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ABB ACH480, Hardware Manual

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ABB ACH480 Hardware Manual Download Page 121

Capacitors

The DC link of the drive contains several electrolytic capacitors. Operating time, load,
and surrounding air temperature have an effect on the life of the capacitors. Capacitor
life can be extended by decreasing the surrounding air temperature.

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.

￭

Reforming the capacitors

The capacitors must be reformed if the drive has not been powered (either in storage
or unused) for a year or more. The manufacturing date is on the type designation label.
For information on reforming the capacitors, see

Capacitor reforming instructions

(3BFE64059629 [English]) in the ABB Library (

https://library.abb.com/en

).

Maintenance 121

Summary of Contents for ACH480

Page 1: ... ABB DRIVES FOR HVAC ACH480 drives Hardware manual ...

Page 2: ......

Page 3: ...0 drives Hardware manual Table of contents 1 Safety instructions 4 Mechanical installation 6 Electrical installation IEC 7 Electrical installation North America 3AXD50000245949 Rev B EN EFFECTIVE 2020 03 31 ...

Page 4: ......

Page 5: ... installation start up maintenance 21 Safety in operation 2 Introduction to the manual 23 Contents of this chapter 23 Applicability 23 Target audience 23 Categorization by frame size 24 Quick installation and commissioning flowchart 25 Terms and abbreviations 26 Related manuals 3 Operation principle and hardware description 29 Contents of this chapter 29 Operation principle 30 Simplified main circ...

Page 6: ...European Union 46 North America 46 Other regions 46 Selecting the main contactor 46 Checking the compatibility of the motor and drive 46 Selecting the power cables 46 General guidelines 47 Typical power cable sizes 48 Power cable types 48 Preferred power cable types 49 Alternate power cable types 50 Not allowed power cable types 50 Additional guidelines North America 51 Metal conduit 51 Power cabl...

Page 7: ...ol of a contactor between drive and motor 58 Protecting the contacts of relay outputs 6 Electrical installation IEC 61 Contents of this chapter 61 Warnings 61 Required tools 62 Measuring the insulation 62 Measuring the insulation of the drive 62 Measuring the insulation of the input power cable 62 Measuring the insulation of the motor and motor cable 63 Measuring the insulation of the brake resist...

Page 8: ... input power cable 88 Measuring the insulation of the motor and motor cable 89 Measuring the insulation of the brake resistor circuit 89 Earthing system compatibility check North America 90 EMC filter 90 Ground to phase varistor 90 When to disconnect ground to phase varistor or connect EMC filter 92 Disconnecting the ground to phase varistor or connecting the EMC filter 92 EMC VAR screw location 9...

Page 9: ...e drive 111 Contents of this chapter 111 Checklist 9 Maintenance 115 Contents of this chapter 115 Maintenance intervals 116 Cleaning the heatsink 117 Replacing the cooling fans 117 To replace the cooling fan for frame sizes R1 R2 and R3 119 To replace the cooling fan for frame R4 121 Capacitors 121 Reforming the capacitors 10 Technical data 123 Contents of this chapter 123 Electrical ratings 123 I...

Page 10: ...ty and motor cable length 144 EMC compatibility and motor cable length 145 Brake resistor connection data 145 Control connection data 146 Efficiency 146 Protection classes 146 Ambient conditions 147 Materials 147 Disposal 148 Applicable standards 148 Markings 149 EMC compliance IEC EN 61800 3 2004 A1 2012 149 Definitions 150 Category C1 150 Category C2 151 Category C3 151 Category C4 152 UL checkl...

Page 11: ...ter 173 Safety 173 Operation principle 173 Selecting the brake resistor 175 Reference brake resistors 176 Definitions 176 Selecting and routing the brake resistor cables 176 Minimizing electromagnetic interference 176 Maximum cable length 176 Placing the brake resistors 177 Protecting the system in brake circuit fault situations 177 Protecting the system in cable and brake resistor short circuit s...

Page 12: ...g acceptance test 190 Competence 190 Acceptance test reports 190 Acceptance test procedure 192 Use 193 Maintenance 193 Competence 194 Fault tracing 195 Safety data 196 Abbreviations 197 TÜV certificate 198 Declaration of conformity 14 BAPO 01 auxiliary power extension module 199 Contents of this chapter 199 Safety instructions 199 Hardware description 200 Layout 200 Mechanical installation 200 Ele...

Page 13: ...ule 207 Contents of this chapter 207 Safety instructions 207 Hardware description 207 Product overview 208 Layout 208 Mechanical installation 208 Electrical installation 209 Start up 209 Configuration parameters 211 Technical data Further information Table of contents 13 ...

Page 14: ...14 ...

Page 15: ...l you how to prevent the danger Notes draw attention to a particular condition or fact or give information on a subject The manual uses these warning symbols WARNING Electricity warning tells about hazards from electricity which can cause injury or death or damage to the equipment WARNING General warning tells about conditions other than those caused by electricity which can cause injury or death ...

Page 16: ...t there is sufficient cooling See the technical data Before you connect voltage to the drive make sure that all covers are in place Do not remove the covers when voltage is connected Before you adjust the drive operation limits make sure that the motor and all driven equipment can operate throughout the set operation limits Before you activate the automatic fault reset or automatic restart functio...

Page 17: ...nection is not possible Lock out and tag out Open the main disconnecting device of the drive If you have a permanent magnet motor connected to the drive disconnect the motor from the drive with a safety switch or by other means Disconnect any dangerous external voltages from the control circuits After you disconnect power from the drive always wait 5 minutes to let the intermediate circuit capacit...

Page 18: ...ealth hazard Note The motor cable terminals of the drive are at a dangerous voltage when the input power is on regardless of whether the motor is running or not When the input power is on the drive DC bus is at a dangerous voltage If brake chopper and resistor are in use they are at a dangerous voltage External wiring can supply dangerous voltages to the relay outputs of the control units of the d...

Page 19: ...urrent of the drive is higher than 3 5 mA AC or 10 mA DC you must use a fixed protective earth PE connection The minimum size of the protective earth conductor must comply with the local safety regulations for high protective earth conductor current equipment See standard IEC EN 61800 5 1 UL 61800 5 1 and the electrical planning instructions of the drive To comply with standard IEC EN 61800 5 1 UL...

Page 20: ...matically and continue operation after a fault or supply break If these functions are activated the installation must be clearly marked as defined in IEC EN 61800 5 1 subclause 6 5 3 for example THIS MACHINE STARTS AUTOMATICALLY Note The maximum drive power cycles is five times in ten minutes Power cycling the drive too often can damage the charging circuit of the DC capacitors If you need to star...

Page 21: ...usbar is close to 0 V Make sure that the voltage between the drive output terminals T1 U T2 V T3 W and the grounding PE busbar is close to 0 V Make sure that the voltage between the drive DC terminals R UDC and UDC and the grounding terminal PE is close to 0 V Install temporary grounding to the drive output terminals T1 U T2 V T3 W Connect the output terminals together as well as to the PE During ...

Page 22: ...22 ...

Page 23: ...ll start up and do maintenance work on the drive or create instructions for the end user of the drive concerning the installation and maintenance of the drive Read the manual before working on the drive You are expected to know the fundamentals of electricity wiring electrical components and electrical schematic symbols Categorization by frame size The drives are manufactured in frame sizes for ex...

Page 24: ... system compatibility check North America page 89 Installing the drive page 41 Install the drive Routing the cables page 53 Route the cables Measuring the insulation page 62 Measure the insulation of the input cable motor and motor cable Connecting the power cables IEC shielded cables page 69 Connect the power cables Connecting the power cables North America wiring in conduits page 94 Connecting t...

Page 25: ...cuit board in which the control program runs Control board DC circuit between rectifier and inverter DC link Energy storage which stabilizes the intermediate circuit DC voltage DC link capacitors Frequency converter for controlling AC motors Drive Embedded fieldbus EFB Electromagnetic compatibility EMC Fieldbus adapter FBA BACnet IP adapter module FBIP 21 Optional CANopen adapter module FCAN Optio...

Page 26: ...05 DPMP 02 03 mounting platform for ACx AP x control panel 3AXD50000009929 CDPI 01 02 panel bus adapter user s manual 3AXD50000158171 FBIP 21 BACnet IP adapter module quick guide 3AXD50000028468 FBIP 21 BACnet IP adapter module user s manual 3AXD50000158522 FENA 21 Ethernet adapter module quick guide 3AXD50000158560 FMBT 21 Modbus TCP adapter module quick guide 3AXD50000158607 FMBT 21 Modbus TCP a...

