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Installation checklist 77

Installation checklist

Contents of this chapter

This chapter contains an installation checklist which you must complete before you
start up the drive.

Warnings

WARNING!

Obey the instructions in chapter

Safety instructions

on page

. If

you ignore them, injury or death, or damage to the equipment can occur.

Checklist

Do the steps in

Precautions before electrical work

on page

before you start the

work. Read the checklist together with another person.

Make sure that …

The ambient operating conditions meet the specification in

Ambient conditions

page

111

If the drive is connected to an IT (ungrounded) or corner-grounded TN supply network:
Internal EMC filter is disconnected.
If the drive is connected to an IT (non-grounded) system, disconnect the varistor
grounding screw.
Refer to

Compatibility with IT (ungrounded) and corner-grounded TN systems

on page

If the drive is stored over one year: The electrolytic DC capacitors in the DC link of the
drive are reformed. Refer to

Servicing the capacitors

on page

Summary of Contents for ACS380 Series

Page 1: ...ABB MACHINERY DRIVES ACS380 drives Hardware manual...

Page 2: ...he manuals applicable to the product ACS380 manuals Drive manuals and guides Code English ACS380 drives hardware manual 3AXD50000029274 ACS380 quick installation and start up guide 3AXD50000018553 ACS...

Page 3: ...Hardware manual ACS380 drives 3AXD50000029274 Rev D EN EFFECTIVE 2018 05 25 2018 ABB Oy All Rights Reserved 1 Safety instructions Table of contents 4 Mechanical installation 6 Electrical installation...

Page 4: ......

Page 5: ...ntents of this chapter 21 Applicability 21 Target audience 21 Purpose of the manual 21 Contents of this manual 22 Related documents 22 Categorization by frame size 22 Quick installation and commission...

Page 6: ...cables 54 Shielding 54 Signals in separate cables 54 Signals that can be run in the same cable 54 Relay cable 54 Drive composer PC tool cable 54 Routing the cables 55 Separate control cable ducts 56...

Page 7: ...standard macro 69 Fieldbus connection diagram 72 Control cable connection procedure 73 Auxiliary voltage connection 74 Option modules 75 To install a front option 75 To remove a front option 76 To ins...

Page 8: ...pecification 106 Motor cable length 107 Motor connection data 107 Control connection data 109 Brake resistor connection 110 Efficiency 110 Degrees of protection 110 Ambient conditions 111 Materials 11...

Page 9: ...fault situations 135 Protecting the system in cable and brake resistor short circuit situations 135 Protecting the system against thermal overload 135 Mechanical installation 135 Electrical installati...

Page 10: ...der adapter settings 166 These parameters display the configuration of the encoder interface modules Encoder con figuration 166 Diagnostics 167 Technical data 168 Encoder interface 168 Back up power s...

Page 11: ...79 Start up 179 Technical data 180 Voltage and current rating for the auxiliary power supply 180 Power loss 180 Dimensions 180 16 BIO 01 I O extension module Contents of this chapter 181 Safety instru...

Page 12: ...12 Table of contents...

Page 13: ...damage to the equipment They also tell 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 Elec...

Page 14: ...e 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 automatic fault reset functions of the dri...

Page 15: ...attach a warning notice to it Disconnect any external power sources from the control circuits before you do work on the control cables After you disconnect the drive always wait for 5 minutes to let t...

Page 16: ...lter increases the conducted emission and reduces the drive EMC compatibility considerably Use all ELV extra low voltage circuits connected to the drive only within a zone of equipotential bonding tha...

Page 17: ...protective earth PE conductors is sufficient Refer to Selecting the power cables on page 48 Obey the local regulations Connect the power cable shields to the protective earth PE terminals of the driv...

Page 18: ...e 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 Measure that the installation is d...

Page 19: ...the I O or fieldbus interface Give a stop command to the drive before you reset a fault If you have an external source for the start command and the start is on the drive will start immediately after...

Page 20: ...20 Safety instructions...

Page 21: ...and commissioning of the drive Applicability The manual applies to ACS380 drives The 3 phase 230V device has limited availability Please contact your local ABB representative for information on avail...

Page 22: ...stallation checklist on page 77 contains a checklist for the mechanical and electrical installation of the drive before start up Maintenance on page 79 contains the preventive maintenance instructions...

Page 23: ...Introduction to the manual 23 can read the frame size from the type designation label on the drive refer to Drive labels on page 33...

