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

The ABB ACS480-04-09A8-1 is a remarkable hardware device that guarantees efficient performance. To help you make the most of this product, we are pleased to offer the accompanying manual as a free download. Access the comprehensive "Hardware manual" on our website manualshive.com, ensuring seamless operation and long-lasting satisfaction.

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3

Operation principle and
hardware description

Contents of this chapter

This chapter briefly describes the operation principle and construction of the drive.

Operation principle

The ACS480 is a drive for controlling asynchronous AC induction motors, permanent
magnet synchronous motors and ABB synchronous reluctance motors (SynRM motors).
The drive is optimized for cabinet installation.

Operation principle and hardware description 29

Summary of Contents for ACS480-04-09A8-1

Page 1: ... ABB GENERAL PURPOSE DRIVES ACS480 drives Hardware manual ...

Page 2: ......

Page 3: ...rdware manual Table of contents 1 Safety instructions 4 Mechanical installation 6 Electrical installation IEC 7 Electrical installation North America 3AXD50000047392 Rev E EN Original instructions EFFECTIVE 2021 10 04 ...

Page 4: ......

Page 5: ...tart 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 circuit diagram 30 ...

Page 6: ...opean Union and United Kingdom 46 North America 46 Other regions 46 Selecting the main contactor 46 North America 46 Other regions 47 Checking the compatibility of the motor and drive 47 Selecting the power cables 47 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 51 Additional guide...

Page 7: ...ng the Safe torque off function 61 Using a safety switch between the drive and the motor 61 Implementing the control of a contactor between drive and motor 61 Protecting the contacts of relay outputs 6 Electrical installation IEC 63 Contents of this chapter 63 Warnings 63 Required tools 64 Measuring the insulation resistance IEC 64 Measuring the insulation resistance of the drive 64 Measuring the ...

Page 8: ...merica 89 Contents of this chapter 89 Warnings 89 Required tools 90 Measuring the insulation resistance North America 90 Measuring the insulation resistance of the drive 90 Measuring the insulation resistance of the input power cable 90 Measuring the insulation resistance of the motor and motor cable 91 Measuring the insulation resistance of the brake resistor circuit 91 Grounding system compatibi...

Page 9: ...torque off 110 Auxiliary voltage connection 111 Connecting a PC 111 Installing options 112 Installing a front option 113 Installing a side option 8 Installation checklist 115 Contents of this chapter 115 Checklist 9 Maintenance 119 Contents of this chapter 119 Maintenance intervals 119 Description of symbols 120 Recommended maintenance intervals after start up 120 Functional safety components 121 ...

Page 10: ...56 Terminal data for the power cables 158 Terminal data for the control cables 158 External EMC filters 160 Electrical power network specification 161 Motor connection data 161 Motor cable length 161 Operational functionality and motor cable length 162 EMC compatibility and motor cable length 163 Brake resistor connection data 163 Control connection data 164 Energy efficiency data ecodesign 165 Pr...

Page 11: ...ide UL Type 1 kit installed 189 Frame R3 bottom rear UL Type 1 kit installed 190 Frame R4 190 Frame R4 front side IP20 UL open type 191 Frame R4 bottom rear IP20 UL open type 192 Frame R4 front side UL Type 1 kit installed 193 Frame R4 bottom rear UL Type 1 kit installed 12 Resistor braking 195 Contents of this chapter 195 Safety 195 Operation principle 195 Selecting the brake resistor 197 Referen...

Page 12: ... ACS480 drive external power supply 208 Multiple ACS480 drives internal power supply 209 Multiple ACS480 drives external power supply 209 Activation switch 210 Cable types and lengths 210 Grounding of protective shields 211 Operation principle 212 Start up including validation test 212 Competence 212 Validation test reports 212 Validation test procedure 214 Use 216 Maintenance 216 Competence 217 F...

Page 13: ...ion 228 Terminal configuration 229 Electrical installation 229 Start up 229 Technical data 16 BREL 01 relay output extension module 233 Contents of this chapter 233 Safety instructions 233 Hardware description 233 Product overview 234 Layout 234 Mechanical installation 234 Electrical installation 235 Start up 235 Configuration parameters 237 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: ...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 functions...

Page 17: ...top 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 the fault reset unless you configure the drive for pulse start See the firmware manual Before you activate the automatic fault reset or automatic restart functions of the drive control program make sure that no dangerous situations can oc...

Page 18: ...connect all dangerous external voltages from the control circuits After you disconnect power from the drive always wait 5 minutes to let the intermediate circuit capacitors discharge before you continue 3 Protect any other energized parts in the work location against contact 4 Take special precautions when close to bare conductors 5 Measure that the installation is de energized Use a quality volta...

Page 19: ...ields present which can interfere with the function of such devices This can cause a health hazard Note When the drive is connected to the input power the motor cable terminals and the DC bus are at a dangerous voltage The brake circuit including the brake chopper and brake resistor if installed are also at a dangerous voltage After disconnecting the drive from the input power these remain at a da...

Page 20: ... electromagnetic emission and interference In a multiple drive installation connect each drive separately to the protective earth PE busbar of the power supply Additional instructions for permanent magnet motor drives Safety in installation start up maintenance These are additional warnings concerning permanent magnet motor drives The other safety instructions in this chapter are also valid WARNIN...

Page 21: ...ut terminals T1 U T2 V T3 W Connect the output terminals together as well as to the PE During the start up Make sure that the motor cannot run overspeed for example driven by the load Motor overspeed causes overvoltage that can damage or destroy the capacitors in the intermediate circuit of the drive Safety in operation WARNING Make sure that the motor cannot run overspeed for example driven by th...

Page 22: ...22 ...

Page 23: ...art 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 example...

Page 24: ...erica page 91 Installing the drive page 41 Install the drive Routing the cables page 55 Route the cables Measuring the insulation resistance IEC page 64 Measure the insulation of the input cable motor and motor cable Measuring the insulation resistance North America page 90 Connecting the power cables IEC shielded cables page 71 Connect the power cables Connecting the power cables North America wi...

Page 25: ...tion adapter CCA 01 Communication adapter module CDPI 01 The part in which the control program runs Control unit 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 Optional CANopen adap...

Page 26: ...s manual 3AUA0000100140 DPMP 01 mounting platform for ACx AP x control panel 3AUA0000136205 DPMP 02 03 mounting platform for ACx AP x control panel 3AXD50000009929 CDPI 01 02 panel bus adapter user s manual 3AXD50000158584 FEIP 21 Ethernet IP adapter module quick guide 3AXD50000158621 FEIP 21 Ethernet IP fieldbus adapter module user s manual 3AXD50000158522 FENA 21 Ethernet adapter module quick gu...

Page 27: ... user s manual 3AXD50000235254 UL Type 1 kit for ACS380 ACH480 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 P...

Page 28: ...28 ...

Page 29: ...on principle and construction of the drive Operation principle The ACS480 is a drive for controlling asynchronous AC induction motors permanent magnet synchronous motors and ABB synchronous reluctance motors SynRM motors The drive is optimized for cabinet installation Operation principle and hardware description 29 ...

Page 30: ... the DC link voltage 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 DC connection UDC UDC 5 Product variants The drive has two product variants Standard unit drive with assistant control panel and RIIO 01 I O EIA 485 module Base unit drive without control panel and without RII...

Page 31: ...12 Firmware information label 3 Control terminals 13 Control panel connection 4 Cold configuration adapter connection CCA 01 14 Control panel 5 Front option slot 15 EMC filter grounding screw 6 Front option module 16 Varistor grounding screw 7 Side option slot for side mounted options 17 PE connection motor 8 Input power terminals 9 Operation principle and hardware description 31 ...

Page 32: ...DI2 IN1 IN2 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 output 2 Digital inputs 3 Safe torque off connections 4 Relay output connections 5 Cold configuration adapter 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 9 Auxiliar...

Page 33: ...2 Digital inputs 3 Safe torque off connections 4 Relay output connection 5 Cold configuration adapter connection for CCA 01 6 Front option module slot 1 Option modules The drive supports optional extension modules on the front and on the right side Refer to Type designation key page 36 Operation principle and hardware description 33 ...

Page 34: ...mounting and cable 1 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 the ordering codes and installation instructions refer to the table that follows Installat...