Page 27: ...and ACS480 installation guide frames R0 to R2 3AXD50000242375 UL Type 1 kit for ACS380 ACH480 and ACS480 installation guide frames R3 to R4 Tool and maintenance manuals 3AUA0000094606 Drive composer PC tool user s manual 3BFE64059629 Converter module capacitor reforming instructions You can find manuals and other product documents in PDF format on the Internet at www abb com drives documents The c...

Page 28: ...28 ...

Page 29: ...gnation information It shows a general diagram of the power connections and control interfaces Operation principle The ACH480 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 mounting Operation principle and hardware description 29 ...

Page 30: ...age exceeds a certain maximum limit The voltage rise is typically caused by deceleration braking of a motor The user obtains and installs the brake resistor when necessary 4 Product variants The drive has two product variants Standard unit drive for example ACH480 04 02A7 4 with ACH AP H assistant control panel and I O EIA 485 module RIIO 01 Base unit drive for example ACH480 04 02A7 4 0J400 0L540...

Page 31: ...ation label 3 Fixed control terminals 13 Control panel connection 4 Cold configuration connection CCA 01 14 Control panel 5 Option slot for communication modules 15 EMC filter grounding screw 6 I O or fieldbus module 16 Varistor grounding screw 7 Side option slot for side mounted options 17 PE connection motor 8 Input power terminal 9 Operation principle and hardware description 31 ...

Page 32: ...ON RO1C RO1A RO1B 24V DGND DCOM SGND OUT1 1 1 3 2 4 4 5 6 7 8 9 10 Connections of the base unit 1 Auxiliary voltage outputs 2 Digital inputs 3 Safe torque off connections 4 Relay output connections 5 Cold configuration connection for CCA 01 Connections of the RIIO 01 I O EIA 485 module 6 Digital inputs 7 Analog inputs and outputs 8 Embedded fieldbus EIA 485 Modbus RTU BACnet MS TP N2 9 Auxiliary v...

Page 33: ...ary 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 Option modules The drive can be equipped with various option module s See Type designation key page 36 Operation principle and hardware description 33 ...

Page 34: ...ing platform flush mounting and cable1 DPMP 01 Control panel mounting platform surface mounting and cable1 DPMP 02 DPMP 02 panel mounting platform and cable and RDUM 01 blank panel with RJ 45 connector DPMP EXT2 1 You need also RDUM 01 blank panel or CDPI 02 panel bus adapter to connect the panel cable at the drive end UL Type 1 kits There are UL Type 1 kit options available for the drive For more...

Page 35: ...l UL NEC 1 2 3 4 5 6 Type designation 1 Frame size 2 Degree of protection 3 Nominal ratings 4 Valid markings 5 S N Serial number of format MYYWWXXXX where M Manufacturer YY Year of manufacture 15 16 17 for 2015 2016 2017 WW Week of manufacture 01 02 03 for week 1 week 2 week 3 XXXX Running item number that starts each week from 0001 6 Operation principle and hardware description 35 ...

Page 36: ...es Description Code Control panel and panel options ACH AP H control panel J400 RDUM 01 blank cover with RJ45 connection for remote mounting of the control panel J424 ACH AP W control panel with Bluetooth J429 Without control panel 0J400 I O options BREL 01 relay output extension module L511 BIO 01 I O extension module front option can be used with fieldbus L515 BAPO 01 external 24 V DC power exte...

Page 37: ...uage An English manual is included if a translation is not available English R700 German R701 Italian R702 Dutch R703 Danish R704 Swedish R705 Finnish R706 French R707 Spanish R708 Portuguese Brazil R709 Russian R711 Chinese R712 Polish R713 Turkish R714 Operation principle and hardware description 37 ...

Page 38: ...38 ...

Page 39: ...e has an IP20 UL open type protection classification for cabinet installation A UL Type 1 kit is available as an option Make sure that there is a minimum of 75 mm 3 in of free space at the top and bottom of the drive at the cooling air inlet and outlet measured from the frame With the optional UL Type 1 kit make sure that there is at least 50 mm 2 in of free space at the top measured from the top ...

Page 40: ...e technical data The wall behind the unit and the material above and below the unit is of non flammable material The installation surface is as close to vertical as possible and strong enough to support the drive There is sufficient free space around the drive for cooling maintenance and operation See the free space specifications for the drive Make sure that there are no sources of strong magneti...

Page 41: ...arning sticker sheet residual voltage warning Safety instructions Quick installation and start up guide Hardware and firmware manuals if ordered with a plus code Installing the drive To install the drive with screws 1 Make marks onto the surface for the mounting holes Use the included mounting template for frames R3 and R4 For other frames see the dimension drawings 2 Drill the holes for the mount...

Page 42: ...ht 35 7 5 mm 1 4 0 3 in 1 Move the locking part to the left 1 2 3 2 Push and hold the locking button down 1 2 3 3 Put the top tabs of the drive onto the top edge of the DIN installation rail 4 Put the drive against the bottom edge of the DIN installation rail 5 Release the locking button 42 Mechanical installation ...

Page 43: ...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 Mechanical installation 43 ...

Page 44: ...44 ...

Page 45: ...isconnecting device You must equip the drive with a main supply disconnecting device which meets the local safety regulations You must be able to lock the disconnecting device to the open position for installation and maintenance work European Union To meet the European Union Directives according to standard EN 60204 1 Safety of Machinery the disconnecting device must be one of the following types...

Page 46: ...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 Make sure that the motor s and the drive are compatible according to the rating table in the technical data Selecting the...

Page 47: ...e same metal If this is not so the cross sectional area of the protective earthing conductor shall be determined in a manner which produces a conductance equivalent to that which results from the application of this table Minimum cross sectional area of the corres ponding protective conductor Sp mm2 Cross sectional area of the phase conduct ors S mm2 S1 S 16 16 16 S 35 S 2 35 S 1 To comply with st...

Page 48: ... phase conductors and concentric PE conductor as shield or armor Yes Yes PE Symmetrical shielded or ar mored cable with three phase conductors and symmetrically constructed PE conductor and a shield or armor Yes Yes PE Symmetrical shielded or ar mored cable with three phase conductors and a shield or ar mor and separate PE conduct or cable1 1 A separate PE conductor is required if the conductivity...

Page 49: ... 100 kW 135 hp A potential equaliza tion between the frames of mo tor and driven equipment is re quired Yes Well shielded Al Cu shield or armor four conductor cable three phase conductors and a PE No Yes PE WARNING If you use unshielded single core cables in an IT network make sure that the non conductive outer sheath jacket of the cables have good contact with a properly grounded conductive sur f...

Page 50: ... of symmetrical shielded VFD cable between drive and motor s Notes Wiring method Conduit Metallic1 2 Prefer symmetrical shielded VFD cable Electrical metallic tubing Type EMT Use separate conduit run for each motor Rigid metal conduit Type RMC Do not run input power wiring and motor wiring in the same conduit Liquid tight flexible metal electrical conduit Type LFMC Conduit Non metallic2 3 Prefer s...

Page 51: ...f the joint Also bond the conduits to the drive enclosure and motor frame Use separate conduits for input power motor brake 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 To effectively s...

Page 52: ...s in the same cable Signals that can be run in the same cable If their voltage does not exceed 48 V relay controlled signals can be run in the same cables as digital input signals The relay controlled signals should be run as twisted pairs 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...

Page 53: ...nd to the grounding electrodes Aluminum tray systems can be used to improve local equalizing of potential The following figure illustrates the cable routing guidelines with an example drive Note When motor cable is symmetrical and shielded and it has short parallel runs with other cables 1 5 m 5 ft distances between the motor cable and other cables can be reduced by half min 200 mm 8 in 90 min 500...

Page 54: ...n level when safety switches contactors connection boxes or similar equipment are installed on the motor cable between the drive and the motor Install the equipment in a metal enclosure Use either a symmetrical shielded cable or install the cabling in a metal conduit Make sure that there is a good and continuous galvanic connection in the shield conduit between drive and motor Connect the shield c...

Page 55: ...protect the input power cable against short circuits See the drive technical data for alternative short circuit protections Protecting the motor and motor cable in short circuits The drive protects the motor cable and motor in a short circuit situation when the motor cable is sized according to the nominal current of the drive No additional protection devices are needed Protecting the drive and th...