Page 24: ...e internal EMC filter is not connected Type designation key on page 35 Compatibility with IT ungrounded and corner grounded TN systems on page 63 Install the drive Installing the drive on page 44 Rout...

Page 25: ...TAC 02 Optional side mounted pulse encoder interface module CCA 01 Optional cold configuration adapter DC link DC circuit between rectifier and inverter DC link capacitors Energy storage which stabili...

Page 26: ...viceNet adapter module user s manual 3AFE68573360 English FENA 01 11 21 Ethernet adapter module user s manual 3AUA0000093568 English Parameter User adjustable operation instruction to the drive or sig...

Page 27: ...asynchronous AC induction motors permanent magnet synchronous motors and ABB synchronous reluctance motors SynRM motors It is optimized for cabinet mounting Product variants The drive has three prima...

Page 28: ...ol panel display and status LED 2 Input power connection terminal 12 Fixed control terminals 3 Motor and braking resistor connection terminal 13 Option slot 1 for communication modules I O or Fieldbus...

Page 29: ...s follows ACS380 04xS Refer to Type designation key on page 35 Connections 1 Auxiliary voltage outputs 2 Digital inputs 3 Safe torque off connections 4 Relay output connection 5 Cold configuration con...

Page 30: ...riant to order a product with a specific fieldbus extension module Refer to Type designation key on page 35 Connections 1 Auxiliary voltage outputs 2 Digital inputs 3 Safe torque off connections 4 Rel...

Page 31: ...connections of the base unit 1 Auxiliary voltage outputs 2 Digital inputs 3 Safe torque off connections 4 Relay output connection 5 Cold configuration connection for CCA 01 6 Option module slot 1 RC...

Page 32: ...n on the assistant control panels refer to the ACX AP x Assistant control panels user s manual 3AUA0000085685 EN PC connection To connect a PC to the drive use a USB to RJ45 converter There are 2 alte...

Page 33: ...the drive Type designation label on the left side of the drive Model information label No Description 1 Drive type 2 Frame size and ratings 3 Serial number 4 QR code to register the drive ACS380 3 400...

Page 34: ...to Ratings on page 88 5 Valid markings 6 UL CSA data Refer to Electric power network specification on page 106 7 S N Serial number of format MYYWWXXXX where M Manufacturer YY Year of manufacture 15 1...

Page 35: ...0 V 4 3 phase 380 to 480 V F Option codes Fieldbus K451 FDNA 01 DeviceNet protocol K454 FPBA 01 Preconfigured Profibus DP protocol K457 FCAN 01 Preconfigured CANopen protocol K469 FECA 01 Preconfigure...

Page 36: ...ortuguese in Portugal R711 Russian R712 Chinese R714 Turkish The option code determines the language variants of the Hardware manual and Firmware manual The product package includes the User interface...

Page 37: ...voltage 4 Brake chopper Conducts the surplus energy from the intermediate DC circuit of the drive to the brake resistor when it is necessary and if an external brake resistor is connected to the driv...

Page 38: ...parameters 1 Display Home view a Control location local or remote b Status icons c Reference target value d Actual measured value e Left and right softkey actions 2 Back key opens the Options view in...

Page 39: ...d right arrow keys The status bar at the top of the Home view shows The control location Loc for local control and Rem for remote control The status icons The reference target value From the Home view...

Page 40: ...pen the Options view push the Back key in the Home view In the Options view you can Set the control location Set the direction of the motor Set the reference View the active fault View a list of the a...

Page 41: ...hapter tells you how to examine the installation site unpack check the delivery and install the drive mechanically Installation alternatives You can install the drive With screws on to a wall With scr...

Page 42: ...e cooling air inlet at the bottom of the drive Make sure that the hot cooling air from a drive does not go into the cooling inlet of other equipment The drive has an IP20 ingress protection classifica...

Page 43: ...tape measure and spirit level Personal protective equipment Unpacking the delivery The figure shows the drive package with its contents Make sure that all of the items are present and that there are...

Page 44: ...rated lock To install the drive with screws 1 Make marks on to the surface for the mounting holes Refer to Dimensions and weights on page 100 Use the mounting template for R3 and R4 frames 2 Make the...

Page 45: ...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 6 Move the locking par...

Page 46: ...46 Mechanical installation...

Page 47: ...d the drive may experience problems that the warranty does not cover Selecting the supply disconnecting device Install a hand operated input disconnecting device between the AC power source and the dr...

Page 48: ...must be sufficient refer to page 49 A 600 V AC cable is accepted for up to 500 V AC To comply with the EMC requirements of the CE mark use an approved cable type Refer to Recommended power cable types...