Page 35: ...l 1 2 3 4 5 6 7 8 Type designation 1 Frame size 2 Degree of protection 3 Losses according to IEC 61800 9 2 4 Nominal ratings 5 Valid markings 6 S N Serial number of format MYYWWXXXXX where M Manufacturer YY Year of manufacture 19 20 21 for 2019 2020 2021 WW Week of manufacture 01 02 03 for week 1 week 2 week 3 XXXX Running item number that starts each week from 0001 7 QR code to product informatio...

Page 36: ...ule EMC category C2 filter Safe torque off brake chopper coated boards quick installation and start up guide Size See the ratings table in the technical data 12A7 Input voltage 4 1 1 phase 200 240 V AC1 2 3 phase 200 240 V AC 1 4 3 phase 380 480 V AC 1 Not available at the time of publication of this manual Option codes Option codes are separated by plus signs The table below gives the option code...

Page 37: ... CANopen K457 FSCA 01 Modbus RTU K458 FECA 01 EtherCAT K469 FEPL 02 Ethernet POWERLINK K470 FENA 21 2 port Ethernet Ethernet IP Modbus TCP PROFINET K475 FEIP 21 Ethernet IP K490 FMBT 21 Modbus TCP K491 FPNO 21 PROFINET K492 Documentation1 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 ...

Page 38: ...38 ...

Page 39: ...a degree of protection of IP20 UL open type as standard 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 a minimum of 50 mm 2 in of free space at the top measured from the top of the hood and 75...

Page 40: ...the specifications See the technical data The wall behind the drive 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...

Page 41: ...e clamps cable ties hardware multilingual warning sticker sheet residual voltage warning safety instructions quick installation and start up guide hardware and firmware manuals if ordered with an option code Make sure that there are no signs of damage to the items Installing the drive To install the drive with screws 1 Make marks onto the surface for the mounting holes Use the included mounting te...

Page 42: ...EN 60715 top hat type installation rail width height 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 42 Mechanical installation ...

Page 43: ...se the locking button 6 Move the locking part to the right 7 Make sure that the drive is correctly installed To remove the drive use a flat head screwdriver to open the locking part Mechanical installation 43 ...

Page 44: ...44 ...

Page 45: ...soever for any installation which breaches the local laws and or other regulations Furthermore if the recommendations given by ABB are not followed the drive may experience problems that the warranty does not cover Selecting the main supply disconnecting 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 dis...

Page 46: ...he disconnecting device must conform to the applicable local safety regulations Selecting the main contactor You can equip the drive with a main contactor Follow these guidelines when you select a customer defined main contactor Dimension the contactor according to the nominal voltage and current of the drive Also consider the environmental conditions such as surrounding air temperature IEC device...

Page 47: ...egulations and laws Temperature For an IEC installation select a cable rated for at least 70 C 158 F maximum permissible temperature of conductor in continuous use For North America select a cable rated for at least 75 C 167 F Important For certain product types or option configurations higher temperature rating may be required See the technical data for details Voltage 600 V AC cable is accepted ...

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: ...l con duit is always recommended to minimize radio frequency inter ference Yes with phase conductor smaller than 10 mm2 8 AWG Cu or motors up to 30 kW 40 hp Yes EMT Four conductor cabling in met al conduit three phase con ductors and PE For example EMT or four conductor ar mored cable Yes with motors up to 100 kW 135 hp A potential equaliza tion between the frames of mo tor and driven equipment is...

Page 50: ...may act as an EMC shield as long as it provides the same performance as a concentric EMC shield of a shielded cable To be effective at high frequencies the shield conductivity must be at least 1 10 of the phase conductor conductivity The effectiveness of the shield can be evaluated based on the shield inductance which must be low and only slightly dependent on frequency The requirements are easily...

Page 51: ...or wiring in the same conduit Wireways 2 Prefer symmetrical shielded VFD cable Metallic Separate motor wiring from input power wiring and other low voltage wiring Do not run outputs of multiple drives parallel Bundle each cable wiring together and use separators where possible Free air 2 Prefer symmetrical shielded VFD cable Enclosures air handlers etc Allowed internally in enclosures when in acco...

Page 52: ... gives general requirements for grounding the drive When you plan the grounding of the drive obey all the applicable national and local regulations The conductivity of the protective earth conductor s must be sufficient Unless local wiring regulations state otherwise the cross sectional area of the protective earth conductor must agree with the conditions that require automatic disconnection of th...

Page 53: ...ents IEC This section gives grounding requirements according to standard IEC EN 61800 5 1 Because the normal touch current of the drive is more than 3 5 mA AC or 10 mA DC the minimum size of the protective earth conductor must comply with the local safety regulations for high protective earth conductor current equipment and you must use one of these connection methods 1 a fixed connection and a pr...

Page 54: ...ecting the control cables Shielding Only use shielded control cables Use a double shielded twisted pair cable for analog signals This type of cable is recommended for the pulse encoder signals also Use one individually shielded pair for each signal Do not use common return for different analog signals A double shielded cable a is the best alternative for low voltage digital signals but single shie...

Page 55: ...next to each other Install the motor cable input power cable and control cables on separate trays Avoid long parallel runs of motor cables with other cables Where control cables must cross power cables make sure that they are arranged at an angle as near to 90 degrees as possible Do not run extra cables through the drive Make sure that the cable trays have good electrical bonding to each other and...

Page 56: ...guidelines North America Make sure that the installation is in accordance with national and local codes Obey these general guidelines Use separate conduits for the input power motor brake resistor optional and control cabling Use separate conduit for each motor cabling The following figure illustrates the cable routing guidelines with an example drive 56 Guidelines for planning the electrical inst...

Page 57: ...quipment 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 conduit to the protective ground terminal of the drive and the motor G...

Page 58: ...rd the fuses also 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 output current of the drive Protecting the drive and the input power and m...

Page 59: ... 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 and the common UL IEC 61800 5 1 standard in conjunction with UL IEC 60947 4 1 The standards allow for motor overload protection without external temperature sensors The protection feature allows the user to specify ...

Page 60: ...n connect a sensor to a digital input of the drive via an external relay The sensor and the relay must form a double or reinforced insulation between the motor live parts and the digital input of the drive Make sure that the voltage does not exceed the maximum allowed voltage over the sensor Protecting the drive against ground faults The drive is equipped with an internal ground fault protective f...

Page 61: ... If vector motor control mode is in use do not open the output contactor while the 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 ...

Page 62: ...230 V AC 230 V AC 24 V DC 1 2 3 4 Relay output 1 Varistor 2 RC filter 3 Diode 4 62 Guidelines for planning the electrical installation ...

Page 63: ... 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 screwdriver or wrench with a set of suitable bits For motor cable terminals the...

Page 64: ...nsulation resistance 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 18 before you start the work 2 Make sure that the motor cable is disconne...

Page 65: ...esistor 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 1000 V DC 1 Mohm Grounding system compatibility c...

Page 66: ...etrically grounded TN S system center grounded wye For other systems refer to Compatibility of EMC filter and ground to phase varistor with the grounding system page 66 In some product variants the varistor circuit is disconnected at the factory WARNING Do not install the drive with the ground to phase varistor connected to a system that the varistor is not suitable for If you do the varistor circ...

Page 67: ...ms i e center grounded wye A Remove Remove Do not remove Metal EMC Do not remove Do not remove Do not remove1 Plastic Remove Do not remove Do not remove Metal VAR Do not remove Do not remove Do not remove 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 1 Can install the metal screw included in the drive delivery to connect the internal EMC filter For t...

Page 68: ...ibility of EMC filter and ground to phase varistor with the grounding system page 66 To disconnect the EMC filter remove the metal EMC screw To disconnect the ground to phase varistor remove the metal VAR screw EMC VAR screw location Frames R0 R2 Frame R4 Frame R3 68 Electrical installation IEC ...

Page 69: ...unding 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 grounding syste...

Page 70: ... 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 ...

Page 71: ...cable line side Use a separate grounding cable or a cable with a separate PE conductor for the line side if the conductivity of the fourth conductor or shield does not meet the requirements for the PE conductor 5 Motor cable Note ABB recommends to use a symmetrical shielded cable VFD cable as the motor cable 6 Separate PE cable motor side Use a separate grounding cable for the motor side if the co...

Page 72: ... the steps in section Electrical safety precautions page 18 before you start the work 2 Remove the screw on 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 for 360 degree grounding 6 Twist the motor cable shield into a bundle mark it w...

