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WARNING!

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. This is the
case also if you use the scalar motor control mode.

Protecting the contacts of relay outputs

Inductive loads (relays, contactors, motors) cause voltage transients when switched off. It
is highly recommended that inductive loads are equipped with noise attenuating circuits
(varistors, RC filters [AC] or diodes [DC]) in order to minimize the EMC emission at switch-off.
If not suppressed, the disturbances may connect capacitively or inductively to other
conductors in the control cable and form a risk of malfunction in other parts of the system.

Install the protective component as close to the inductive load as possible. Do not install
protective components at the relay outputs.

2

3

4

230 V AC

230 V AC

+ 24 V DC

1

Relay output

1

Varistor

2

RC filter

3

Diode

4

50 Guidelines for planning the electrical installation

Summary of Contents for ACS480

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

Page 2: ......

Page 3: ...CS480 drives Hardware manual Table of contents 1 Safety instructions 4 Mechanical installation 6 Electrical installation IEC 2019 ABB Oy All Rights Reserved 3AXD50000047392 Rev D EN EFFECTIVE 2019 09 23 ...

Page 4: ......

Page 5: ... manual 19 Contents of this chapter 19 Applicability 19 Target audience 19 Purpose of the manual 19 Categorization by frame size 20 Quick installation and commissioning flowchart 21 Terms and abbreviations 22 Related manuals 3 Operation principle and hardware description 25 Contents of this chapter 25 Operation principle 26 Simplified main circuit diagram 26 Product variants 26 IEC and UL NEC prod...

Page 6: ...arate cables 44 Signals that can be run in the same cable 44 Relay cable type 45 Control panel to drive cable 45 Routing the cables 45 General guidelines IEC 45 General guidelines North America 46 Continuous motor cable shield conduit or enclosure for equipment on the motor cable 47 Separate control cable ducts 47 Implementing short circuit and thermal overload protection 47 Protecting the drive a...

Page 7: ...nection diagram 61 Control cable connection procedure 62 Additional information on the control connections 62 Connecting EIA 485 fieldbus cable to the drive 62 Connection examples of two wire and three wire sensors 63 AI and AO or AI DI and 10 V as PTC motor temperature sensor interface 64 AI1 and AI2 as Pt100 Pt1000 Ni1000 KTY83 and KTY84 sensor inputs 65 Auxiliary voltage connection 66 Connectin...

Page 8: ...85 Installing a side option 8 Installation checklist of the drive 87 Contents of this chapter 87 Checklist 9 Maintenance 89 Contents of this chapter 89 Maintenance intervals 90 Cleaning the heatsink 91 Replacing the cooling fans 91 To replace the cooling fan for frame sizes R1 R2 and R3 92 To replace the cooling fan for frame R4 94 Capacitors 94 Reforming the capacitors 10 Technical data 95 Conten...

Page 9: ... C4 120 UL and CSA checklist 121 Disclaimers 121 Generic disclaimer 121 Cybersecurity disclaimer 11 Dimension drawings 123 Contents of this chapter 124 Frame R1 124 Frame R1 front side IP20 UL type open 125 Frame R1 bottom rear IP20 UL type open 126 Frame R1 front side UL type 1 kit installed 127 Frame R1 bottom rear UL type 1 kit installed 128 Frame R2 128 Frame R2 front side IP20 UL type open 12...

Page 10: ...the insulation 146 Connecting power cables 146 Connection the control cables 146 Start up 13 The Safe torque off function 147 Contents of this chapter 147 Description 148 Compliance with the European Machinery Directive 149 Wiring 149 Connection principle 149 Single ACS480 drive internal power supply 150 Single ACS480 drive external power supply 150 Wiring examples 150 Single ACS480 drive internal...

Page 11: ...69 Contents of this chapter 169 Safety instructions 169 Hardware description 169 Product overview 170 Layout 170 Mechanical installation 170 Electrical installation 171 Start up 171 Technical data 16 BREL 01 relay output extension module 173 Contents of this chapter 173 Safety instructions 173 Hardware description 173 Product overview 174 Layout 174 Mechanical installation 174 Electrical installat...

Page 12: ...12 ...

Page 13: ...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 or...

Page 14: ...throughout the set operation limits Before you activate the automatic fault reset or automatic restart functions of the drive control program make sure that no dangerous situations can occur These functions reset the drive automatically and continue operation after a fault or supply break If these functions are activated the installation must be clearly marked as defined in IEC EN 61800 5 1 subcla...

Page 15: ... than 1 Mohm Make sure that the voltage between the drive input power terminals L1 L2 L3 and the grounding PE busbar is close to 0 V Make sure that the voltage between the drive DC terminals R UDC and UDC and the grounding terminal PE is close to 0 V Make sure that the voltage between the drive output terminals T1 U T2 V T3 W and the grounding PE busbar is close to 0 V 6 Install temporary groundin...