Page 49: ...mm2 Cu 1 AWG 1 phase UN 200 240 V ACS380 04xx 02A4 1 R0 3 1 5 1 5 16 ACS380 04xx 03A7 1 R0 3 1 5 1 5 16 ACS380 04xx 04A8 1 R1 3 1 5 1 5 16 ACS380 04xx 06A9 1 R1 3 1 5 1 5 16 ACS380 04xx 07A8 1 R1 3 1...

Page 50: ...al data for the power cables on page 103 ACS380 04xx 02A6 4 R1 3 1 5 1 5 16 ACS380 04xx 03A3 4 R1 3 1 5 1 5 16 ACS380 04xx 04A0 4 R1 3 1 5 1 5 16 ACS380 04xx 05A6 4 R1 3 1 5 1 5 16 ACS380 04xx 07A2 4...

Page 51: ...structed PE conductor and a shield The PE conductor must meet the requirements of IEC 61800 5 1 refer to page 48 A four conductor system three phase conductors and a protective conductor on a cable tr...

Page 52: ...type MC continuous corrugated aluminum armor cable with symmetrical grounds or shielded power cable for the motor cables if metallic conduit is not used For the North American market 600 V AC cable i...

Page 53: ...und conductors type MC continuous corrugated aluminum armor cable with symmetrical grounds is available from the following suppliers trade names in parentheses Anixter Wire Cable VFD RSCC Wire and Cab...

Page 54: ...als in separate cables Put analog and digital signals in separate shielded cables Do not mix 24 V and 115 230 V AC signals in the same cable Signals that can be run in the same cable If their voltage...

Page 55: ...rol cables cross the input power or motor cables put the cables at 90 degrees to each other You can put several motor cables in parallel Do not install other cables in parallel with the motor cables M...

Page 56: ...h the incoming and outgoing cables or connect the shields otherwise together If cabling is put into conduits make sure that they are continuous Implementing short circuit protection Protecting the dri...

Page 57: ...a calculated temperature value or an actual temperature indication given by motor temperature sensors The user can tune the thermal model by feeding in additional motor and load data The most common t...

Page 58: ...on how you use the drive When you use the vector control mode and motor ramp stop open the contactor as follows 1 Give a stop command to the drive 2 Wait until the drive stops the motor 3 Open the con...

Page 59: ...ductively to other conductors and cause a malfunction in the system Use a noise attenuating circuit varistors RC filters AC or diodes DC to minimize the EMC emission of inductive loads at switch off I...

Page 60: ...60 Planning the electrical installation...

Page 61: ...WARNING Obey the instructions in Safety instructions on page 13 If you ignore them injury or death or damage to the equipment can occur WARNING Make sure that the drive is disconnected from the input...

Page 62: ...tor and the protective earth conductor Use a measuring voltage of 1 000 V DC The insulation resistance of an ABB motor must be more than 100 Mohm reference value at 25 C or 77 F For the insulation res...

Page 63: ...rive When the internal EMC filter is disconnected the EMC compatibility of the drive decreases Refer to Motor cable length on page 107 EMC filter disconnection This is applicable only to product varia...

Page 64: ...t from ground remove the varistor grounding screw Refer to Hardware overview on page 28 In some product variants the varistor protection circuit is disconnected from electrical ground at the factory w...

Page 65: ...Separate grounding cable line side Use it if the conductivity of the fourth conductor or shield is not sufficient for the protective grounding c Separate grounding cable motor side Use it if the condu...

Page 66: ...the drive is connected to an IT non grounded system disconnect the varistor grounding screw Before you start the work stop the drive and do the steps in Precautions before electrical work on page 15 F...

Page 67: ...t power cable 7 If the input power cable has a shield twist it into a bundle put yellow green insulation tape on it fit a cable lug and connect it to the grounding terminal 8 Connect the PE conductor...

Page 68: ...BB standard macro For other macros refer to the ACS380 Firmware manual 3AXD50000029275 English Connect the cables as shown in Control cable connection procedure on page 73 WARNING Obey the instruction...

Page 69: ...2 1 Digital output function Ready to run 0 Not ready 1 Digital output auxiliary voltage Digital input output common Analog I O Output frequency Speed reference 0 10 V Analog input circuit common Not...

Page 70: ...r 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 The connection diagram is shown below Process...

Page 71: ...The sensor is supplied through its current output and the drive feeds the supply voltage 24 V The output signal must be 4 20 mA not 0 20 mA AI2 Process actual value measurement or reference 0 4 20 mA...