Page 73: ... shield under the clamp for 360 degree grounding Twist the shield also into a bundle mark it with yellow green insulation tape install a cable lug and connect it to the grounding terminal 12 Connect the protective earth ground conductor s of the input power cable to the grounding terminal 13 Connect the phase conductors of the input power cable to the drive as follows 1 phase drives connect the ph...

Page 74: ...ohm Output frequency 0 10 V AI1 2 Analog input circuit common AGND 3 Reference voltage 10 V DC 10V 4 Not configured AI2 5 Analog input circuit common AGND 6 Output frequency 0 20 mA AO1 7 Motor current 0 20 mA AO2 8 Analog output circuit common AGND 9 Digital inputs and auxiliary voltage output Aux voltage output 24 V DC max 250 mA3 24V 10 24 V DGND DCOM DI1 DI2 DI3 DI4 DI5 DI6 24 V DGND DCOM DI1 ...

Page 75: ... S100 Safe torque off Safe torque off Factory connection Both circuits must be closed for the drive to start SGND 34 OUT1 SGND IN1 IN2 IN1 35 IN2 36 OUT1 37 Auxiliary voltage input output Aux voltage output 24 V DC max 250 mA 3 24V 42 24 V DGND DCOM Aux voltage output common DGND 43 Digital input common for all DCOM 44 1 Terminal size 0 14 1 5 mm2 26 16 AWG Tightening torque 0 5 0 6 N m 4 4 5 3 lb...

Page 76: ... input common for all DCOM 12 Ready run 250 V AC 30 V DC 2 A Common RO1C 19 Norm closed RO1A 20 Norm open RO1B 21 Safe torque off Safe torque off Factory connection Both circuits must be closed for the drive to start SGND 34 OUT1 SGND IN1 IN2 IN1 35 IN2 36 OUT1 37 Fieldbus connection K457 FCAN 01 CANopen DSUB9 See the applicable fieldbus adapter manu al K454 FPBA 01 Profibus DP DSUB9 K469 FECA 01 ...

Page 77: ...cal safety precautions page 18 before you start the work 2 Remove the screw on the drive front cover and lift the front cover up 3 Strip a part of the outer shield of the control cable for grounding 4 Use a cable tie to ground the outer shield to the grounding tab For 360 degree grounding use metallic cable ties 5 Strip the control cable conductors 6 Connect the conductors to the correct control t...

Page 78: ...e acceptable Connect the cable to the EIA 485 terminal on the RIIO 01 I O module Obey these wiring instructions Attach the cable shields together at each drive but do not connect them to the drive Connect the cable shields only to the grounding terminal in the automation controller Connect the signal ground DGND conductor to the signal ground reference terminal in the automation controller If the ...

Page 79: ... ON 1 B A B A B A Without signal ground reference terminal G B A DGND 1 2 B A DGND 2 B A DGND 2 100 ohm 3 3 3 ON 1 ON 1 ON 1 Automation controller 1 Drive 2 Termination switch The devices at the ends of the fieldbus must have termination on All other devices must have termination off 3 Electrical installation IEC 79 ...

Page 80: ... 24 V 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 figures below External 24 V power supply with BAPO 01 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 80 Ele...

Page 81: ... examples 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 24...

Page 82: ...page 59 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 o...

Page 83: ...ce voltage 3 AI1 and AI2 as Pt100 Pt1000 Ni1000 KTY83 and KTY84 sensor inputs WARNING IEC 61800 5 1 requires 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 dri...

Page 84: ...efore connecting external Safe torque off circuitry to the drive See chapter The Safe torque off function Auxiliary voltage 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 kee...

Page 85: ... 9 8 ft to connect to the PC Connect the cable as follows 1 Open the USB connector cover on the control panel 2 Connect the USB cable Mini B plug to the control panel USB connector 3 Connect the USB cable A plug to the USB port of the PC The panel shows text USB 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 pan...

Page 86: ...ge 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 18 before you start the work 2 Remove the screw on the drive 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 slo...

Page 87: ...alified electrical professional do not do installation or maintenance work 1 Do the steps in section Electrical safety precautions page 18 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 Torque the screw...

Page 88: ...to the bottom of the side option and to the front ground tab on the drive Torque the screws to 1 N m 8 8 lbf in 7 Connect the control cables See the control cable connection instructions 5 6 7 2 3 4 88 Electrical installation IEC ...

Page 89: ...ect 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 i...

Page 90: ...nsulation resistance according to local regulations Measuring the insulation resistance 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 18 bef...

Page 91: ...ical safety precautions page 18 before 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 ...

Page 92: ... Ground to phase varistor The drive has a ground to phase varistor circuit as standard You can install a drive that has the varistor circuit connected to a symmetrically grounded TN S system center grounded wye For other systems refer to Compatibility of EMC filter and ground to phase varistor with the grounding system page 92 In some product variants the varistor circuit is disconnected at the fa...

Page 93: ...r grounded wye A Remove Remove Do not remove Metal EMC Do not remove Do not remove Do not remove1 Plastic Remove Do not remove Do not remove Metal VAR Do not remove Do not remove Do not remove 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 1 Can install the metal screw included in the drive delivery to connect the internal EMC filter For the locations...

Page 94: ...d to phase varistor with the grounding system page 92 To disconnect the ground to phase varistor remove the metal VAR screw 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 Frames R0 R2 Frame R4 Frame R3 94 Electrical installation North America ...

Page 95: ...g 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 grounding system exa...

Page 96: ...dpoint 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 versu...

Page 97: ...ion diagram PE PE L1 L2 L3 R R UDC UDC U1 W1 PE T1 U T2 V T3 W V1 1 2 3 4 5 6 7 PE L1 L2 L3 L N M 3 Drive 1 Drive enclosure 2 Supply disconnecting device and fuses 3 Input power wiring 4 Protective earth ground conductor s 5 Motor wiring Note ABB recommends to use a symmetrical shielded cable VFD cable as the motor cable 6 Brake resistor optional 7 Electrical installation North America 97 ...

Page 98: ...page 18 before you start the work 2 Install the conduits and attach them to the cable entry plate of the enclosure that the drive is installed in 3 Make sure that the conduit is correctly grounded at the cable entry 4 Strip the conductor ends and pull the conductors through the conduits 5 Remove the screw on the drive front cover then lift the front cover up 6 Attach the residual voltage warning s...

Page 99: ...do not connect cables to the terminals 11 Connect the protective earth ground conductor s of the input power wiring to the grounding terminal 12 Connect the phase conductors of the input power wiring to the drive as follows 1 phase drives connect the phase and neutral conductors to terminals L1 and L2 For example connect phase to L1 and neutral to L2 3 phase drives connect the phase conductors to ...

Page 100: ...module ABB standard macro parameter 96 04 is used with the default parameter settings 2 Description Terminal1 Connection Analog inputs and outputs Signal cable shield screen SCR 1 SCR AI1 AGND 10 V AI2 AGND AO1 AO2 AGND 1 10 kohm Max 500 ohm Output frequency 0 10 V AI1 2 Analog input circuit common AGND 3 Reference voltage 10 V DC 10V 4 Not configured AI2 5 Analog input circuit common AGND 6 Outpu...

Page 101: ...250 mA 3 24V 10 RO2C RO2A RO2B RO3C RO3A RO3B RO1C RO1A RO1B 24 V DGND DCOM 24 V DGND DCOM Aux voltage output common DGND 11 Digital input common for all DCOM 12 Ready run 250 V AC 30 V DC 2 A Common RO1C 19 Norm closed RO1A 20 Norm open RO1B 21 Running 250 V AC 30 V DC 2 A Common RO2C 22 Norm closed RO2A 23 Norm open RO2B 24 Fault 1 250 V AC 30 V DC 2 A Common RO3C 25 Norm closed RO3A 26 Norm ope...

Page 102: ... 28 72 28 73 28 74 and 28 75 Default fieldbus connection diagram The connection diagrams are applicable to the base unit with an optional fieldbus adapter module ABB standard macro parameter 96 04 is used with its default parameter settings 2 Description Terminal1 Connection Auxiliary voltage output and digital inputs Aux voltage output 24 V DC max 250 mA 24V 10 24 V DGND DCOM DI1 DI2 24 V DGND DC...