Page 56: ...r against overload without using motor thermal model or temperature sensors Motor overload protection is required and specified by multiple standards including the US National Electric Code NEC UL 508C and the common UL IEC 61800 5 1 standard in conjunction with IEC 60947 4 1 The standards allow for motor overload protection without external temperature sensors The protection feature allows the us...

Page 57: ...forced insulation between the motor live parts and the digital input of the drive Protecting the drive against ground faults The drive is equipped with an internal ground fault protective function to protect the unit against ground faults in the motor and motor cable This function is not a personnel safety or a fire protection feature See the firmware manual for more information Residual current d...

Page 58: ...he drive controls the motor The motor control operates faster than the contactor and tries to maintain the load current This can cause damage to the contactor When you select the vector motor control mode and the motor coast stop mode you can open the contactor immediately after the drive has received the stop command This is the case also if you use the scalar motor control mode Protecting the co...

Page 59: ...230 V AC 230 V AC 24 V DC 1 2 3 4 Relay output 1 Varistor 2 RC filter 3 Diode 4 Guidelines for planning the electrical installation 59 ...

Page 60: ...60 ...

Page 61: ...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 Required tools To do the electrical installation you need the following tools wire stripper screwdriver or wrench with a set of suitable bits For motor cable terminals the recommended screwdriver s...

Page 62: ...the motor and motor cable 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 Do the steps in section Electrical safety precautions page 17 before you start the work 2 Make sure that the motor cable is disconnected from the drive outp...

Page 63: ...ore you start the work 2 Make sure that the resistor cable is connected to the resistor and disconnected from the drive output terminals 3 At the drive end connect the R and R conductors of the resistor cable together Measure the insulation resistance between the conductors and the PE conductor with a measuring voltage of 1000 V DC The insulation resistance must be more than 1 Mohm R R ohm PE 1 kV...

Page 64: ...amage to the drive Ground to phase varistor A drive with the ground to phase varistor connected can be installed to a symmetrically grounded TN S system If you install the drive to another system you may need to disconnect the varistor See When to disconnect EMC filter or ground to phase varistor WARNING Do not install the drive with the ground to phase varistor connected to a system that the vari...

Page 65: ...resistance groun ded C Corner grounded delta B1 mid point grounded delta B2 and TT D systems Symmetrically grounded TN S systems i e center grounded wye A Remove Remove Do not remove Metal EMC Remove Do not remove Do not remove Frames R1 R3 R4 Metal VAR Do not remove Do not remove Do not remove Frame R2 Plastic A B1 B2 A C D L1 L2 L3 N PE L1 L2 L3 PE L1 L2 L3 L1 L2 L3 N PE L1 L2 L3 PE L1 L2 L3 N E...

Page 66: ...ase varistor page 64 Obey the guidelines 1 Do the steps in section Electrical safety precautions page 17 before you start the work 2 To disconnect the EMC filter remove the metal EMC screw 3 To disconnect the varistor remove the metal VAR screw EMC VAR screw location Frame R1 R2 Frame R4 Frame R3 66 Electrical installation IEC ...

Page 67: ...thing system of the electrical power network WARNING Only a qualified electrical professional may do the work instructed in this section Depending on the installation site the work may even be categorized as live working Continue only if you are an electrical professional certified for the work Obey the local regulations If you ignore them injury or death can occur To identify the earthing system ...

Page 68: ...X Midpoint grounded delta system nonsym metrical 0 5 X 0 5 X 0 866 X X IT systems ungrounded or high resistance grounded 30 ohms nonsymmetrical Varying level versus time Varying level versus time Varying level versus time X TT system the protective earth connection for the consumer is provided by a local earth electrode and there is another inde pendently installed at the generator Varying level v...

Page 69: ...oss sectional area of 10 mm2 Cu the minimum cross sectional area of an individual PE conductor is 2 5 mm2 Cu Separate PE cable line side Use it if the conductivity of the fourth conductor or shield is not sufficient for the protective grounding 4 Motor cable 5 Separate PE cable motor side Use it if the conductivity of the shield is not sufficient for the protective earth conductor or there is no s...

Page 70: ...utions page 17 before you start the work 2 Open the locking screw of the drive front cover and lift the front cover up 3 Attach the residual voltage warning sticker in the local language to the drive 4 Strip the motor cable 5 Ground the motor cable shield under the grounding clamp 360 degree grounding 6 Twist the motor cable shield into a bundle mark it with yellow green insulation tape fit a cabl...

Page 71: ... the shield under the clamp 360 degree grounding Twist the shield also into a bundle mark it with yellow green insulation tape fit a cable lug and connect it to the grounding terminal 11 Connect the PE conductors of the input power cable to the grounding terminal 12 Connect the phase conductors of the input power cable to the L1 L2 and L3 input terminals 13 Mechanically attach all of the cables on...

Page 72: ...utput frequency 0 10 V AI1 Analog input circuit common AGND Reference voltage 10 V DC 10V Not configured AI2 Analog input circuit common AGND Output frequency 0 20 mA AO1 Motor current 0 20 mA AO2 Analog output circuit common AGND Digital inputs and auxiliary voltage output Aux voltage output 24 V DC max 250 mA3 24V 24 V DGND DCOM DI1 DI2 DI3 DI4 DI5 DI6 24 V DGND DCOM DI1 DI2 DI3 DI4 DI5 DI6 Aux ...

Page 73: ... on 1 off TERM Safe torque off Safe torque off Factory connection Both circuits must be closed for the drive to start SGND OUT1 SGND IN1 IN2 IN1 IN2 OUT1 Auxiliary voltage input output Aux voltage output 24 V DC max 250 mA3 24V 24 V DGND DCOM Aux voltage output common DGND Digital input common for all DCOM 1 Terminal size 0 14 1 5 mm2 26 16 AWG Tightening torque 0 5 0 6 N m 4 4 5 3 lbf in 2 base u...

Page 74: ...ommon RO1C Norm closed RO1A Norm open RO1B Safe torque off Safe torque off Factory connection Both circuits must be closed for the drive to start SGND OUT1 SGND IN1 IN2 IN1 IN2 OUT1 Fieldbus connection K457 FCAN 01 CANopen DSUB9 See the applicable fieldbus adapter manu al K454 FPBA 01 Profibus DP DSUB9 K465 FBIP 21 BACnet IP RJ45 2 K469 FECA 01 EtherCAT RJ45 2 K475 FENA 21 Ethernet IP Profinet Mod...

Page 75: ...ties 4 Strip the control cable conductors 5 Connect the conductors to the correct control terminals Tightening torque 0 5 0 6 N m 4 4 5 3 lbf in 6 Connect the shields and grounding wires to the SCR terminal Tightening torque 0 5 0 6 N m 4 4 5 3 lbf in 7 Mechanically attach the control cables on the outside of the drive Additional information on the control connections Connecting EIA 485 fieldbus c...

Page 76: ...n at both ends on the fieldbus For the drive the termination switch position is ON 2 Fieldbus controller 3 Fieldbus 4 PNP configuration for digital inputs Internal and external 24 V power supply connections for PNP source configuration are shown in the figure below External 24 V power supply Internal 24 V power supply 0 V DC 24 V DC DI1 DI2 DI3 DI4 DI5 DI6 24 V DGND DCOM DI1 DI2 DI3 DI4 DI5 DI6 24...

Page 77: ...I5 DI6 24 V DGND DCOM DI1 DI2 DI3 DI4 DI5 DI6 24 V DGND DCOM 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 AO2 AGND 500 ohm 0 10 V AO2 AGND 1 kohm 0 10 V 1 kohm Analog output 2 Default output 0 20 mA AO2 Analog common ground A...

Page 78: ... 24V DGND AI and AO or AI DI and 10 V as PTC motor temperature sensor interface WARNING IEC 60664 and IEC 61800 5 1 require double or reinforced insulation between live parts and accessible parts when the accessible parts are not conductive or the accessible parts are conductive but not connected to the protective earth Obey this requirement when you plan the connection of the motor temperature se...

Page 79: ...ND AOn 1 2 3 AGND 1 3 PTC sensors 1 Analog input Set the analog input type to V volt in parameter group 12 Standard AI Define the temperature sensor type signal source etc with parameters 35 11 35 24 For the sensor type select PTC analog I O 2 Analog output Select the Excitation mode for the analog output in parameter group 13 Standard AO 3 PTC connection 2 If no analog output is available for the...