Page 72: ...s interface Not configured Safe torque off STO Safe torque off function Connected at factory Drive starts only when both circuits are closed Refer to Safe torque off function on page 139 Relay output...

Page 73: ...outer shield of the control cable for grounding 2 Use a cable tie to ground the outer shield to the grounding tab Use the metallic cable ties for 360 degree grounding 3 Strip the control cable conduct...

Page 74: ...to BAPO 01 power extension module on page 177 For voltage input specifications refer to Control connection data on page 109 There is a DC to DC flyback converter power supply inside BAPO 01 module Thi...

Page 75: ...tion on the side mounted options BTAC 02 pulse encoder interface module on page 153 BREL 01 relay output extension module on page 171 BAPO 01 power extension module on page 177 Before you start the wo...

Page 76: ...h the connectors on the right side of the drive 3 Fully push the option module into position 4 Tighten the locking screw of the option module 5 Attach the grounding bar to the bottom of the side optio...

Page 77: ...rt the work Read the checklist together with another person Make sure that The ambient operating conditions meet the specification in Ambient conditions on page 111 If the drive is connected to an IT...

Page 78: ...and disconnector are installed The motor cable is connected to the correct terminals the phase order is right and the terminals are tightened Pull the conductors to check The brake resistor cable if...

Page 79: ...Maintenance 79 8 Maintenance Contents of this chapter The chapter contains the preventive maintenance instructions and LED indicator descriptions...

Page 80: ...O O Other useful tasks Tightness of the cable and busbar terminals Tighten if needed I I I I I I I I I I I I I Ambient conditions dustiness moisture and temperature I I I I I I I I I I I I I Clean th...

Page 81: ...vacuum cleaner can cause static discharges which can cause damage to circuit boards To clean the heat sink 1 Stop the drive and disconnect it from the input power 2 Wait for 5 minutes and measure to m...

Page 82: ...m ABB Use only ABB specified spare parts To replace the cooling fan for frames R1 R3 WARNING Obey the instructions in Safety instructions on page 13 Ignoring the instructions can cause physical injury...

Page 83: ...9 Connect the fan power cable 10 Put the fan power cable into the cable slot in the drive 11 Carefully put the fan cover into position in the drive Make sure that the fan power cable is routed correc...

Page 84: ...and pull the fan from its base 6 Unplug the fan power cable from the extension cable connector 7 Replace the old fan carefully Pay attention to the correct installation direction of the fan by follow...

Page 85: ...a fault in the drive Contact ABB if you think that a capacitor failed You can get spare parts from ABB Use only ABB specified spare parts Capacitor reforming You must reform the capacitors if the driv...

Page 86: ...86 Maintenance...

Page 87: ...data Contents of this chapter The chapter contains the technical specifications of the drive such as ratings sizes and technical requirements as well as provisions for fulfilling the requirements for...

Page 88: ...9 3 2 2 7 8 1 5 R1 12A2 2 19 5 12 2 17 6 12 2 3 0 11 6 3 0 9 8 2 2 R2 17A5 2 28 0 17 5 22 0 17 5 4 0 16 7 4 0 12 2 3 0 R3 25A0 2 40 0 25 0 31 5 25 0 5 5 24 2 5 5 17 5 4 0 R3 032A 2 51 2 32 0 45 0 32 0...

Page 89: ...R1 12A6 4 17 6 11 0 11 0 7 5 7 6 5 0 R2 17A0 4 22 4 14 0 14 0 10 0 11 0 7 5 R3 25A0 4 33 6 21 0 21 0 15 0 14 0 10 0 R3 032A 4 37 9 27 0 27 0 20 0 12 0 15 0 R4 038A 4 44 7 34 0 34 0 25 0 27 0 20 0 R4...

Page 90: ...e is 400 V and the drive is situated at 1500 m calculate the appropriate drive size requirement as follows Switching frequency derating page 91 From the table the minimum size required is IN 9 4 A Alt...

Page 91: ...8 6 6 5 8 09A8 1 9 8 9 8 8 3 7 2 12A2 1 12 2 12 2 10 0 8 4 3 phase UN 200 240 V 02A4 2 2 4 2 4 2 0 1 8 03A7 2 3 7 3 7 3 1 2 7 04A8 2 4 8 4 8 4 0 3 1 06A9 2 6 9 6 9 5 8 4 5 07A8 2 7 8 7 8 6 4 4 7 09A8...