Page 103: ... 6 N m 4 4 5 3 lbf in 2 base unit empty fieldbus module Control cable connection procedure Do the connections according to the control macro parameter 96 04 used Keep the signal wire pairs twisted as near to the terminals as possible to prevent inductive coupling 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...

Page 104: ...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 Connect the cable to the EIA 485 terminal on the RIIO 01 I O module Obey these wiring instructions Attach the cable shields together at each drive but do not connect them to the drive Connect the cable shields only to the grounding termi...

Page 105: ... B A B A B A Without signal ground reference terminal G B A DGND 1 2 B A DGND 2 B A DGND 2 100 ohm 3 3 3 ON 1 ON 1 ON 1 Automation controller 1 Drive 2 Termination switch The devices at the ends of the fieldbus must have termination on All other devices must have termination off 3 Electrical installation North America 105 ...

Page 106: ...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 figures below External 24 V power supply with BAPO 01 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 106 Electric...

Page 107: ...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 108: ...59 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 over t...

Page 109: ...tage 3 AI1 and AI2 as Pt100 Pt1000 Ni1000 KTY83 and KTY84 sensor inputs WARNING IEC 61800 5 1 requires 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 drive If ...

Page 110: ...connecting external Safe torque off circuitry to the drive See chapter The Safe torque off function Auxiliary voltage 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 ...

Page 111: ...t to connect to the PC Connect the cable as follows 1 Open the USB connector cover on the control panel 2 Connect the USB cable Mini B plug to the control panel USB connector 3 Connect the USB cable A plug to the USB port of the PC The panel shows text USB 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...

Page 112: ... 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 18 before you start the work 2 Remove the screw on the drive 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 and...

Page 113: ...d electrical professional do not do installation or maintenance work 1 Do the steps in section Electrical safety precautions page 18 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 Torque the screw on th...

Page 114: ... bottom of the side option and to the front ground tab on the drive Torque the screws to 1 N m 8 8 lbf in 7 Connect the control cables See the control cable connection instructions 5 6 7 2 3 4 114 Electrical installation North America ...

Page 115: ... ignore them injury or death or damage to the equipment can occur If you are not a qualified electrical professional do not do installation or maintenance work WARNING Stop the drive and do the steps in section Electrical safety precautions page 18 before you start the work Make sure that The ambient operating conditions meet the drive ambient conditions specification and enclosure rating IP code ...

Page 116: ...red 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 The motor cable is routed away from other cables No power factor compensation capacitors are connected to the motor cable If an external brake resistor is connected to the drive There is an adequately sized pro tective earth ground ...

Page 117: ...nt of the drive is clean the drive cooling fan cannot draw any dust or dirt inside Drive covers and cover of the motor connection box are in place The motor and the driven equipment are ready for power up Installation checklist 117 ...

Page 118: ...118 ...

Page 119: ...The complete maintenance schedule is available on the Internet www abb com drivesservices For more information consult your local ABB Service representative www abb com searchchannels Description of symbols Description Action Inspection visual inspection and maintenance action if needed I Performance of on off site work commissioning tests measurements or other P work Replacement R Maintenance 119...

Page 120: ...ent replacement intervals are based on the assumption that the equipment is operated within the specified ratings and ambient conditions ABB recommends annual drive inspections to ensure the highest reliability and optimum performance Long term operation near the specified maximum ratings or ambient conditions may require shorter maintenance intervals for certain components Consult your local ABB ...

Page 121: ...tsink as follows WARNING Use the required personal protective equipment Wear protective gloves and long sleeves Some parts have sharp edges WARNING Use a vacuum cleaner with antistatic hose and nozzle and wear a grounding wristband Using a normal vacuum cleaner creates static discharges which can damage circuit boards 1 Stop the drive and do the steps in section Electrical safety precautions page ...

Page 122: ...essional do not do installation or maintenance work 1 Stop the drive and do the steps in section Electrical safety precautions page 18 before you start the work 2 Use a suitable flat screwdriver to open the fan cover 3 Carefully lift the fan cover out of the drive The fan cover holds the cooling fan 2 3 4 Remove the fan power cable from the cable slot in the drive 5 Disconnect the fan power cable ...

Page 123: ...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 11 Push the cover to lock into position 10 11 Maintenance 123 ...

Page 124: ...al professional do not do installation or maintenance work 1 Stop the drive and do the steps in section Electrical safety precautions page 18 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 4 Lift and pull the fan from its base 5 Disconnect the fan power cable from the extension cable connector 4 5 124 Maintenance ...

Page 125: ... 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...

Page 126: ...126 ...

Page 127: ... IEC ratings Frame Output ratings Input current IEC type ACS480 04 Heavy duty use Light duty use Nominal use Max cur rent With choke No choke PHd IHd PLd ILd PN IN Imax I1N I1N kW A kW A kW A A A A 1 phase UN 230 V R0 0 25 1 8 0 37 2 3 0 37 2 4 3 2 4 2 5 0 02A4 1 R0 0 37 2 4 0 55 3 5 0 55 3 7 4 3 6 4 7 1 03A7 1 R1 0 55 3 7 0 75 4 6 0 75 4 8 6 7 8 3 8 8 04A8 1 R1 0 75 4 8 1 1 6 6 1 1 6 9 8 6 11 9 1...

Page 128: ... 5 25 0 7 5 30 8 7 5 32 0 45 0 32 0 37 0 032A 2 R4 7 5 32 0 11 0 46 2 11 0 48 0 57 6 48 0 50 0 048A 2 R4 11 0 48 0 15 0 52 8 15 0 55 0 86 4 55 0 60 0 055A 2 3 phase UN 400 V R1 0 55 1 8 0 75 2 5 0 75 2 6 3 2 2 6 3 8 02A7 4 R1 0 75 2 6 1 1 3 1 1 1 3 3 4 7 3 3 5 1 03A4 4 R1 1 1 3 3 1 5 3 8 1 5 4 0 5 9 4 0 6 4 04A1 4 R1 1 5 4 0 2 2 5 3 2 2 5 6 7 2 5 6 8 9 05A7 4 R1 2 2 5 6 3 0 6 8 3 0 7 2 10 1 7 2 10...

Page 129: ... 3 06A6 2 R1 1 5 6 6 2 0 7 5 12 4 7 5 9 2 07A5 2 R2 3 0 9 3 3 0 11 6 17 6 11 6 12 8 11A6 2 R3 3 0 11 6 5 0 16 7 22 0 16 7 20 5 017A 2 R3 5 0 16 7 7 5 24 2 31 5 24 2 29 7 024A 2 R4 7 5 24 2 10 0 30 8 45 0 30 8 36 0 031A 2 R4 10 0 30 8 15 0 46 2 57 6 46 2 50 5 046A 2 R4 15 0 46 2 20 0 52 8 86 4 52 8 57 6 053A 2 3 phase UN 480 V R1 0 75 1 6 1 0 2 1 3 2 2 1 3 0 02A1 4 R1 1 0 2 1 1 5 3 0 4 7 3 0 4 3 03...

Page 130: ...ypical motor power in nominal use no overloading The kilowatt ratings are applicable to most IEC 4 pole motors ILd Continuous rms output 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 motors The horsepower ratings are applicable to most NEMA 4 pole motors IHd Continuous rms output...

Page 131: ...at 400 V Calculate the derated output current at 4 kHz switching frequency at 1500 m altitude and at 55 C surrounding air temperature Switching frequency derating Derating is not necessary at 4 kHz Altitude derating The derating factor for 1500 m is Surrounding air temperature derating The derating factor for 55 C surrounding air temperature is Multiply the nominal drive output current by all the ...

Page 132: ...e output current In this example the derated output current is sufficient because it is higher than the required current Example 2 UL NEC How to calculate the required drive The application 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 ai...

Page 133: ...28 ft above 1000 m 3281 ft 400 480 V drives At altitudes 1000 4000 m 3281 13123 ft above sea level the derating is 1 for each added 100 m 328 ft above 1000 m 3281 ft In addition A maximum altitude of 4000 m 13123 ft is permitted for these grounding systems TN S TT A maximum altitude of 2000 m 6562 ft is permitted for these grounding systems corner grounded delta midpoint grounded delta IT unground...