Page 80: ...nductive but not connected to the protective earth Obey this requirement when you plan the connection of the motor temperature sensor to the drive If the motor temperature sensor has a reinforced insulation vs the motor windings you can connect it directly to the drive IO interface This section shows the connection If the sensor has no reinforced insulation you must use another type of connection ...

Page 81: ... auxiliary power supply terminals both on the base unit and on the RIIO 01 module You can use them to supply auxiliary power from the drive to external control circuits or option modules to supply external auxiliary power to the drive to keep the control and cooling in operation if there is a power outage See the technical data for the specifications for the auxiliary power supply terminals input ...

Page 82: ...connected Note You cannot use the control panel keys when the drive is connected to a PC If you have a RDUM 01 blank panel or CDPI 02 panel bus adapter installed use a BCBL 01 USB RJ45 converter to connect to the PC It is also possible to use a CCA 01 configuration adapter when the drive is not connected to the power supply network or to an external 24 V supply The CCA 01 does not operate if the d...

Page 83: ...start the work 2 Loosen the locking screw of the front cover and lift the front cover up 3 If the option module has a locking tab pull it up 4 Carefully align the option module with the option module slot in the front of the drive 5 Fully push the option module into position 6 If the option module has a locking tab push it down until it locks 7 Tighten the locking screw to fully attach and electri...

Page 84: ...fied electrical professional do not do installation or maintenance work 1 Stop the drive and do the steps in section Electrical safety precautions page 17 before you start the work 2 Remove the two screws from the front most grounding clamp at the bottom of the drive 3 Carefully align the side option with the connectors on the right side of the drive 4 Fully push the option module into position 5 ...

Page 85: ... the grounding bar to the bottom of the side option and to the front ground tab on the drive 7 Connect the control cables See the control cable connection instructions 5 6 7 2 3 4 Electrical installation IEC 85 ...

Page 86: ...86 ...

Page 87: ...ct the power and control cables install optional modules connect a PC Warnings 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 Required tools To do the electrical installation you need the following tools wire stripper Electrical in...

Page 88: ...rive measure its insulation according to local regulations Measuring the insulation of the motor and motor cable 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 Do the steps in section Electrical safety precautions page 17 before ...

Page 89: ...u start the work 2 Make sure that the resistor cable is connected to the resistor and disconnected from the drive output terminals 3 At the drive end connect the R and R conductors of the resistor cable together Measure the insulation resistance between the conductors and the PE conductor with a measuring voltage of 1000 V DC The insulation resistance must be more than 1 Mohm R R ohm PE 1 kV DC 1 ...

Page 90: ...varistor The drive is equipped with an internal ground to phase varistor as standard For frame sizes R1 R3 and R4 the varistor is connected as default For frame size R2 the varistor is disconnected as default A drive with the ground to phase varistor connected can be installed to a symmetrically grounded TN S system If you install the drive to another system you may need to disconnect the varistor...

Page 91: ...stems i e center grounded wye A Maintain the plastic screw Maintain the plastic screw Can install the metal screw 1 Plastic EMC Remove the metal screw Maintain the metal screw Maintain the metal screw Frames R1 R3 R4 metal VAR Maintain the plastic screw Maintain the plastic screw Maintain the plastic screw Frame R2 plastic A B1 B2 A C D L1 L2 L3 N PE L1 L2 L3 PE L1 L2 L3 L1 L2 L3 N PE L1 L2 L3 PE ...

Page 92: ...the guidelines 1 Do the steps in section Electrical safety precautions page 17 before you start the work 2 To disconnect the varistor remove the metal VAR screw 3 To connect the EMC filter remove the plastic EMC screw and replace it with the metal screw included in the drive delivery EMC VAR screw location Frame R1 R2 Frame R4 Frame R3 92 Electrical installation North America ...

Page 93: ... system of the electrical power network WARNING Only a qualified electrical professional may do the work instructed in this section Depending on the installation site the work may even be categorized as live working Continue only if you are an electrical professional certified for the work Obey the local regulations If you ignore them injury or death can occur To identify the earthing system exami...

Page 94: ...ymmetrical Varying level versus time Varying level versus time Varying level versus time X TT system the protective earth connection for the consumer is provided by a local earth electrode and there is another inde pendently installed at the generator Varying level versus time Varying level versus time Varying level versus time X Connecting the power cables North America wiring in conduits Use ins...

Page 95: ...n individual PE conductor is 2 5 mm2 Cu Motor wiring 5 Brake resistor wiring optional 6 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 140 for the tightening tor...

Page 96: ...es make sure that all option modules are installed Default I O connection diagrams HVAC default The connection diagrams below are valid for the standard drive variant that is drive equipped with the RIIO 01 I O EIA 485 module 2 Description Term 1 Connection Analog inputs and outputs Signal cable shield screen SCR SCR AI1 AGND 10 V AI2 AGND AO1 AO2 AGND 1 10 kohm Max 500 ohm Output frequency 0 10 V...

Page 97: ...max 250 mA3 24V RO2C RO2A RO2B RO3C RO3A RO3B RO1C RO1A RO1B 24 V DGND DCOM 24 V DGND DCOM Aux voltage output common DGND Digital input common for all DCOM Damper control 250 V AC 30 V DC 2 A Common RO1C Norm closed RO1A Norm open RO1B Running 250 V AC 30 V DC 2 A Common RO2C Norm closed RO2A Norm open RO2B Fault 1 250 V AC 30 V DC 2 A Common RO3C Norm closed RO3A Norm open RO3B Embedded EIA 485 E...

Page 98: ...us connection diagram The connection diagrams are valid for the base unit equipped with an optional fieldbus adapter module 2 Description Term 1 Connection Auxiliary voltage output and digital inputs Aux voltage output 24 V DC max 250 mA 24V 24 V DGND DCOM DI1 DI2 24 V DGND DCOM DI1 DI2 Aux voltage output common DGND Digital input common for all DCOM Stop 0 Start 1 DI1 Not configured DI2 Relay out...

Page 99: ...inals as possible to prevent inductive coupling 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 Stop the drive and do the steps in Electrical safety precautions page 17 before you start the work 2 Strip a part of the outer shield ...

Page 100: ...for data signaling The distributed capacitance between conductors is less than 100 pF per meter 30 pF per foot Distributed capacitance between conductors and shield is less than 200 pF per meter 60 pF per foot Foil or braided shields are acceptable ON 1 ON 1 ON 1 B A DGND ON 1 ON 1 ON 1 B A DGND ON 1 ON 1 ON 1 B A DGND 1 2 1 2 1 2 3 4 Drive 1 Termination switch Termination must be on at both ends ...

Page 101: ...DC DI1 DI2 DI3 DI4 DI5 DI6 24 V DGND DCOM DI1 DI2 DI3 DI4 DI5 DI6 24 V DGND DCOM NPN configuration for digital inputs Internal and external 24 V power supply connections for NPN sink configuration are shown in the figure below External 24 V power supply Internal 24 V power supply 0 V DC 24 V DC DI1 DI2 DI3 DI4 DI5 DI6 24 V DGND DCOM DI1 DI2 DI3 DI4 DI5 DI6 24 V DGND DCOM Electrical installation No...

Page 102: ...les of connections for a two wire or three wire sensor transmitter that is supplied by the auxiliary voltage output of the drive P I 4 20 mA AI2 AGND 24V DGND Process actual value measurement or reference 0 4 20 mA Rin 137 ohm If the sensor power supply comes through its current output circuit use 4 20 mA signal not 0 20 mA AI2 AGND Auxiliary voltage output non isolated 24 V DC max 250 mA 24V DGND...

Page 103: ... page 56 See the firmware manual for information on the related Motor thermal protection function and the required parameter settings PTC connection 1 1 3 PTC sensors can be connected in series to an analog input and an analog output The analog output feeds a constant excitation current of 1 6 mA through the sensor The sensor resistance increases as the motor temperature rises as does the voltage ...

Page 104: ... AI1 and AI2 as Pt100 Pt1000 Ni1000 KTY83 and KTY84 sensor inputs WARNING IEC 60664 and IEC 61800 5 1 require double or reinforced insulation between live parts and accessible parts when the accessible parts are not conductive or the accessible parts are conductive but not connected to the protective earth Obey this requirement when you plan the connection of the motor temperature sensor to the dr...