Page 92: ...on module maximum potential difference between adjacent relays is 30 V e g it is not allowed to connect 250 V to Relay Output 2 and 30 V to Relay Output 3 If the conditions are not met the maximum alt...

Page 93: ...urrent Min short circuit current Nominal current I2 t Voltage rating ABB type IEC 60269 size A A A A2 s V 1 phase UN 200 240 V 02A4 1 5 0 80 10 380 500 OFAF000H10 000 03A7 1 7 8 80 10 380 500 OFAF000H...

Page 94: ...28 16 740 500 OFAF000H16 000 12A6 4 20 2 200 25 2500 500 OFAF000H25 000 17A0 4 27 2 256 32 4500 500 OFAF000H32 000 25A0 4 40 0 400 50 15500 500 OFAF000H50 000 032A 4 51 2 504 63 20000 500 OFAF000H63 0...

Page 95: ...S TJS20 UL class T 12A2 2 19 5 200 25 600 JJS TJS25 UL class T 17A5 2 28 0 256 35 600 JJS TJS35 UL class T 25A0 2 40 0 400 50 600 JJS TJS50 UL class T 032A 2 51 2 504 60 600 JJS TJS60 UL class T 048A...

Page 96: ...2 15 7 128 40 490 690 170M2696 00 12A2 2 19 5 200 50 1000 690 170M2697 00 17A5 2 28 0 256 63 1800 690 170M2698 00 25A0 2 40 0 400 80 3600 690 170M2699 00 032A 2 51 2 504 100 6650 690 170M2700 00 048A...

Page 97: ...it breakers not listed below Furthermore if the recommendations given by ABB are not obeyed the drive can experience problems the warranty does not cover Note Miniature circuit breakers with or withou...

Page 98: ...tor protectors may require adjusting the trip limit from the factory setting at or above the drive input Amps to avoid nuisance tripping If the manual motor protector is set to the maximum current tri...

Page 99: ...her of the two ratings e g 480 V AC The lower rating represents the device s interrupting capability per pole 5 For all drives the enclosure must be sized to accommodate the specific thermal considera...

Page 100: ...205 8 07 220 8 66 170 6 69 70 2 76 174 6 85 191 7 52 50 1 97 191 7 52 1 6 3 5 R2 205 8 07 220 8 66 170 6 69 95 3 74 174 6 85 191 7 52 75 2 95 191 7 52 1 9 4 2 R3 205 8 07 220 8 66 170 6 69 169 6 65 1...

Page 101: ...75 3 75 3 0 0 3AXD10000299801 xls Type ACS380 04xx Heat dissipation Air flow Noise Frame size Main circuit at rated I1N and I2N Control circuit minimum Control circuit maximum Main and control boards...

Page 102: ...128 66 dB R3 25A0 4 322 11 22 344 128 66 dB R3 032A 4 435 18 30 465 216 69 dB R4 038A 4 537 18 30 566 216 69 dB R4 045A 4 638 18 30 668 216 69 dB R4 050A 4 709 18 30 668 216 69 dB R4 3AXD10000299801 x...

Page 103: ...8 6 6 8 0 5 0 6 5 1 2 10 6 12A2 2 0 2 0 2 24 6 6 10 0 5 0 6 5 1 2 10 6 17A5 2 0 5 0 5 20 16 16 6 1 2 1 5 11 13 1 2 10 6 25A0 2 0 5 0 5 20 16 16 6 1 2 1 5 11 13 1 2 10 6 032A 2 0 5 0 5 20 25 35 2 2 5 3...

Page 104: ...0 14 1 5 26 16 0 5 0 6 4 4 5 3 12A2 2 0 14 1 5 26 16 0 5 0 6 4 4 5 3 17A5 2 0 14 1 5 26 16 0 5 0 6 4 4 5 3 25A0 2 0 14 1 5 26 16 0 5 0 6 4 4 5 3 032A 2 0 14 1 5 26 16 0 5 0 6 4 4 5 3 048A 2 0 14 1 5...

Page 105: ...C1 C2 C3 1 phase UN 200 240 V 02A4 1 RFI 11 FN 21754 6 1 07 x x x 03A7 1 RFI 12 FN 21754 16 1 07 x x x 04A8 1 RFI 12 FN 21754 16 1 07 x x x 06A9 1 RFI 12 FN 21754 16 1 07 x x x 07A8 1 N A N A 09A8 1 N...

