT1 SGND Drive Control unit Activation switch ￭ Activation switch In the wiring diagrams, the activation switch has the designation [K]. This represents a component such as a manually operated switch, an emergency stop push button switch, or the contacts of a safety relay or safety PLC.

  • Page 210: Cable Types And Lengths

    210 The Safe torque off function • In case a manually operated activation switch is used, the switch must be of a type that can be locked out to the open position. • The contacts of the switch or relay must open/close within 200 ms of each other. ￭...

  • Page 211: Operation Principle

    The Safe torque off function 211 Operation principle 1. The Safe torque off activates (the activation switch is opened, or safety relay contacts open). 2. The STO inputs of the drive control unit de-energize. 3. The control unit cuts off the control voltage from the output IGBTs. 4.

  • Page 212: Start-Up Including Validation Test

    212 The Safe torque off function Start-up including validation 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 a validation test. The test must be performed •...
  • Page 213 The Safe torque off function 213 Action Test the operation of the STO function when the motor is stopped. •Give a stop command for the drive (if running) and wait until the motor shaft is at a standstill. Make sure that the drive operates as follows: •Open the STO circuit.

  • Page 214: Use

    214 The Safe torque off function 1. Open the activation switch, or activate the safety functionality that is wired to the STO connection. 2. The STO inputs on the drive control unit de-energize, and the control unit cuts off the control voltage from the output IGBTs. 3.
  • Page 215 The Safe torque off function 215 or is not otherwise acceptable, stop the drive and machinery using the appropriate stop mode before activating the Safe torque off function. • The Safe torque off function overrides all other functions of the drive. •...

  • Page 216: Maintenance

    If any wiring or component change is needed after start-up, or the parameters are restored, do the test given in section Validation test procedure (page 212). Use only spare parts approved by ABB. Record all maintenance and proof test activities in the machine logbook. ￭ Competence...

  • Page 217: Fault Tracing

    See the firmware manual of the drive control program 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 218: Safety Data

    218 The 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. PFD avg PFD avg Frame...

  • Page 219: Terms And Abbreviations

    The Safe torque off function 219 • 85 °C board temperature at 2.3% of time. • The STO is a type A safety component as defined in IEC 61508-2. • Relevant failure modes: • The STO trips spuriously (safe failure) •...

  • Page 220: Tüv Certificate

    After the mission time elapses, the safety device must be replaced. Note that any T M values given cannot be regarded as a guarantee or warranty. ￭ TÜV certificate The TÜV certificate is available on the Internet at www.abb.com/drives/documents.

  • Page 221: Declarations Of Conformity

    The Safe torque off function 221 ￭ Declarations of conformity...
  • Page 222 The product(s) referred in this declaration of conformity fulfil(s) the relevant provisions of other UK statutory requirements, which are notified in a single declaration of conformity 3AXD10001324452. Authorized to compile the technical file: ABB Limited, Daresbury Park, Cheshire, United Kingdom, WA4 4BT. Helsinki, May 7, 2021...

  • Page 223: Bapo-01 Auxiliary Power Extension Module

    BAPO-01 auxiliary power extension module 223 BAPO-01 auxiliary power extension module Contents of this chapter This chapter contains a description and technical data of the optional BAPO-01 auxiliary power extension module. Safety instructions WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur.

  • Page 224: Layout

    224 BAPO-01 auxiliary power extension module Note: The BAPO-01 is not a battery. If you change drive parameters when the control board is energized by the BAPO-01 module, force parameter saving by setting the value of parameter 96.07 PARAM SAVE to (1) SAVE.

  • Page 225: Mechanical Installation

    BAPO-01 auxiliary power extension module 225 Mechanical installation See the electrical installation instructions of the drive. Electrical installation Connect the external power supply to the +24 V and DGND terminals on the drive. See the electrical installation instructions of the drive. Do not chain an external 24 V DC power supply to several drives.

  • Page 226: Technical Data

    226 BAPO-01 auxiliary power extension module Technical data Voltage and current rating for the auxiliary power supply: +24 V DC ±10%, max. 1000 mA (including internal fan load). Power loss: Power losses with maximum load 4 W. Dimensions: 26 [1.024] 11.3 [0.444] 86.1 [3.391] 16 [0.63]...

  • Page 227: Bio-01 I/O Extension Module

    BIO-01 I/O extension module 227 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. Safety instructions WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur.

  • Page 228: Layout

    228 BIO-01 I/O extension module ￭ Layout 1. Locking tab 2. Option module slot 3. Chassis screw 4. I/O connector 5. Switches for configur- ing terminals S1 and S2 Mechanical installation See the electrical installation instructions of the drive. Before you install the BIO-01 option module, make sure that the chassis screw slider is in the top position.

  • Page 229: Electrical Installation

    The BIO-01 module has removable spring clamp terminals. Use ferrules on the multistranded conductor ends. The connection diagram below is applicable to drives with the BIO-01 I/O extension module when the ABB standard macro is selected (parameter 96.04). Terminal Description...
  • Page 230 230 BIO-01 I/O extension module Internal connections of GND and SCR terminals +24 V +24 V DGND DGND DCOM DCOM DIO1 +10V SGND OUT1...
  • Page 231 BIO-01 I/O extension module 231 Dimensions...

  • Page 233: Brel-01 Relay Output Extension Module

    BREL-01 relay output extension module 233 BREL-01 relay output extension module Contents of this chapter This chapter contains a description and technical data of the optional BREL-01 relay output extension module. Safety instructions WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur.

  • Page 234: Layout

     Product overview BREL-01 relay output extension module (option +L511) adds four relay outputs to the 234 BREL-01 relay output extension module drive.  Layout ￭ Layout 1. BREL module 1. BREL-01 module 2. Locking screw hole 2. Locking screw hole 3.

  • Page 235: Start-Up

    BREL-01 relay output extension module 235 Identification Description X103 Relay outputs RO4…RO7: Max. switching voltage: 250 V AC / 30 V DC Common Max. switching current: 2 A Normally closed Galvanically isolated. Normally open X104 Common Normally closed Normally open X105 Common Normally closed...
  • Page 236 236 BREL-01 relay output extension module Name/Value Description Def / FbEq16/32 15.04 RO status Displays the status of the relay outputs. This parameter 1 = 1 is read-only. Bit 0 RO4 1 = Relay output 4 is ON. Bit 1 RO5 1 = Relay output 5 is ON.

  • Page 237: Technical Data

    BREL-01 relay output extension module 237 Name/Value Description Def / FbEq16/32 Not energized Output is not energized. Energized Output is energized. For the complete parameter list, refer to the drive firmware manual. … 15.11 RO5 ON delay Defines the activation delay for relay output RO5. 0.0 s 0.0 …...
  • Page 238 238 BREL-01 relay output extension module Dimensions: 3AXD50000031148 rev. A...

  • Page 239: Further Information

    Product and service inquiries Address any inquiries about the product to your local ABB representative, quoting the type designation and serial number of the unit in question. A listing of ABB sales, support and service contacts can be found by navigating to www.abb.com/searchchannels.
  • Page 240 3AXD50000047392E © Copyright 2021 ABB. All rights reserved. Specifications subject to change without notice.

This manual is also suitable for:

Acs480 seriesAcs480-04-06a9-1Acs480-04-04a8-1Acs480-04-03a7-1Acs480-04-02a4-1Acs480-04-12a2-1

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