Page 105: ...age connection The drive has 24 V DC 10 auxiliary power supply terminals both on the base unit and on the RIIO 01 module You can use them to supply auxiliary power from the drive to external control circuits or option modules to supply external auxiliary power to the drive to keep the control and cooling in operation if there is a power outage See the technical data for the specifications for the ...

Page 106: ...cted Note You cannot use the control panel keys when the drive is connected to a PC If you have a RDUM 01 blank panel or CDPI 02 panel bus adapter installed use a BCBL 01 USB RJ45 converter to connect to the PC It is also possible to use a CCA 01 configuration adapter when the drive is not connected to the power supply network or to an external 24 V supply The CCA 01 does not operate if the drive ...

Page 107: ...the work 2 Loosen the locking screw of the front cover and lift the front cover up 3 If the option module has a locking tab pull it up 4 Carefully align the option module with the option module slot in the front of the drive 5 Fully push the option module into position 6 If the option module has a locking tab push it down until it locks 7 Tighten the locking screw to fully attach and electrically ...

Page 108: ...lectrical professional do not do installation or maintenance work 1 Stop the drive and do the steps in section Electrical safety precautions page 17 before you start the work 2 Remove the two screws from the front most grounding clamp at the bottom of the drive 3 Carefully align the side option with the connectors on the right side of the drive 4 Fully push the option module into position 5 Tighte...

Page 109: ...rounding bar to the bottom of the side option and to the front ground tab on the drive 7 Connect the control cables See the control cable connection instructions 5 6 7 2 3 4 Electrical installation North America 109 ...

Page 110: ...110 ...

Page 111: ... 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 17 before you start the work Make sure that The ambient operating conditions meet the drive ambient condi...

Page 112: ... an adequately sized protective earth ground conductor between the motor and the drive and the conductor is connected to the correct terminal and the terminal is tightened to the correct torque Proper grounding has also been measured according to the regulations The motor cable is connected to the correct terminals the phase order is correct and the terminals are tightened to the correct torque Th...

Page 113: ...al overload device must be used for protection when bypassing the drive Refer to local codes and regulations There are no tools foreign objects or dust from drilling inside the drive 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 ...

Page 114: ...114 ...

Page 115: ... available on the Internet www abb com drivesservices For more information consult your local ABB Service representative www abb com searchchannels Recommended annual actions by the user Connections and environment P Quality of the supply voltage Spare parts I Spare parts P Reforming DC circuit capacitors of spare modules Inspections I Tightness of terminals I Dustiness corrosion and temperature P...

Page 116: ... your local ABB Service representative for additional maintenance recommendations 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 When necessary clean the heatsink as follows WARNING Obey the safety instructions of the drive If you ignore them injury or death or damage to the...

Page 117: ...ement fans from ABB Use only ABB specified spare parts To replace the cooling fan for frame sizes R1 R2 and 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 1 Stop the drive and do the steps in section Electrical safety precaution...

Page 118: ...hat 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 6 7 8 Connect the fan power cable 9 Put the fan power cable into the cable slot in the drive 8 9 10 Carefully put the fan cover into position in the drive Make sure that the fan power cable is routed correctly 118 Maintenance ...

Page 119: ...r death or damage to the equipment can occur If you are not a qualified electrical professional do not do installation or maintenance work 1 Stop the drive and do the steps in section Electrical safety precautions page 17 before you start the work 2 Use a suitable flat screwdriver to open the fan cover 2 3 Lift out the fan cover and set it aside 3 Maintenance 119 ...

Page 120: ... power cable from the extension cable connector 4 5 6 Replace the fan The arrow indicating the air flow direction must point up 7 Connect the fan power cable 6 7 8 Place the fan cover back on the frame 9 Push the cover to lock into position 8 9 120 Maintenance ...

Page 121: ... 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 Reforming the capacitors The capacitors must be reformed if the drive has not been powered either in storage or unused for a year or more The manufacturing date is on the type designation label For information on reforming the capacitors see Capacitor reforming ...

Page 122: ...122 ...

Page 123: ... current With choke No choke PLd ILd PN IN Imax I1 I1 kW A kW A A A A 3 phase UN 400 V R1 0 75 2 5 0 75 2 6 3 2 2 6 4 2 02A7 4 R1 1 1 3 1 1 1 3 3 4 7 3 3 5 3 03A4 4 R1 1 5 3 8 1 5 4 0 5 9 4 0 6 4 04A1 4 R1 2 2 5 3 2 2 5 6 7 2 5 6 9 0 05A7 4 R1 3 0 6 8 3 0 7 2 10 1 7 2 11 5 07A3 4 R1 4 0 8 9 4 0 9 4 13 0 9 4 15 0 09A5 4 R2 5 5 12 0 5 5 12 6 16 9 12 6 20 2 12A7 4 R3 7 5 16 2 7 5 17 0 22 7 17 0 27 2 ...

Page 124: ...e PLd ILd PN IN Imax I1 I1 hp A hp A A A A 3 phase UN 480 V R1 1 0 2 1 1 0 2 1 2 9 2 1 3 4 02A1 4 R1 1 5 3 0 1 5 3 0 3 8 3 0 4 8 03A0 4 R1 2 0 3 5 2 0 3 5 5 4 3 5 5 6 03A5 4 R1 3 0 4 8 3 0 4 8 6 1 4 8 7 7 04A8 4 R1 3 0 6 0 3 0 6 0 7 2 6 0 9 6 06A0 4 R1 5 0 7 6 5 0 7 6 8 6 7 6 12 2 07A6 4 R2 7 5 11 0 7 5 11 0 13 7 11 0 17 6 011A 4 R3 10 0 14 0 10 0 14 0 19 8 14 0 22 4 014A 4 R3 15 0 21 0 15 0 21 0 ...

Page 125: ...current Allows 10 overload for 1 minute every 10 minutes PLd Typical motor power in light duty use 10 overload The kilowatt ratings are applicable to most IEC 4 pole 400 V 50 Hz motors The horsepower ratings are applicable to most NEMA 4 pole motors 460 V 60 Hz Sizing ABB recommends the DriveSize tool for selecting the drive motor and gear combination http new abb com drives software tools drivesi...

Page 126: ...late the derated current The drive type is ACH480 04 014A 4 which has nominal output current IN of 14 A at 480 V Calculate the derated output current at 4 kHz switching frequency at 6000 ft altitude and at 131 F surrounding air temperature Switching frequency derating Derating is not necessary at 4 kHz Altitude derating The derating factor for 6000 ft is Surrounding air temperature derating The de...

Page 127: ...lication requires a maximum of 12 0 A of motor current with a 10 overload for one minute every ten minutes ILd at a switching frequency of 8 kHz The supply voltage is 480 V the altitude is 5500 ft and the surrounding air temperature is 95 F Altitude derating The derating factor for 5500 ft is Surrounding air temperature derating Derating is not necessary at 95 F surrounding air temperature To see ...

Page 128: ... A maximum altitude of 4000 m 13123 ft is permitted for these earthing systems TN S TT A maximum altitude of 2000 m 6562 ft is permitted for these earthing systems corner grounded delta IT ungrounded Above 2000 m 6562 ft the maximum permitted voltage for the relay output RO1 decreases At 4000 m 13123 ft it is 30 V Above 2000 m 6562 ft the maximum permitted potential difference between the adjacent...

Page 129: ... range 40 60 C 104 140 F Derating factor IEC type ACH480 04 12 kHz 8 kHz 4 kHz 3 phase UN 400 V 0 48 0 65 1 0 02A7 4 0 48 0 65 1 0 03A4 4 0 48 0 65 1 0 04A1 4 0 48 0 65 1 0 05A7 4 0 48 0 65 1 0 07A3 4 0 48 0 65 1 0 09A5 4 0 51 0 68 1 0 12A7 4 0 51 0 68 1 0 018A 4 0 51 0 67 1 0 026A 4 0 49 0 65 1 0 033A 4 0 49 0 65 1 0 039A 4 0 49 0 66 1 0 046A 4 0 49 0 66 1 0 050A 4 Derating factor UL NEC type ACH...

Page 130: ...rating time of the fuse is less than 0 5 seconds Obey the local regulations gG fuses Min short circuit current1 Drive input current IEC type ACH480 04 IEC 60269 size ABB type Voltage rating I2t Nominal current V A2s A A A 3 phase UN 400 V 000 OFAF000H6 500 110 6 48 4 2 02A7 4 000 OFAF000H6 500 110 6 48 5 3 03A4 4 000 OFAF000H10 500 360 10 80 6 4 04A1 4 000 OFAF000H10 500 360 10 80 9 0 05A7 4 000 O...