Page 106: ...SA C22 2 No 274 13 US and Canada The drive is suitable for use on a circuit capable of delivering not more than 100 kA symmetrical amperes rms at 480 V maximum when protected by fuses given in the fus...

Page 107: ...ng frequency 2 4 8 or 12 kHz Motor cable length Operational functionality and motor cable length The drive is designed to operate with optimum performance with the following maximum motor cable length...

Page 108: ...ons C2 limits with an external EMC filter For 3 phase 380 400 V drives the maximum motor cable lengths are according to C3 in the above table with an internal EMC filter For 1 phase and 3 phase 208 24...

Page 109: ...24 V DC 10 max 1000 mA incl internal fan load Digital inputs DI1 DI4 Voltage 12 24 V DC int or ext supply Max 30 V DC Type PNP and NPN Input impedance Rin 2 kohm Programmable digital I O DIO1 DIO2 As...

Page 110: ...tive Rated conditional short circuit current as defined in IEC 60439 1 Efficiency Approximately 98 at nominal power level Degrees of protection Degree of protection IEC EN 60529 IP20 cabinet installat...

Page 111: ...90 1 For frame R0 10 50 C 14 122 F 40 70 C 2 40 158 F 2 40 70 C 2 40 158 F 2 Relative humidity 0 95 Max 95 Max 95 No condensation allowed Maximum allowed relative humidity is 60 in the presence of co...

Page 112: ...cled as material Plastics rubber cardboard and other packaging material can be used in energy recovery Printed circuit boards and DC capacitors C1 1 to C1 x need selective treatment according to IEC 6...

Page 113: ...on page 115 The declaration is available on the Internet Compliance with the European RoHS Directive The RoHS Directive defines the restriction of the use of certain hazardous substances in electrical...

Page 114: ...fe torque off function and can be equipped with other safety functions for machinery which as safety components are in the scope of the Machinery Directive These functions of the drive comply with Eur...

Page 115: ...less than 1000 V intended for use in the second environment and not intended for use in the first environment Category C1 The conducted emission limits are complied with the following provisions 1 The...

Page 116: ...not install a drive with internal EMC filter connected on corner grounded TN systems otherwise the drive will be damaged To disconnect the EMC filter refer to EMC filter disconnection on page 63 Cate...

Page 117: ...ry and secondary windings can be used 2 An EMC plan for preventing disturbances is drawn up for the installation A template is available from the local ABB representative 3 The motor and control cable...

Page 118: ...ven in the table on page 95 The ampere rating is based on tests done according to the appropriate UL standard The cables located within the motor circuit must be rated for at least 75 C 167 F in UL co...

Page 119: ...s failed as a result of ordinary wear and tear Cyber security disclaimer This product is designed to be connected to and to communicate information and data via a network interface It is Customer s so...

Page 120: ...120 Technical data...

Page 121: ...nsion drawings of ACS380 drive frame sizes R0 R1 R2 R3 and R4 The dimensions are in millimeters and inches Note Drives with the BIO 01 I O extension module are supplied with a high cover part part no...

Page 122: ...122 Dimension drawings Frame R0 1 phase 230 V...

Page 123: ...Dimension drawings 123 Frame R0 400 V...

Page 124: ...124 Dimension drawings Frame R1 230 V...

Page 125: ...Dimension drawings 125 Frame R1 3 phase 230 V and 3 phase 400 V...

Page 126: ...126 Dimension drawings Frame R2 230 V...

Page 127: ...Dimension drawings 127 Frame R2 400 V...

Page 128: ...128 Dimension drawings Frame R3 400 V...

Page 129: ...Dimension drawings 129 Frame R4 400 V...

Page 130: ...130 Dimension drawings...

Page 131: ...esistor can be disconnected Selecting the brake resistor Drives have in built in brake chopper as standard equipment The brake resistor is selected using the table and equations presented in this sect...

Page 132: ...braking pulse J ton length of the braking pulse s T length of the braking cycle s WARNING Do not use a brake resistor with a resistance below the minimum value specified for the particular drive The...

Page 133: ...H 360 C T 406 210R or CAR 200 D T 406 210R Refer to braking resistor manufacturer s documentation 03A7 2 39 319 0 37 0 50 0 56 0 74 04A8 2 39 217 0 55 0 75 0 83 1 10 06A9 2 39 145 0 75 1 00 1 13 1 50...

Page 134: ...gth of the resistor cable s is 10 m 33 ft EMC compliance of the complete installation ABB has not verified that the EMC requirements are fulfilled with external user defined brake resistors and cablin...