Page 134: ...efault value 1 5 kHz Higher switching frequencies decrease the product life time or the performance in the temperature range 40 60 C 104 140 F Derating factor IEC type ACS480 04 12 kHz 8 kHz 4 kHz 1 phase UN 230 V 0 66 0 80 1 0 02A4 1 0 66 0 80 1 0 03A7 1 0 68 0 81 1 0 04A8 1 0 68 0 81 1 0 06A9 1 0 74 0 85 1 0 07A8 1 0 74 0 85 1 0 09A8 1 0 69 0 82 1 0 12A2 1 3 phase UN 230 V 0 73 0 84 1 0 02A4 2 0...

Page 135: ...V 0 66 0 80 1 0 02A3 1 0 66 0 80 1 0 03A5 1 0 68 0 81 1 0 04A6 1 0 68 0 81 1 0 06A6 1 0 74 0 85 1 0 07A4 1 0 74 0 85 1 0 09A3 1 0 69 0 82 1 0 11A6 1 3 phase UN 230 V 0 73 0 84 1 0 02A3 2 0 73 0 84 1 0 03A5 2 0 73 0 84 1 0 04A6 2 0 73 0 84 1 0 06A6 2 0 70 0 83 1 0 07A5 2 0 61 0 76 1 0 11A6 2 0 61 0 76 1 0 017A 2 0 60 0 75 1 0 024A 2 0 59 0 75 1 0 031A 2 0 60 0 74 1 0 046A 2 0 60 0 74 1 0 053A 2 3 p...

Page 136: ... meet the ratings and if the melting curve of the fuse does not exceed the melting curve of the fuse mentioned in the table IEC fuses Either fuse type can be used if it operates rapidly enough gG fuses IEC Make sure that the operating 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 ACS480 04 IEC 60269 size ABB ty...

Page 137: ...hase 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 OFAF000H16 500 740 16 128 11 5 07A3 4 000 OFAF000H16 500 740 16 128 15 0 09A5 4 000 OFAF000H25 500 2500 25 200 20 2 12A7 4 000 OFAF000H32 500 4500 32 256 27 2 018A 4 000 OFAF000H50 500 15500 50 400 40 0 026A 4 000 OFAF000H63 5...

Page 138: ... 1000 50 200 18 3 12A2 2 00 170M2698 690 1800 63 256 24 6 17A5 2 00 170M2699 690 3600 80 400 35 1 25A0 2 00 170M2700 690 6650 100 504 45 032A 2 00 170M2702 690 22500 160 800 57 6 048A 2 00 170M2702 690 22500 160 800 60 055A 2 3 phase UN 400 V 00 170M2694 690 125 25 48 4 2 02A7 4 00 170M2694 690 125 25 48 5 3 03A4 4 00 170M2695 690 275 32 80 6 4 04A1 4 00 170M2695 690 275 32 80 9 0 05A7 4 00 170M26...

Page 139: ...7 2 04A6 2 25 UL class T JJS TJS20 600 20 10 4 06A6 2 25 UL class T JJS TJS20 600 20 11 7 07A5 2 30 UL class T JJS TJS25 600 25 18 3 11A6 2 40 UL class T JJS TJS35 600 35 24 6 017A 2 40 UL class T JJS TJS40 600 40 35 1 024A 2 100 UL class T JJS TJS60 600 60 45 0 031A 2 100 UL class T JJS TJS100 600 100 57 6 046A 2 100 UL class T JJS TJS100 600 100 60 0 053A 2 3 phase UN 480 V 25 UL class T JJS TJS...

Page 140: ...r UL listed 248 fast acting time delay or high speed fuses must be used to maintain the UL listing of the drive Additional protection can be used Refer to local codes and regulations 5 A fuse of a different class can be used at the high fault rating where the Ipeak and I2t of the new fuse is not greater than that of the specified fuse 6 UL listed 248 fast acting time delay or high speed fuses from...

Page 141: ...S020 JJS 20 600 20 15 0 07A6 4 TJS25 A6T25 JLLS025 JJS 25 600 25 20 2 011A 4 TJS35 A6T35 JLLS035 JJS 35 600 35 27 2 014A 4 TJS40 A6T40 JLLS040 JJS 40 600 40 40 0 021A 4 TJS60 A6T60 JLLS060 JJS 60 600 60 45 0 027A 4 TJS80 A6T80 JLLS080 JJS 80 600 80 50 0 034A 4 TJS100 A6T100 JLLS100 JJS 100 600 100 60 0 042A 4 UL 248 8 Fast Acting Class J Fuses Fuse Drive input current UL NEC type ACS480 04 Edison ...

Page 142: ...JKS 100 600 100 60 0 042A 4 UL 248 8 High Speed Class J Fuses Fuse Drive input current UL NEC type ACS480 04 Edison Mersen Ferraz Shawmut Littelfuse Bussmann Voltage rating Max current V A A 3 phase UN 230 V JHL6 HSJ6 LDFJ006 DFJ 6 600 6 3 6 02A3 2 JHL10 HSJ10 LDFJ010 DFJ 10 600 10 5 6 03A5 2 JHL10 HSJ10 LDFJ010 DFJ 10 600 10 7 2 04A6 2 JHL20 HSJ20 LDFJ020 DFJ 20 600 20 10 4 06A6 2 JHL20 HSJ20 LDF...

Page 143: ... Max current V A A 3 phase UN 230 V HCLR6 ATMR6 KLKR6 KTK R 6 600 6 3 6 02A3 2 HCLR10 ATMR10 KLKR10 KTK R 10 600 10 5 6 03A5 2 HCLR10 ATMR10 KLKR10 KTK R 10 600 10 7 2 04A6 2 HCLR20 ATMR20 KLKR20 KTK R 20 600 20 10 4 06A6 2 HCLR20 ATMR20 KLKR20 KTK R 20 600 20 11 7 07A5 2 HCLR25 ATMR25 KLKR25 KTK R 25 600 25 18 3 11A6 2 3 phase UN 480 V HCLR6 ATMR6 KLKR6 KTK R 6 600 6 4 2 02A1 4 HCLR6 ATMR6 KLKR6 ...

Page 144: ...6 4 03A5 4 FCF10RN 600 10 9 0 04A8 4 FCF20RN 600 20 11 5 06A0 4 FCF20RN 600 20 15 0 07A6 4 FCF25RN 600 25 20 2 011A 4 FCF25RN 600 35 27 2 014A 4 FCF40RN 600 40 40 0 021A 4 FCF60RN 600 60 45 0 027A 4 FCF80RN 600 80 50 0 034A 4 FCF100RN 600 100 60 0 042A 4 Input chokes The table in section Electrical power network specification page 160 shows when to use an input choke The tables that follow give th...

Page 145: ...ABB 25A0 2 R4 Contact ABB 032A 2 R4 Contact ABB 048A 2 R4 Contact ABB 055A 2 3 phase UN 400 V R1 ABB CHK 01 02A7 4 R1 ABB CHK 01 03A4 4 R1 ABB CHK 02 04A1 4 R1 ABB CHK 02 05A7 4 R1 ABB CHK 02 07A3 4 R1 ABB CHK 03 09A5 4 R2 ABB CHK 03 12A7 4 R3 ABB CHK 04 018A 4 R3 ABB CHK 04 026A 4 R4 ABB CHK 05 033A 4 R4 ABB CHK 06 039A 4 R4 ABB CHK 06 046A 4 R4 ABB CHK 07 050A 4 Frame Input choke UL NEC type ACS...

Page 146: ...B CHK 01 02A1 4 R1 ABB CHK 01 03A0 4 R1 ABB CHK 02 03A5 4 R1 ABB CHK 02 04A8 4 R1 ABB CHK 02 06A0 4 R1 ABB CHK 03 07A6 4 R2 ABB CHK 03 011A 4 R3 ABB CHK 04 014A 4 R3 ABB CHK 04 021A 4 R4 ABB CHK 05 027A 4 R4 ABB CHK 06 034A 4 R4 ABB CHK 07 042A 4 Alternative short circuit protection Miniature circuit breakers IEC If you use a miniature circuit breaker for the short circuit protection of the drive ...

Page 147: ...h the drive if they provide the same electrical characteristics ABB does not assume any liability whatsoever for the correct function and protection of the circuit breakers not specified by ABB Furthermore if the specifications given by ABB are not obeyed the drive can experience problems the warranty does not cover Network SC 1 Miniature circuit breaker Frame IEC type ACS480 04 kA ABB type 1 phas...