Page 16: ...electrical planning instructions of the drive Obey the local regulations Connect the power cable shields to protective earth PE terminals of the drive to make sure of personnel safety Make a 360 grounding of the power and control cable shields at the cable entries to suppress electromagnetic disturbances In a multiple drive installation connect each drive separately to the protective earth PE busb...

Page 17: ...as defined in IEC EN 61800 5 1 subclause 6 5 3 for example THIS MACHINE STARTS AUTOMATICALLY Note The maximum drive power cycles is five times in ten minutes Power cycling the drive too often can damage the charging circuit of the DC capacitors If you need to start or stop the drive use the control panel start and stop keys or commands through the I O terminals of the drive Depending on the wiring...

Page 18: ...t power terminals L1 L2 L3 and the grounding PE busbar is close to 0 V Make sure that the voltage between the drive DC terminals R UDC and UDC and the grounding terminal PE is close to 0 V Install temporary grounding to the drive output terminals U2 V2 W2 Connect the output terminals together as well as to the PE During the start up Make sure that the motor cannot be run into overspeed eg driven b...

Page 19: ...of electricity wiring electrical components and electrical schematic symbols The manual is written for readers worldwide Both SI and imperial units are shown Purpose of the manual This manual gives information needed to plan the installation install commission and service the drive Categorization by frame size The drives is manufactured in frame sizes for example R1 R2 and so on The information th...

Page 20: ...N S system make sure of the compatibility Installing the drive page 37 Install the drive Routing the cables page 45 Route the cables Measuring the insulation page 52 Measure the insulation of the input cable motor and motor cable Connecting the power cables IEC shiel ded cables page 56 Connect the power cables Connecting the power cables North America wiring in conduits page 74 Connecting the cont...

Page 21: ...ibility EMC Fieldbus adapter FBA Optional CANopen adapter module FCAN Optional ControlNet adapter module FCNA 01 Optional DeviceNet adapter module FDNA 01 Optional EtherCAT adapter module FECA 01 Optional Ethernet adapter module FEIP 21 Optional Ethernet adapter module for EtherNet IP Modbus TCP and PROFINET IO protocols 2 port FENA 21 Optional Ethernet POWERLINK adapter module FEPL 02 Optional Et...

Page 22: ...FINET adapter module quick guide 3AXD50000158614 FPNO 21 PROFINET fieldbus adapter module user s manual 3AXD50000158515 FDNA 01 DeviceNet adapter module quick guide 3AFE68573360 FDNA 01 DeviceNet adapter user s manual 3AXD50000158195 FCAN 01 CANopen adapter module quick guide 3AFE68615500 FCAN 01 CANopen adapter module user s manual 3AXD50000158546 FSCA 01 RS 485 adapter module quick guide 3AUA000...

Page 23: ...See https library abb com en for all ABB product documentation on the Internet Introduction to the manual 23 ...

Page 24: ...24 ...

Page 25: ...ignation information It shows a general diagram of the power connections and control interfaces Operation principle The ACS480 is a drive for controlling asynchronous AC induction motors permanent magnet synchronous motors and ABB synchronous reluctance motors SynRM motors It is optimized for cabinet mounting 3 Operation principle and hardware description 25 ...

Page 26: ...ltage 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 needed 4 Product variants The drive has two product variants Standard unit drive for example ACS480 04 02A7 4 with ACS AP S assistant control panel and I O EIA 485 module RIIO 01 Base unit drive for example ACS480 04 02A7 4 0J400 0L540 ...

Page 27: ...ation label 3 Fixed control terminals 13 Control panel connection 4 Cold configuration connection CCA 01 14 Control panel 5 Option slot for communication modules 15 EMC filter grounding screw 6 I O or fieldbus module 16 Varistor grounding screw 7 Side option slot for side mounted options 17 PE connection motor 8 Input power terminal 9 Operation principle and hardware description 27 ...

Page 28: ... IN1 IN2 ON ROC RO1A RO1B 24V DGND DCOM SGND OUT1 1 1 2 3 4 5 4 9 7 8 6 10 Connections of the base unit 1 Auxiliary voltage outputs 2 Digital inputs 3 Safe torque off connections 4 Relay output connections 5 Cold configuration connection for CCA 01 Connections of the RIIO 01 I O EIA 485 module 6 Digital inputs 7 Analog inputs and outputs 8 Embedded fieldbus EIA 485 Modbus RTU 9 Auxiliary voltage o...

Page 29: ...ary voltage outputs 2 Digital inputs 3 Safe torque off connections 4 Relay output connection 5 Cold configuration connection for CCA 01 6 Front option module slot 1 Option modules The drive can be equipped with various option module s See Type designation key page 32 Operation principle and hardware description 29 ...