Page 135: ...case the resistor overheats This is essential for safety since the drive will not otherwise be able to interrupt the main supply if the chopper remains conductive in a fault situation An example wiri...

Page 136: ...ake resistor assembly on page Brake resistor assembly Connection diagram See section Connecting the power cables on page 65 Connection procedure See section Connecting the power cables on page 65 Conn...

Page 137: ...1 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 paramet...

Page 138: ...138 Resistor braking...

Page 139: ...of the machinery without switching off the power supply to the inverter Note The Safe torque off function does not disconnect the voltage from the drive see the warning on page 146 When activated the...

Page 140: ...quirements for safety related systems and for equipment intended to perform safety related functions functional safety General industrial applications IEC 61508 1 2010 Functional safety of electrical...

Page 141: ...with internal 24 V DC power supply Connection with external 24 V DC power supply S 24 V DC S1 S2 T1 U T2 V T3 W Control board SGND STO UDC UDC A Drive Control logic K S S1 S2 T1 U T2 V T3 W Control bo...

Page 142: ...is 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 If a manually operated activation switch is used the s...

Page 143: ...safety relay contacts open 2 The STO inputs S1 and S2 on the drive control board de energize 3 The STO cuts off the control voltage from the output IGBTs 4 The control program generates an indication...

Page 144: ...safety function Competence The acceptance test of the safety function must be carried out by a competent person with adequate expertise and knowledge of the safety function as well as functional safe...

Page 145: ...rcuit The drive generates an indication if one is defined for the stopped state in parameter 31 22 STO indication run stop see the firmware manual Give a start command to verify that the STO function...

Page 146: ...olating the drive from the main supply 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 S1 If the mot...

Page 147: ...p If this causes danger 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 override...

Page 148: ...ddition 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 Safe torque off operation test desc...

Page 149: ...irmware manual for the indications generated by the drive and for details on directing fault and warning indications to an output on the control unit for external diagnostics Any failures of the Safe...

Page 150: ...odes The STO trips spuriously safe failure The STO does not activate when requested Frame size SIL SILCL PL SFF PFH 1 h PFDavg T1 2a PFDavg T1 5a MTTFD 1 a DC 2 Cat SC HFT CCF Lifetime a 1 phase UN 20...

Page 151: ...ak 1 ms STO response time 5 ms typical 10 ms maximum Fault detection time Channels in different states for longer than 200 ms Fault reaction time Fault detection time 10 ms STO fault indication parame...

Page 152: ...undetected failures during a particular measurement interval under stated conditions PFDavg IEC 61508 Average probability of dangerous failure on demand PFH IEC 61508 Average frequency of dangerous fa...

Page 153: ...r This chapter contains a description and technical data of the optional BTAC 02 pulse encoder interface module and describes how to start up the module Safety instructions WARNING Obey the instructio...

Page 154: ...r to the encoder For more information refer to Wiring Encoder power supply interface on page 157 The BTAC module has the features of the BAPO 01 auxiliary power extension module It provides back up po...

Page 155: ...f you ignore them injury or death or damage to the equipment can occur Wiring General Connect the pulse encoder to the BTAC module with cables as specified in this table If the encoder supply voltage...

Page 156: ...2 B B Encoder signal B terminal B 2 B B Encoder signal B terminal GND Encoder ground X106 Z 3 Z Z Encoder signal Z terminal Z 3 Z Z Encoder signal Z terminal GND Encoder ground Channels Description BT...

Page 157: ...not exceed the load capacity Refer to Auxiliary voltage connection on page 74 Use the following table to determine if you can use the drive s supply Add the missing figures and sum all the sum value...

Page 158: ...ypes refer to the manufacturer s recommendation for the connection You can use single ended or differential output 3 Refer to Wiring diagrams Push pull type encoder output Wiring diagrams Open collect...

Page 159: ...ne the leading channel refer to the encoder documentation or use an oscilloscope Connect the encoder output channel that leads when the drive runs Forward to BTAC terminal A Connect the output channel...

Page 160: ...se encoder interface module Encoder output types Push pull Open collector sinking Open emitter sourcing VCC Encoder input power supply voltage RL Load resistor at encoder output channel OUT VCC OUT VC...

Page 161: ...order in Forward rotation Pulse A leads For encoders with pulse B leading change the diagram Wire encoder A and B to BTAC terminals B and A respectively Wire encoder A and B if present to BTAC termina...