Page 148: ...rect ABB Type E manual motor protector is selected from the table and used for branch circuit protection the drive is suitable for use in a circuit capable of delivering no more than 65 kA rms symmetrical amperes at the maximum rated voltage of the drive See the table below for the appropriate MMP types and minimum enclosure volume of IP20 UL open type drive mounted in an enclosure If you use a ma...

Page 149: ...3 25 5 R1 02A1 4 1850 30 3 MS132 6 3 S1 M3 25 5 R1 03A0 4 1850 30 3 MS132 10 S1 M3 25 5 R1 03A5 4 1850 30 3 MS132 10 S1 M3 25 5 R1 04A8 4 1850 30 3 MS165 16 R1 06A0 4 1850 30 3 MS165 16 R1 07A6 4 1850 30 3 MS165 20 R2 011A 4 1850 30 3 MS165 32 R3 014A 4 1850 30 3 MS165 42 R3 021A 4 4577 75 0 MS165 54 R4 027A 4 4577 75 0 MS165 65 R4 034A 4 4577 75 0 MS5100 100 MS165 80 R4 042A 4 1 All manual motor ...

Page 150: ...plied with the ABB Type E MMP shown in the table Fuses must be used for wall mounted drives installed with a UL Type 1 kit 5 Requires the use of the S1 M3 25 line side feeder terminal with the manual motor protector to meet Type E self protection class Dimensions and weights Dimensions and weights IP20 UL open type Frame Weight M2 M1 D W H3 H2 H1 lb kg in mm in mm in mm in mm in mm in mm in mm 3 6...

Page 151: ...d from the top of the hood 2 A side mounted option module requires 20 mm 0 8 in of free space on the right side of the drive Losses cooling data and noise Drives with frame size R0 have natural convection cooling Drives with frame size R1 R4 have a cooling fan The air flow direction is from bottom to top Frame size Noise Air flow Typical power loss1 IEC type ACS480 04 dB A CFM m3 h BTU h W 1 phase...

Page 152: ... 69 88 150 2307 676 055A 2 3 phase UN 400 V R1 63 33 57 150 44 02A7 4 R1 63 33 57 188 55 03A4 4 R1 63 33 57 212 62 04A1 4 R1 63 33 57 311 91 05A7 4 R1 63 33 57 341 100 07A3 4 R1 63 33 57 478 140 09A5 4 R2 59 37 63 563 165 12A7 4 R3 66 75 128 884 259 018A 4 R3 66 75 128 1331 390 026A 4 R4 69 88 150 1351 396 033A 4 R4 69 88 150 1696 497 039A 4 R4 69 88 150 1986 582 046A 4 R4 69 88 150 2293 672 050A ...

Page 153: ...63 33 57 150 44 02A1 4 R1 63 33 57 188 55 03A0 4 R1 63 33 57 212 62 03A5 4 R1 63 33 57 311 91 04A8 4 R1 63 33 57 341 100 06A0 4 R1 63 33 57 478 140 07A6 4 R2 59 37 63 563 165 011A 4 R3 66 75 128 884 259 014A 4 R3 66 75 128 1331 390 021A 4 R4 69 88 150 1351 396 027A 4 R4 69 88 150 1696 497 034A 4 R4 69 88 150 2293 672 042A 4 1 Typical drive losses when it operates at 90 of the motor nominal frequen...

Page 154: ...5 1 5 06A9 2 R1 16 3 1 5 1 5 07A8 2 R1 14 3 2 5 2 5 09A8 2 R2 14 3 2 5 2 5 12A2 2 R3 14 3 6 6 17A5 2 R3 10 3 6 6 25A0 2 R4 8 3 10 10 032A 2 R4 4 3 25 16 048A 2 R4 4 3 25 16 055A 2 3 phase UN 400 V R1 16 3 1 5 1 5 02A7 4 R1 16 3 1 5 1 5 03A4 4 R1 16 3 1 5 1 5 04A1 4 R1 16 3 1 5 1 5 05A7 4 R1 16 3 1 5 1 5 07A3 4 R1 14 3 2 5 2 5 09A5 4 R2 14 3 2 5 2 5 12A7 4 R3 10 3 6 6 018A 4 R3 10 3 6 6 026A 4 R4 8...

Page 155: ...5 1 5 04A6 2 R1 16 3 1 5 1 5 06A6 2 R1 16 3 1 5 1 5 07A5 2 R2 14 3 2 5 2 5 11A6 2 R3 14 3 6 6 017A 2 R3 10 3 6 6 024A 2 R4 8 3 10 10 031A 2 R4 4 3 25 16 046A 2 R4 4 3 25 16 053A 2 3 phase UN 480 V R1 16 3 1 5 1 5 02A1 4 R1 16 3 1 5 1 5 03A0 4 R1 16 3 1 5 1 5 03A5 4 R1 16 3 1 5 1 5 04A8 4 R1 16 3 1 5 1 5 06A0 4 R1 14 3 2 5 2 5 07A6 4 R2 14 3 2 5 2 5 011A 4 R3 10 3 6 6 014A 4 R3 10 3 6 6 021A 4 R4 8...

Page 156: ...04A8 2 1 2 6 4 4 2 5 0 5 0 6 4 2 5 0 5 0 5 06A9 2 1 2 6 4 4 2 5 0 5 0 6 4 2 5 0 5 0 5 07A8 2 1 2 6 4 4 2 5 0 5 0 6 4 2 5 0 5 0 5 09A8 2 1 2 6 4 4 2 5 0 5 0 6 4 2 5 0 5 0 5 12A2 2 1 2 6 4 4 2 5 1 2 1 5 10 6 0 5 0 5 17A5 2 1 2 6 4 4 2 5 1 2 1 5 10 6 0 5 0 5 25A0 2 2 9 25 16 10 6 2 5 3 7 25 16 0 5 0 5 032A 2 2 9 25 16 10 6 2 5 3 7 25 16 0 5 0 5 048A 2 2 9 25 16 10 6 2 5 3 7 25 16 0 5 0 5 055A 2 3 pha...

Page 157: ... 12 5 10 18 02A3 1 10 6 10 12 5 10 18 03A5 1 10 6 10 12 5 10 18 04A6 1 10 6 10 12 5 10 18 06A6 1 10 6 10 12 5 10 18 07A4 1 10 6 10 12 5 10 18 09A3 1 10 6 10 12 5 10 18 11A6 1 3 phase UN 230 V 10 6 10 12 5 10 18 02A3 2 10 6 10 12 5 10 18 03A5 2 10 6 10 12 5 10 18 04A6 2 10 6 10 12 5 10 18 06A6 2 10 6 10 12 5 10 18 07A5 2 10 6 10 12 5 10 18 11A6 2 10 6 10 12 11 13 6 18 017A 2 10 6 10 12 11 13 6 18 0...

Page 158: ... The maximum number of conductors per terminal is 1 Terminal data for the control cables This table shows the control cable terminal data of the standard drive variant that is the base unit with RIIO 01 I O EIA 485 module Torque Wire size lbf in N m AWG mm2 4 4 5 3 0 5 0 6 26 16 0 14 1 5 External EMC filters The table shows the external EMC filters See also EMC compatibility and motor cable length...

Page 159: ...55A 2 3 phase UN 400 V FN 3268 16 44 RFI 32 02A7 4 FN 3268 16 44 RFI 32 03A4 4 FN 3268 16 44 RFI 32 04A1 4 FN 3268 16 44 RFI 32 05A7 4 FN 3268 16 44 RFI 32 07A3 4 FN 3268 16 44 RFI 32 09A5 4 FN 3268 30 33 RFI 33 12A7 4 FN 3268 30 33 RFI 33 018A 4 FN 3268 30 33 RFI 33 026A 4 FN 3258 100 35 RFI 34 033A 4 FN 3258 100 35 RFI 34 039A 4 FN 3258 100 35 RFI 34 046A 4 FN 3258 100 35 RFI 34 050A 4 EMC filte...

Page 160: ...68 16 44 RFI 32 07A6 4 FN 3268 30 33 RFI 33 011A 4 FN 3268 30 33 RFI 33 014A 4 FN 3268 30 33 RFI 33 021A 4 FN 3258 100 35 RFI 34 027A 4 FN 3258 100 35 RFI 34 034A 4 FN 3258 100 35 RFI 34 042A 4 If you use an external EMC filter you must disconnect the internal EMC filter Refer to the electrical installation instructions Electrical power network specification Input voltage range ACS480 04 xxxx 1 dr...