Page 131: ...50 0 039A 4 00 170M2702 690 22500 160 800 56 0 046A 4 00 170M2702 690 22500 160 800 60 0 050A 4 1 Minimum permitted short circuit current of the electrical power network UL NEC fuses Fuses Drive in put cur rent UL NEC type ACH480 04 Max fuse rating for group install ation1 Type Bussmann Edison type Voltage rating Nomin al cur rent A V A A 3 phase UN 480 V 25 UL class T JJS TJS6 600 6 4 2 02A1 4 25...

Page 132: ... Littelfuse Bussmann Voltage rating Max current V A A 3 phase UN 480 V TJS6 A6T6 JLLS006 JJS 6 600 6 4 2 02A1 4 TJS6 A6T6 JLLS006 JJS 6 600 6 5 3 03A0 4 TJS10 A6T10 JLLS010 JJS 10 600 10 6 4 03A5 4 TJS10 A6T10 JLLS010 JJS 10 600 10 9 0 04A8 4 TJS20 A6T20 JLLS020 JJS 20 600 20 11 5 06A0 4 TJS20 A6T20 JLLS020 JJS 20 600 20 15 0 07A6 4 TJS25 A6T25 JLLS025 JJS 25 600 25 20 2 011A 4 TJS35 A6T35 JLLS035...

Page 133: ...FJ006 DFJ 6 600 6 4 2 02A1 4 JHL6 HSJ6 LDFJ006 DFJ 6 600 6 5 3 03A0 4 JHL10 HSJ10 LDFJ010 DFJ 10 600 10 6 4 03A5 4 JHL10 HSJ10 LDFJ010 DFJ 10 600 10 9 0 04A8 4 JHL20 HSJ20 LDFJ020 DFJ 20 600 20 11 5 06A0 4 JHL20 HSJ20 LDFJ020 DFJ 20 600 20 15 0 07A6 4 JHL25 HSJ25 LDFJ025 DFJ 25 600 25 20 2 011A 4 JHL35 HSJ35 LDFJ035 DFJ 35 600 35 27 2 014A 4 JHL40 HSJ40 LDFJ040 DFJ 40 600 40 40 0 021A 4 JHL60 HSJ6...

Page 134: ...A 4 FCF60RN 600 60 45 0 027A 4 FCF80RN 600 80 50 0 034A 4 FCF100RN 600 100 60 0 042A 4 Alternate short circuit protection Miniature circuit breakers IEC Note Miniature circuit breakers with or without fuses have not been evaluated for use as short circuit protection in North America UL environments The protective characteristics of the circuit breakers depend on the type construction and settings ...

Page 135: ... B 32 R3 018A 4 5 S 203P B 50 R3 026A 4 5 S 203P B 63 R4 033A 4 5 S 803S B 80 R4 039A 4 5 S 803 B 100 R4 046A 4 5 S 803 B 100 R4 050A 4 1 Maximum allowed rated conditional short circuit current IEC 61800 5 1 of the electrical power network Manual self protected combination motor controller Type E USA UL NEC You can use the ABB Type E manual motor protectors MMP MS132 S1 M3 25 MS165 xx and MS5100 1...

Page 136: ...on they must be UL listed Type E manual motor protectors otherwise they can be used only as an At Motor Disconnect At Motor Disconnect is a disconnect just ahead of the motor on the load side of the panel 2 480Y 277 V delta systems only Short circuit protective devices with slash voltage ratings e g 480Y 277 V AC can be applied only in solidly grounded networks where the voltage from line to groun...

Page 137: ... Dimensions and weights UL Type 1 kit installed Frame Weight1 M2 M1 D W H3 H2 H1 lb kg in mm in mm in mm in mm in mm in mm in mm 1 0 0 4 7 52 191 1 97 50 8 2 208 2 9 73 9 8 247 11 6 293 8 1 205 R1 1 1 0 5 7 52 191 2 95 75 8 2 208 4 4 111 9 8 247 11 6 293 8 1 205 R2 1 6 0 7 7 52 191 5 83 148 8 2 208 7 4 186 10 3 261 13 0 329 8 1 205 R3 2 7 1 3 7 52 191 9 21 234 8 4 213 11 2 284 12 3 312 15 4 391 8 ...

Page 138: ...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 Noise Air flow Heat dissipation IEC type ACH480 04 Main and control circuit max Control circuit max 2 Control circuit min 1 Main circuit at rated current dB A m3 h W W W W 3 phase UN 400 V 63 57 55 20 9 35 02A7 4 63 57 62 20 9 42 03A4 4 63 57 70 20 9 ...

Page 139: ...709 208 014A 4 66 75 1174 344 75 22 36 11 1098 322 021A 4 69 88 1587 465 102 30 62 18 1486 435 027A 4 69 88 1934 566 102 30 62 18 1832 537 034A 4 69 88 2281 668 102 30 62 18 2179 638 042A 4 1 Without I O module or fieldbus adapter installed 2 With I O module and fieldbus adapter installed Typical power cable sizes These are the typical power cable and conductor sizes at the nominal drive current F...

Page 140: ...6 034A 4 R4 4 042A 4 Terminal data for the power cables PE L1 L2 L3 T1 U T2 V T3 W R R UDC IEC type ACH480 04 Tightening torque Maximum solid stran ded Minimum solid stran ded Tightening torque Maximum solid stran ded Minimum solid stran ded N m mm2 mm2 N m mm2 mm2 3 phase UN 400 V 1 2 6 4 4 2 5 0 5 0 6 4 2 5 0 5 0 5 02A7 4 1 2 6 4 4 2 5 0 5 0 6 4 2 5 0 5 0 5 03A4 4 1 2 6 4 4 2 5 0 5 0 6 4 2 5 0 5...

Page 141: ...ghtening torque Maximum Minimum Tightening torque Maximum Minimum lbf in AWG AWG lbf in AWG AWG 3 phase UN 480 V 10 6 10 12 5 10 18 02A1 4 10 6 10 12 5 10 18 03A0 4 10 6 10 12 5 10 18 03A5 4 10 6 10 12 5 10 18 04A8 4 10 6 10 12 5 10 18 06A0 4 10 6 10 12 5 10 18 07A6 4 10 6 10 12 5 10 18 011A 4 10 6 10 12 11 13 6 18 014A 4 10 6 10 12 11 13 6 18 021A 4 25 7 4 8 22 32 2 18 027A 4 25 7 4 8 22 32 2 18 ...

Page 142: ...N 3268 16 44 RFI 32 09A5 4 x x x FN 3268 30 33 RFI 33 12A7 4 x x x FN 3268 30 33 RFI 33 018A 4 x x x FN 3268 30 33 RFI 33 026A 4 x x x FN 3258 100 35 RFI 34 033A 4 x x x FN 3258 100 35 RFI 34 039A 4 x x x FN 3258 100 35 RFI 34 046A 4 x x x FN 3258 100 35 RFI 34 050A 4 Category EMC filter type UL NEC type ACH480 04 C3 C2 C1 Schaffner order code ABB type code 3 phase UN 480 V x x x FN 3268 16 44 RFI...

Page 143: ...otection UL 61800 5 1 CSA C22 2 No 274 13 Note If the short circuit current is more than specified in the table below it is necessary to use a mains choke Use a mains choke if the short circuit capacity of the network at the drive terminals is more than in the table Mains choke R3 R4 R1 R2 Frame Voltage rating 10 kA 5 0 kA 3 phase 380 480 V You can use one choke for several drives if the short cir...

Page 144: ... motor cable length To comply with the EMC limits in the European EMC Directive standard IEC EN 61800 3 do not exceed these maximum motor cable lengths They are valid for 4 kHz switching frequency Maximum motor cable length 4 kHz Frame C3 C2 C11 ft m ft m ft m With internal EMC filter 3 phase 380 480 V 100 30 33 10 R1 66 20 33 10 R2 100 30 33 10 R3 100 30 33 10 R4 With optional external EMC filter...

Page 145: ...10 overrange 22 mA max into 500 ohm load AO2 only supports output current Current output mode Analog output AO1 AO2 0 10 V DC 10 overrange 11 V DC max into 200 kohm minimum load resistive Voltage output mode 2 of full scale Inaccuracy 24 V DC 10 max 250 mA from base unit and or RIIO 01 module As output Auxiliary power out put or input 24V DGND 24 V DC 10 max 1000 mA incl internal fan load As input...