Page 162: ...162 BTAC 02 pulse encoder interface module Single ended connection 1 Encoder 2 BTAC module 3 Encoder power supply 1 2 3 Vin Vout GND A A GND B B GND Z GND Z 1 0 0V VCC 2 SCR 1...

Page 163: ...rotation Pulse A leads For encoders with pulse B leading change the diagram Wire encoder A and B to BTAC terminals B and A respectively 1 Encoder 2 BTAC module 3 Encoder power supply 4 Three identical...

Page 164: ...rotation Pulse A leads For encoders with pulse B leading change the diagram Wire encoder A and B to BTAC terminals B and A respectively 1 Encoder 2 BTAC module 3 Encoder power supply 4 Three identical...

Page 165: ...r speed filter time This parameter is read only 32768 32767 Motor speed used for control 1 1 rpm 100 1 rpm 90 02 Motor position Displays the motor position within one revolution received from the sour...

Page 166: ...dback by running the drive on estimated feedback see 90 41 Motor feedback sel 1 90 46 Force open loop Defines the speed feedback used for motor control No No The motor model uses the feedback selected...

Page 167: ...ation using estimated feedbacks If the drive generates this fault or warning No Name Value Description Def FbEq16 32 92 Encoder 1 configuration 92 10 Pulses rev Defines the TTL or HTL pulse number per...

Page 168: ...size pitch 5 0 mm For the terminals refer to Terminal designations on page 156 Cable The maximum permitted cable length is 100 m Encoder and BTAC module power supply 50 mA BTAC encoder current consump...

Page 169: ...BTAC 02 pulse encoder interface module 169 Dimensions 3AXD50000031154 rev A...

Page 170: ...170 BTAC 02 pulse encoder interface module...

Page 171: ...tents 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 instructions in Safety instructi...

Page 172: ...output extension module option L511 adds four relay outputs to the drive Layout 1 BREL module 2 Locking screw hole 3 X103 connector 4 X104 connector 5 X105 connector 6 X106 connector 7 Internal X100...

Page 173: ...ing Use 0 5 to 2 5 mm2 20 to 14 AWG cable with an appropriate voltage rating for digital signals Refer to Terminal designations on page 173 and connect control wires to the BREL module Apply power 1 T...

Page 174: ...nsion module 5 15 04 RO status Status of the relay outputs 1 1 Bit 0 RO2 Relay 2 output status 1 open 0 closed Bit 1 RO3 Relay 3 output status 1 open 0 closed Bit 2 RO4 Relay 4 output status 1 open 0...

Page 175: ...3 10 1 s 15 13 RO4 source Relay output 4 source selection Relay output 4 is open 0 Relay output 4 is closed 1 For complete parameter list refer to ACS380 Firmware manual 3AXD50000029275 English 15 14...

Page 176: ...2 wire size pitch 5 0 mm For the terminal markings refer to Terminal designations on page 173 Internal connectors Connector X102 provides relay control signals from the control board 1 8 pin header pi...

Page 177: ...ion and technical data of the optional BAPO 01 auxiliary power extension module The chapter also contains references to the relevant other content elsewhere in the manual Safety instructions WARNING O...

Page 178: ...e drive on during a power outage Connect the auxiliary voltage supply to the 24V and DGND terminals on the drive If you change the drive parameters when the control board is energized with the BAPO mo...

Page 179: ...auxiliary voltage supply to the 24V and DGND terminals on the drive Refer to Auxiliary voltage connection on page 74 The BAPO module has internal connections to provide back up power to the control bo...

Page 180: ...extension module Technical data Voltage and current rating for the auxiliary power supply Refer to Auxiliary voltage connection on page 74 Power loss Power losses with maximum load 4 W Dimensions 3AXD...

Page 181: ...iption and technical data of the optional BIO 01 I O extension module The chapter also contains references to the relevant other content elsewhere in the manual Safety instructions WARNING Obey the in...

Page 182: ...e 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...

Page 183: ...e wiring with the ABB standard macro Start up The BIO 01 module is automatically identified by the drive firmware To configure the inputs refer to the ACS380 firmware manual 3AXD50000029275 English Te...

Page 184: ...Technical data Control connection data For BIO 01 electrical data refer to Technical data on page 87 Dimensions Note BIO 01 is supplied with a high cover part part no 3AXD50000190188 that increases t...

Page 185: ...e contacts can be found by navigating to abb com searchchannels Product training For information on ABB product training navigate to new abb com service training Providing feedback on ABB Drives manua...

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ABB ACS380 Series, Hardware Manual

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Summary of Contents for ACS380 Series

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