Page 161: ...he table 47 63 Hz maximum rate of change 2 s Frequency f1 Max 3 of nominal phase to phase input voltage Imbalance 0 98 at nominal load Fundamental power factor cos phi Motor connection data Asynchronous AC induction motors permanent magnet synchronous motors or ABB synchronous reluctance motors SynRM motors Motor type 0 U1 3 phase symmetrical Voltage U2 The motor output is short circuit proof by I...

Page 162: ...ngths The values 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 1 phase 200 240 V 33 10 33 10 R0 33 10 33 10 R1 33 10 33 10 R2 3 phase 380 480 V 98 30 33 10 R1 66 20 33 10 R2 98 30 33 10 R3 98 30 33 10 R4 With optional external EMC filter 1 phase 200 240 V 33 10 33 10 33 10 R0 33 10 33 10 33 10 R1 R2 3 phase 200 240 ...

Page 163: ...module 0 10 V DC 10 overrange 11 V DC max Voltage signal single ended Analog inputs AI1 AI2 Rin 221 6 kohm 0 20 mA 10 overrange 22 mA max Current signal single ended Rin 137 ohm 1 0 of full scale Inaccuracy up to 30 V DC Overvoltage protection 10 V DC 1 max load current 10 mA Potentiometer refer ence value 0 20 mA 10 overrange 22 mA max into 500 ohm load AO2 only supports output current Current ou...

Page 164: ...elded twisted pair cable with twisted pair for data and a wire or pair for signal ground nominal impedance 100 165 ohm for example Belden 9842 Transmission rate 9 6 115 2 kbit s Termination by switch USB Type A Type Mini B cable maximum cable length 3 m 9 8 ft Control panel PC connection Energy efficiency data ecodesign Energy efficiency data according to IEC 61800 9 2 is available from the ecodes...

Page 165: ...n the protect ive package Operation installed for stationary use Requirement 230 V drives 0 2000 m 0 6562 ft above sea level with output derating above 1000 m 3281 ft Installation site alti tude 400 480 V drives 0 4000 m 0 13123 ft above sea level with output derating above 1000 m 3281 ft See Output derat ing page 131 40 70 C 2 40 70 C 2 10 60 C 14 140 F For frame R0 10 50 C 14 122 F Surrounding a...

Page 166: ...tted 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 mm 0 08 in PC 10 GF 2 5 3 mm 0 10 0 12 in and PA66 25 GF 1 5 mm 0 06 in all in color NCS 1502 Y RAL 9002 PMS 420 C Drive enclosure Corrugated cardboard Package Disposal The main parts o...

Page 167: ...MC 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 IEC EN 61800 5 1 2007 Adjustable speed electrical power drive systems Part 9 2 Ecodesign for power drive systems motor starters power electronics and their driven applications Energy efficiency indica...

Page 168: ...Information Products EIP symbol including an Environment Friendly Use Period EFUP Product is compliant with the People s Republic of China Electronic Industry Standard SJ T 11364 2014 about hazardous substances The EFUP is 20 years 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...

Page 169: ...as specified in the EMC filter manual 2 The motor and control cables are selected as specified in this manual The EMC recommendations are obeyed 3 The maximum motor cable length does not exceed the specified maximum value See EMC compatibility and motor cable length page 162 4 The drive is installed according to the instructions IEC given in this manual This product can cause radio frequency infer...

Page 170: ...erence do not use a category C2 drive on a low voltage public network that supplies domestic premises Category C3 The drive has an 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 ...

Page 171: ...ge public network that supplies domestic premises UL checklist WARNING Operation of this drive requires detailed installation and operation instructions provided in the hardware 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 Mak...

Page 172: ...pted 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 not provide branch circuit protection The drive provides motor overload protection For adjustments see the firmware manual Disclaimers Generic disclaimer The manufacturer shall have...

Page 173: ... any kind of security breaches unauthorized access interference intrusion leakage and or theft of data or information Notwithstanding any other provision to the contrary and regardless whether the contract is terminated or not ABB and its affiliates are under no circumstances liable for damages and or losses related to such security breaches any unauthorized access interference intrusion leakage a...

Page 174: ...174 ...

Page 175: ...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 175 ...

Page 176: ...Frame R0 Frame R0 front side IP20 UL open type 176 Dimension drawings ...

Page 177: ... Frame R0 bottom rear IP20 UL open type Dimension drawings 177 ...

Page 178: ...Frame R1 Frame R1 front side IP20 UL open type 178 Dimension drawings ...

Page 179: ... Frame R1 bottom rear IP20 UL open type Dimension drawings 179 ...

Page 180: ... Frame R1 front side UL Type 1 kit installed 180 Dimension drawings ...

Page 181: ... Frame R1 bottom rear UL Type 1 kit installed Dimension drawings 181 ...

Page 182: ...Frame R2 Frame R2 front side IP20 UL open type 182 Dimension drawings ...

Page 183: ... Frame R2 bottom rear IP20 UL open type Dimension drawings 183 ...

Page 184: ... Frame R2 front side UL Type 1 kit installed 184 Dimension drawings ...

Page 185: ... Frame R2 bottom rear UL Type 1 kit installed Dimension drawings 185 ...

Page 186: ...Frame R3 Frame R3 front side IP20 UL open type 186 Dimension drawings ...

Page 187: ... Frame R3 bottom rear IP20 UL open type Dimension drawings 187 ...

Page 188: ... Frame R3 front side UL Type 1 kit installed 188 Dimension drawings ...

Page 189: ... Frame R3 bottom rear UL Type 1 kit installed Dimension drawings 189 ...

Page 190: ...Frame R4 Frame R4 front side IP20 UL open type 190 Dimension drawings ...

Page 191: ... Frame R4 bottom rear IP20 UL open type Dimension drawings 191 ...

Page 192: ... Frame R4 front side UL Type 1 kit installed 192 Dimension drawings ...

Page 193: ... Frame R4 bottom rear UL Type 1 kit installed Dimension drawings 193 ...

Page 194: ...194 ...

Page 195: ...y generated by a decelerating motor The extra 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 cho...

Page 196: ... during the braking cycle T Equations for selecting the resistor Equation 1 When the drive supply voltage is 200 240 V When the drive supply voltage is 380 415 V When the drive supply voltage is 415 480 V Equation 2 Equation 3 ton PRmax PRave T For conversion use 1 hp 746 W R Calculated brake resistor value ohm Make sure that Rmin R Rmax PRmax Maximum power during the braking cycle W PRave Average...

Page 197: ... 19 5 12A2 1 3 phase UN 230 V CBH 360 C T 406 210R 0 50 0 38 0 33 0 25 474 39 02A4 2 or 0 74 0 56 0 50 0 37 319 39 03A7 2 CAR 200 D T 406 210R 1 10 0 83 0 75 0 55 217 39 04A8 2 CBR V 330 D T 406 78R UL 1 50 1 13 1 00 0 75 145 39 06A9 2 2 20 1 65 1 50 1 10 105 39 07A8 2 CBR V 560 D HT 406 39R UL 3 00 2 25 2 00 1 50 71 20 09A8 2 4 40 3 30 2 00 2 20 52 20 12A2 2 CBT H 560 D HT 406 19R 6 00 4 50 3 00 ...

Page 198: ...0 V CBH 360 C T 406 210R 0 50 0 33 0 33 0 25 468 32 5 02A3 1 or 0 74 0 56 0 50 0 37 316 32 5 03A5 1 CAR 200 D T 406 210R 1 10 0 83 0 75 0 55 213 32 5 04A6 1 CBR V 330 D T 406 78R UL 1 50 1 10 1 00 0 75 145 32 5 06A6 1 2 20 1 70 1 50 1 10 96 5 32 5 07A4 1 CBR V 560 D HT 406 39R UL 3 0 2 30 2 00 1 50 69 9 32 5 09A3 1 4 40 3 30 3 00 2 20 47 1 19 5 11A6 1 3 phase UN 230 V CBH 360 C T 406 210R 0 50 0 3...

Page 199: ...other manufacturers are used the characteristics must agree with the values in the table Definitions PBRmax The maximum braking capacity of the drive when the length of the braking pulse is at most 1 minute for each 10 minutes PBRcont 1 5 Must be more than the desired braking power PBRcont The continuous braking capacity of the drive Rmax The maximum resistance value of the brake resistor that can...