Page 146: ...s available as an option Enclosure types UL 61800 5 1 lll Overvoltage category IEC 60664 1 l Protective classes IEC EN 61800 5 1 Ambient conditions Environmental limits for the drive are given below The drive must be used in a heated indoor controlled environment Transportation in the protective package Storage in the protect ive package Operation installed for stationary use Requirement 400 480 V...

Page 147: ...elera tion 10 m s2 33 ft s2 57 56 150 Hz sweep 1 oct min 10 sweep cycles in each axis with STO active uncertainty 5 0 normal mounting According to ISTA 1A According to ISTA 1A Not permitted Shock IEC 60068 2 27 ISTA 1A Max 100 m s2 330 ft s2 11 ms Max 100 m s2 330 ft s2 11 ms 76 cm 30 in 76 cm 30 in Free fall Materials Hot dip zinc coated steel sheet 1 5 mm 0 06 in Extruded aluminum AlSi PC ABS 2 ...

Page 148: ...y Functional safety of safety related electrical electronic and programmable electronic control systems EN 62061 2005 AC 2010 A1 2013 A2 2015 Adjustable speed electrical power drive systems Part 3 EMC require ments and specific test methods EN 61800 3 2004 A1 2012 IEC 61800 3 2004 A1 2011 Adjustable speed electrical power drive systems Part 5 1 Safety re quirements Electrical thermal and energy IE...

Page 149: ...ration values and it is an environmentally friendly product which can be recycled WEEE mark At the end of life the product should enter the recycling system at an appropriate col lection point and not placed in the normal waste stream KC mark Product complies with Korea s product safety requirements for electrical and electronic equipment and components that utilize power from 50 1000 V AC BTL BAC...

Page 150: ...recommendations are obeyed 3 The maximum motor cable length does not exceed the specified maximum value See EMC compatibility and motor cable length page 144 4 The drive is installed according to the instructions IEC given in this manual This product can cause radio frequency inference In a residential or domestic environment supplementary mitigation measures may be required in addition to the req...

Page 151: ... internal EMC C2 filter as standard No EMC C3 filter for category C3 is available Category C4 If the provisions in category 2 or 3 are not met the requirements of the standard can be met as follows 1 It is ensured that no excessive emission is propagated to neighboring low voltage networks In some cases the inherent suppression in transformers and cables is sufficient If in doubt the supply transf...

Page 152: ... and software manuals The manuals are provided in electronic format in the drive package or on the Internet Keep the manuals with the drive at all times Hard copies of the manuals can be ordered through the manufacturer Make sure that the drive type designation label includes the applicable marking DANGER Risk of electric shock After disconnecting the input power always wait for 5 minutes to let t...

Page 153: ...uitable circuit breakers contact your local ABB representative WARNING The opening of the branch circuit protective device may be an indication that a fault current has been interrupted To reduce the risk of fire or electric shock current carrying parts and other components of the device should be examined and replaced if damaged The integral solid state short circuit protection of the drive does ...

Page 154: ... measures such as but not limited to the installation of firewalls application of authentication measures encryption of data installation of anti virus programs etc to protect the product the network its system and the interface against any kind of security breaches unauthorized access interference intrusion leakage and or theft of data or information ABB and its affiliates are not liable for dama...

Page 155: ...11 Dimension drawings Contents of this chapter The chapter contains the dimension drawings of the drive The dimensions are in millimeters and inches Dimension drawings 155 ...

Page 156: ...Frame R1 Frame R1 front side IP20 UL open type 156 Dimension drawings ...

Page 157: ... Frame R1 bottom rear IP20 UL open type Dimension drawings 157 ...

Page 158: ... Frame R1 front side UL Type 1 kit installed 158 Dimension drawings ...

Page 159: ... Frame R1 bottom rear UL Type 1 kit installed Dimension drawings 159 ...

Page 160: ...Frame R2 Frame R2 front side IP20 UL open type 160 Dimension drawings ...

Page 161: ... Frame R2 bottom rear IP20 UL open type Dimension drawings 161 ...

Page 162: ... Frame R2 front side UL Type 1 kit installed 162 Dimension drawings ...

Page 163: ... Frame R2 bottom rear UL Type 1 kit installed Dimension drawings 163 ...

Page 164: ...Frame R3 Frame R3 front side IP20 UL open type 164 Dimension drawings ...

Page 165: ... Frame R3 bottom rear IP20 UL open type Dimension drawings 165 ...

Page 166: ... Frame R3 front side UL Type 1 kit installed 166 Dimension drawings ...

Page 167: ... Frame R3 bottom rear UL Type 1 kit installed Dimension drawings 167 ...

Page 168: ...Frame R4 Frame R4 front side IP20 UL open type 168 Dimension drawings ...

Page 169: ... Frame R4 bottom rear IP20 UL open type Dimension drawings 169 ...

Page 170: ... Frame R4 front side UL Type 1 kit installed 170 Dimension drawings ...

Page 171: ... Frame R4 bottom rear UL Type 1 kit installed Dimension drawings 171 ...

Page 172: ...172 ...

Page 173: ...tra energy increases the DC link voltage 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 Energy consumption by the resistor losses lowers the voltage until the resistor can be disconnected Selecting the brake resistor Drives have a built in brake chopper as standard equipment The brake resis...

Page 174: ...240 V When the drive supply voltage is 380 415 V When the drive supply voltage is 415 480 V Equation 2 Equation 3 R Calculated brake resistor value ohm Make sure that Rmin R Rmax PRmax Maximum power during the braking cycle W PRave Average power during the braking cycle W ERpulse Energy conducted into the resistor during a single braking pulse J ton Braking time one cycle s T Braking cycle time s ...

Page 175: ... 22 00 20 6 050A 4 1 Braking cycle differs from that of the drive Refer to brake resistor manufacturer s documentation Example resistor types1 PBRmax PBRcont Rmax Rmin UL NEC type ACH480 04 Danotherm hp kW hp kW ohm ohm 3 phase UN 480 V CBH 360 C T 406 210R 1 10 0 83 0 75 0 55 628 99 02A1 4 or 1 50 1 13 1 00 0 75 428 99 03A0 4 CAR 200 D T 406 210R 2 20 1 65 1 50 1 10 285 99 03A5 4 3 00 2 25 2 00 1...

Page 176: ...ed emissions Install the cables away from other cable routes Avoid long parallel runs with other cables The minimum parallel cabling separation distance is 0 3 meters 1 ft Cross the other cables at 90 degree angles Keep the cable as short as possible in order to minimize the radiated emissions and stress on chopper IGBTs The longer the cable the greater the radiated emissions inductive load and vo...

Page 177: ... resistor cable when it is identical with the input power cable Protecting the system against thermal overload The drive has a brake thermal model which protects the brake resistor against overload ABB recommends to enable the thermal model at start up Equipping the drive with a main contactor is highly recommended for safety reasons even when you have enabled the resistor thermal model Wire the c...

Page 178: ... thermal switch 4 Digital input Monitors the brake resistor thermal switch 5 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...

Page 179: ...er 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 Set parameter 31 02 External event 1 type to Fault 4 Enable the brake chopper by parameter 43 06 Brake chopper enable If Enabled with thermal model is selected set also the brake resistor overload protection parameters 43 0...

Page 180: ...180 ...

Page 181: ...activated the Safe torque off function disables the control voltage of the power semiconductors of the drive output stage A see the diagrams below thus preventing the drive from generating the torque required to rotate the motor If the motor is running when Safe torque off is activated it coasts to a stop The Safe torque off function has a redundant architecture that is both channels must be used ...

Page 182: ...ted systems IEC 61508 2 2010 Functional safety Safety instrumented systems for the process industry sector IEC 61511 1 2016 Adjustable speed electrical power drive systems Part 5 2 Safety requirements Functional IEC 61800 5 2 2016 EN 61800 5 2 2007 Safety of machinery Functional safety of safety related electric al electronic and programmable electronic control systems IEC 62061 2005 A1 2012 A2 20...

Page 183: ...tion see the technical data of the control unit Connection principle Single ACH480 drive internal power supply OUT1 24 V DC IN1 IN2 SGND UDC UDC A K 2 1 3 4 Drive 1 Control unit 2 Control logic 3 To motor 4 Activation switch K The Safe torque off function 183 ...