Page 200: ...side the drive in a place where it is able to cool effectively Arrange the cooling of the resistor in a way that no danger of overheating is caused to the resistor or nearby materials and the temperature of the room the resistor is located in does not exceed the allowed maximum Supply the resistor with cooling air or coolant according to the resistor manufacturer s instructions WARNING The materia...

Page 201: ... if the chopper remains conductive in a fault situation An example wiring diagram is shown below ABB recommends that you use resistors equipped with a thermal switch 1 inside the resistor assembly The switch indicates overtemperature ABB recommends that you also wire the thermal switch to a digital input of the drive and configure the input to cause a fault trip at resistor overtemperature indicat...

Page 202: ...ntrol cables Connect the thermal switch of the brake resistor as described in Protecting the system against thermal overload page 201 Start up Set the following parameters 1 Disable the overvoltage control of the drive with parameter 30 30 Overvoltage control 2 Set the source of parameter 31 01 External event 1 source to point to the digital input where the thermal switch of the brake resistor is ...

Page 203: ...e When activated the Safe torque off function disables the control voltage for 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 ...

Page 204: ...10 Functional safety Safety instrumented systems for the process industry sector IEC 61511 1 2017 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 2015 EN 62061 2005 AC 2010 A...

Page 205: ...tion see the technical data of the control unit Connection principle Single ACS480 drive internal power supply OUT1 24 V DC IN1 IN2 SGND UDC UDC A K 2 1 4 3 Drive 1 Control unit 2 Control logic 3 To motor 4 Activation switch K The Safe torque off function 205 ...

Page 206: ...Single ACS480 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 206 The Safe torque off function ...

Page 207: ...13 Y1 A2 Y2 A1 31 32 OUT GND IN1 OUT1 IN2 SGND 1 K 2 Drive 1 Safety PLC 2 Safety relay K Single ACS480 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 207 ...

Page 208: ...Multiple ACS480 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 208 The Safe torque off function ...

Page 209: ...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 209 ...

Page 210: ...t 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 pulse tolera...

Page 211: ... 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 212: ...s and report must be documented and signed by this person Validation test reports Signed validation 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 validation tests performed due to changes or maintenance shall be logged into the logbook Validati...

Page 213: ...ibed above in testing 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 If the motor was running it should coast to a stop The drive generates a FA81 Safe Torque Off 1 loss f...

Page 214: ...y and all other voltage sources WARNING The drive cannot detect or memorize any changes in the STO circuitry when the drive control unit is not powered If both STO circuits are closed and a level type start signal is active when the power is restored it is possible that the drive starts without a fresh start command Take this into account in the risk assessment of the system This is also valid whe...

Page 215: ...functions of the drive The Safe torque off function is ineffective against deliberate sabotage or misuse The Safe torque off function has been designed to reduce the recognized hazardous conditions In spite of this it is not always possible to eliminate all potential hazards The assembler of the machine must inform the final user about the residual risks The Safe torque off function 215 ...

Page 216: ...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 217: ...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 218: ...1 20 80 1 3 3 90 2209 1 68E 04 6 71E 05 7 65E 09 99 e 3 R2 20 80 1 3 3 90 2569 1 67E 04 6 68E 05 7 61E 09 99 e 3 R3 20 80 1 3 3 90 2568 1 67E 04 6 68E 05 7 61E 09 99 e 3 R4 3 phase UN 400 480 V 20 80 1 3 3 90 2210 1 68E 04 6 71E 05 7 65E 09 99 e 3 R1 20 80 1 3 3 90 2209 1 68E 04 6 71E 05 7 65E 09 99 e 3 R2 20 80 1 3 3 90 2569 1 67E 04 6 68E 05 7 61E 09 90 e 3 R3 20 80 1 3 3 90 2568 1 67E 04 6 68E ...

Page 219: ... indication parameter 31 22 delay 1000 ms Terms and abbreviations Description Reference Term or ab breviation Classification of the safety related parts of a control system in respect of their resistance to faults and their subsequent behavior in the fault condition and which is achieved by the structural arrangement of the parts fault detection and or by their reliability The categories are B 1 2...

Page 220: ...m SIL level 1 3 that can be claimed for a safety function or subsystem IEC EN 62061 SILCL Safe torque off IEC EN 61800 5 2 STO Proof test interval T1 is a parameter used to define the probabilistic failure rate PFH or PFD for the safety function or subsystem Performing a proof test at a maximum interval of T1 is required to keep the SIL capability valid The same interval must be followed to keep t...

Page 221: ... Declarations of conformity The Safe torque off function 221 ...

Page 222: ...ower drive systems Part 5 2 Safety requirements Functional Safety of machinery Functional safety of safety related electrical electronic and programmable electronic control systems declare under our sole responsibility that the following product ACS480 04 Safe Torque Off Functional safety of electrical electronic programmable electronic safety related systems Adjustable speed electrical power driv...

Page 223: ...xiliary power extension module option L534 lets you use an external 24 V DC power supply with the drive An external power supply is used to keep the drive control board energized during a 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 ...

Page 224: ... BAPO 01 module force parameter saving by setting the value of parameter 96 07 PARAM SAVE to 1 SAVE Otherwise changed data will not be saved Layout 4 1 2 3 5 BAPO 01 module 1 Locking screw hole 2 Internal X100 connector 3 Internal X102 connector 4 Grounding rail 5 224 BAPO 01 auxiliary power extension module ...

Page 225: ... 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 24VDC GND 24V DGND BAPO 01 1 2 3 4 5 External power supply 1 Drive 2 24 V internal 3 Main power supply 4 5 V internal 5 Start up To configure the BAPO 01 module 1 Power up the drive 2 Set the parameter 95 04 Control board supply to ...

Page 226: ... 524 181 3 7 138 171 6 6 754 86 1 3 391 6 24 ein Reproduction bidden Based on Prepared 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 DIMENSI...

Page 227: ...ware description Product overview BIO 01 option L515 is an I O extension module to be used with a fieldbus adapter module The BIO 01 module is installed between the drive and the fieldbus module BIO 01 has two digital inputs DI4 DI5 and one analog input A1 It also has two terminals S1 S2 that can be configured with the switches on the module S1 can be configured as analog output AO1 or digital out...

Page 228: ...round the wires that connect to the BIO 01 option module Terminal configuration You must configure terminals S1 and S2 before you install the fieldbus module Refer to the table that follows for the possible configurations Result Setting Supported configur ation Terminal S2 func tions as Terminal S1 func tions as Switch S2 Switch S1 Yes Digital input DI3 Digital output DO1 DI3 default DO1 default Y...

Page 229: ... S2 DI3 Constant frequency speed selection DI4 Ramp set 1 0 Ramp set 2 1 DI5 Not configured DIO1 S1 DO1 Output frequency speed ref 0 10 V DC AI1 Reference voltage 10 V DC max 10 mA 10V Analog circuit 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 1 on base unit blank on BIO 01 module ...

Page 230: ...Internal connections of GND and SCR terminals OUT1 SGND IN1 IN2 24 V DGND DCOM DI1 DI2 24 V DGND DCOM DI1 DI2 AI1 10V GND SCR DI3 DI4 DI5 DIO1 230 BIO 01 I O extension module ...

Page 231: ...Dimensions BIO 01 I O extension module 231 ...

Page 232: ...232 ...

Page 233: ... 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 233 ...

Page 234: ...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 235: ...on module type to 5 BREL 3 Use the control panel on the drive and set the parameters for relay outputs RO4 RO7 in 15 I O extension module Refer to the ACS480 standard control program firmware manual 3AXD50000047399 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 ...

Page 236: ...llows the data value of a forced relay or digital output to be changed from 0 to 3 RO forced data 15 06 Force the value of this bit to RO4 if so defined 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...

Page 237: ...he deactivation delay for relay output RO6 RO6 OFF delay 15 15 10 1 s Deactivation delay for RO6 0 0 3000 0 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 del...

Page 238: ...Dimensions 3AXD50000031148 rev A 238 BREL 01 relay output extension module ...

Page 239: ... 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 240: ...www abb com drives 3AXD50000047392E Copyright 2021 ABB All rights reserved Specifications subject to change without notice 3AXD50000047392 Rev E EN EFFECTIVE 2021 10 04 ...

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