Page 184: ...Single ACH480 drive external power supply OUT1 IN1 IN2 SGND 24 V DC UDC UDC 24 V DC K 2 1 3 4 A Drive 1 Control unit 2 Control logic 3 To motor 4 Activation switch K 184 The Safe torque off function ...

Page 185: ...13 Y1 A2 Y2 A1 31 32 OUT GND IN1 OUT1 IN2 SGND K 1 2 Drive 1 Safety PLC 2 Safety relay K Single ACH480 drive external power supply 24 14 23 13 Y1 A2 Y2 A1 31 32 OUT GND IN1 OUT1 ÍN2 SGND K 1 2 24 V DC Drive 1 Safety PLC 2 Safety relay K The Safe torque off function 185 ...

Page 186: ...Multiple ACH480 drives internal power supply 24 V OUT1 SGND IN1 IN2 OUT1 SGND IN1 IN2 OUT1 SGND IN1 IN2 K 1 1 1 2 2 2 Drive 1 Control unit 2 Activation switch K 186 The Safe torque off function ...

Page 187: ...2 1 2 1 2 Drive 1 Control unit 2 Activation switch K 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 The Safe torque off function 187 ...

Page 188: ...rt circuit in the wiring between the switch and an STO terminal causes a dangerous fault Therefore it is recommended to use a safety relay including wiring diagnostics or a wiring method shield grounding channel separation which reduces or eliminates the risk caused by the short circuit Note The voltage at the STO input terminals of the drive must be at least 13 V DC to be interpreted as 1 The pul...

Page 189: ... this occurs Note This parameter does not affect the operation of the STO function itself The STO function will operate regardless of the setting of this parameter a running drive will stop upon removal of one or both STO signals and will not start until both STO signals are restored and all faults reset Note The loss of only one STO signal always generates a fault as it is interpreted as a malfun...

Page 190: ...ed and signed by this person Acceptance test reports Signed acceptance test reports must be stored in the logbook of the machine The report shall include documentation of start up activities and test results references to failure reports and resolution of failures Any new acceptance tests performed due to changes or maintenance shall be logged into the logbook Acceptance test procedure After wirin...

Page 191: ...g the operation when the motor is stopped Close the STO circuit Reset any active faults Restart the drive and check that the motor runs normally 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 The drive generates a FA81 Safe Torque Off 1 loss fa...

Page 192: ...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 p denotes the number of pole pairs Notes If a running drive is stopped by using the Safe torque off function the drive ...

Page 193: ...tegrity requirement for the safety function is SIL 2 HFT 1 or PL d cat 3 the proof test for the function must be performed at least every 12 months The STO function of the drive does not contain any electromechanical components In addition to proof testing it is a good practice to check the operation of the function when other maintenance procedures are carried out on the machinery Include the Saf...

Page 194: ...function is performed and the drive trips on an STO hardware failure fault An attempt to use the STO in a non redundant manner for example activating only one channel will trigger the same reaction 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 d...

Page 195: ...on off cycles per year with ΔT 61 66 C 30 on off cycles per year with ΔT 10 0 C 32 C board temperature at 2 0 of time 60 C board temperature at 1 5 of time 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 The STO does not activate when requested A fault exclusion on the failure mode sho...

Page 196: ...an unavailability of a safety related system to perform the specified safety function when a demand occurs IEC 61508 PFDavg Average frequency of dangerous failures per hour that is average frequency of a dangerous failure of a safety related system to perform the specified safety function over a given period of time IEC 61508 PFH Performance level Levels a e correspond to SIL EN ISO 13849 1 PL Sys...

Page 197: ...nction device After the mission time elapses the safety device must be replaced Note that any TM values given cannot be regarded as a guarantee or warranty EN ISO 13849 1 TM TÜV certificate The TÜV certificate is available on the Internet at www abb com drives documents The Safe torque off function 197 ...

Page 198: ... Declaration of conformity 198 The Safe torque off function ...

Page 199: ...y is used to keep the drive control board energized during a drive power outage The BAPO 01 module has internal connections to provide back up power to the control board I O fieldbus There is a DC to DC flyback converter power supply inside the module This power supply takes 24 V DC as input and outputs 5 V DC to the control board to keep the processor and communication links on at all times Note ...

Page 200: ... 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 Each drive must be powered by a single 24 V DC power supply or a separate 24 V DC output of one auxiliary power source 200 BAPO 01 auxiliary power extension module ...

Page 201: ...o configure the BAPO 01 module 1 Power up the drive 2 Set the parameter 95 04 Control board supply to 1 External 24V 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 BAPO 01 auxiliary power extension module 201 ...

Page 202: ...d T Huoso 28 Sep 15 Title DIMENSION DRAWING Doc des Scale Form Customer Check S Lilja 28 Sep 15 BAPO 01 DIMENSION DRW DIMENSION DRAWING 1 1 A2 Appr T Koivuniemi 28 Sep 15 Resp dept Rev ind A AP L Cust Doc No Project name ACM380 Doc No 3AXD50000031166 S DMS Number 3AXD10000458992 Weight kg T so 500000681808 DIMENSION DRAWING FOR 3AXD50000022164 26 1 024 11 3 0 444 16 0 63 86 1 3 391 171 6 6 754 181...

Page 203: ...ware description Product overview The BIO 01 option module option L515 is an I O extension module to be used with fieldbus adapter module The BIO 01 module can be installed between the drive and the fieldbus 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 You...

Page 204: ...w and move the slider to the bottom position The BIO 01 option module kit comes with a higher cable clamp plate Use this cable clamp plate to ground the wires that connect to the BIO 01 option module Electrical installation The BIO 01 module has removable spring clamp terminals Use ferrules on the multistranded conductor ends The connection diagram below is valid for the drive equipped with the BI...

Page 205: ... common DO common GND Signal cable shield SCR Safe torque off Both IN1 AND IN2 circuits must be closed for the drive to start Factory connection SGND IN1 IN2 OUT1 Start up The BIO 01 module is automatically identified by the drive firmware To configure the inputs refer to the drive firmware manual Technical data Control connection data Spring type terminal blocks Conductor size accepted by the ter...

Page 206: ...Dimensions 206 BIO 01 I O extension module ...

Page 207: ... 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 Hardware description Product overview BREL 01 relay output extension module option L511 adds four relay outputs to the drive BREL 01 relay output extension module 207 ...

Page 208: ...X105 connector 6 X106 connector 7 Internal X100 connector 8 Internal X102 connector 9 Grounding rail 10 Grounding screw Mechanical installation See the electrical installation instructions of the drive Electrical installation Use 0 5 2 5 mm2 20 14 AWG cable with a sufficient voltage rating If you connect an inductive load relay or contactor coil motor protect the relay contacts with a varistor RC ...

Page 209: ...panel on the drive and set the parameters for relay outputs 4 7 in 15 I O extension module Refer to the ACH480 HVAC control program firmware manual 3AXD50000247134 English for parameter descriptions Configuration parameters The configuration parameters of the BREL 01 module are in group 15 I O extension module Def FbEq16 32 Description Name Value No 15 I O extension module None Activates and speci...

Page 210: ... in parameter 15 05 RO force selection Bit 0 RO4 Force the value of this bit to RO5 if so defined in parameter 15 05 RO force selection Bit 1 RO5 Force the value of this bit to RO6 if so defined in parameter 15 05 RO force selection Bit 2 RO6 Force the value of this bit to RO7 if so defined in parameter 15 05 RO force selection Bit 3 RO7 Not energized Selects a drive signal to be connected to rela...

Page 211: ... s Not energized Selects a drive signal to be connected to relay output RO7 RO7 source 15 16 0 Output is not energized Not energized 1 Output is energized Energized For the complete parameter list refer to the drive firmware manual 0 0 s Sets the activation delay for relay output 7 RO7 ON delay 15 17 10 1 s Activation delay for relay output 7 0 0 3000 0 s 0 0 s Sets the deactivation delay for rela...

Page 212: ...Dimensions 3AXD50000031148 rev A 212 BREL 01 relay output extension module ...

Page 213: ... by navigating to www abb com searchchannels Product training For information on ABB product training navigate to new abb com service training Providing feedback on ABB manuals Your comments on our manuals are welcome Navigate to new abb com drives manuals feedback form Document library on the Internet You can find manuals and other product documents in PDF format on the Internet at www abb com dr...

Page 214: ...www abb com drives 3AXD50000245949B 2020 ABB All rights reserved Specifications subject to change without notice 3AXD50000245949 Rev B EN EFFECTIVE 2020 03 31 ...

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