Page 30: ...tion Type Control panel mounting platform flush mounting and cable1 DPMP 01 Control panel mounting platform surface mounting and cable1 DPMP 02 DPMP 02 panel mounting platform and cable and RDUM 01 blank panel with RJ 45 connector DPMP EXT2 1 You need also RDUM 01 blank panel or CDPI 02 panel bus adapter to connect the panel cable at the drive end UL Type 1 kits There are UL Type 1 kit options ava...

Page 31: ... YY Year of manufacture 15 16 17 for 2015 2016 2017 WW Week of manufacture 01 02 03 for week 1 week 2 week 3 XXXX Running item number that starts each week from 0001 6 Software information label IEC ACS480 04 02A7 4 3 400 480 V Frame R1 Pld 0 75 kW 1 hp Phd 0 55 kW 0 75 hp S N M19270002 SW v2 05 0 7 1 2 3 4 Model information label IEC ACS480 04 02A7 4 S N M19270002 1 2 3 Type designation input vol...

Page 32: ...k cover with RJ45 connection for remote mounting of the control panel J424 ACS AP I industrial control panel J425 ACS AP W control panel with Bluetooth J429 Without control panel 0J400 I O BIO 01 I O extension module front option can be used with fieldbus L515 BAPO 01 external 24 V DC power extension module side option L534 BREL 01 relay output extension module L511 RIIO 01 I O EIA 485 module fron...

Page 33: ...ish R700 German R701 Italian R702 Dutch R703 Danish R704 Swedish R705 Finnish R706 French R707 Spanish R708 Portuguese R709 Russian R711 Chinese R712 Polish R713 Turkish R714 Operation principle and hardware description 33 ...

Page 34: ...34 ...

Page 35: ...ation requirements The drive has an IP20 UL open type protection classification for cabinet installation UL type 1 kit is available as an option Make sure that there is a minimum of 75 mm 2 95 in of free space at the top and bottom of the drive at the cooling air inlet and outlet You can install several drives side by side Note that side mounted options require 20 mm 0 8 in of space on the right s...

Page 36: ...here are no sources of strong magnetic fields such as high current single core conductors or contactor coils near the drive A strong magnetic field can cause interference or inaccuracy in the operation of the drive Required tools To install the drive mechanically you need the following tools a drill and suitable drill bits a screwdriver or wrench with a set of suitable bits PH0 3 PZ0 3 T15 40 S4 7...

Page 37: ... Drill the holes for the mounting screws 3 Insert anchors or plugs into the holes if necessary and install the screws M1 M2 4 Position the drive onto the mounting screws 5 Tighten the mounting screws 5 To install the drive to a DIN installation rail Use the installation rail type Top Hat W x H 35 x 7 5 mm 1 4 x 0 3 in 1 Move the locking part to the left 1 2 3 Mechanical installation 37 10 ...

Page 38: ...IN installation rail 4 Put the drive against the bottom edge of the DIN installation rail 5 Release the locking button 6 Move the locking part to the right 7 Make sure that the drive is correctly installed To remove the drive use a flat head screwdriver to open the locking part 38 Mechanical installation ...

Page 39: ...st equip the drive with a main supply disconnecting device which meets the local safety regulations You must be able to lock the disconnecting device to the open position for installation and maintenance work European Union To meet the European Union Directives according to standard EN 60204 1 Safety of Machinery the disconnecting device must be one of the following types switch disconnector with ...

Page 40: ...he drive are compatible according to the rating table in the technical data Selecting the power cables General guidelines Select the input power and motor cables according to local regulations Current Select a cable capable of carrying the drive or motor nominal current Temperature For an IEC installation select a cable rated for at least 70 C 158 F maximum permissible temperature of conductor in ...

Page 41: ...econd protective earth conductor of the same cross sectional area as the original protective earthing conductor or use a device which automatically disconnects the supply if the protective earth conductor breaks 2 Drive safety standard IEC EN 61800 5 1 If the protective earth conductor is separate ie it does not form part of the input power cable or the input power cable enclosure the cross sectio...

Page 42: ...t is always recommended to minimize radio fre quency interference Four conductor cabling in PVC con duit or jacket three phase conduct ors and PE 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 metal conduit three phase conductors and PE eg EMT or four conductor ar mored cable Yes with motors up to 100 kW 135 hp A potential equali...

Page 43: ... cable wiring together and use separators where possible Free air2 Prefer symmetrical shielded VFD cable Enclosures air handlers etc Allowed internally in enclosures when in accordance with UL 1 Metallic conduit may be used as an additional ground path provided this path is a solid path capable of handling ground currents 2 See NFPA NEC 70 UL and local codes for your application 3 Non metallic con...

Page 44: ...nals also Employ 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 shielded b twisted pair cable is also acceptable a b Signals in separate cables Run analog and digital signals in separate shielded cables Do not mix 24 V DC and 115 230 V AC signals in the...

Page 45: ...ive Make sure that the cable trays have good electrical bonding to each other and to the grounding electrodes Aluminum tray systems can be used to improve local equalizing of potential This figure illustrates the cable routing guidelines with an example drive Note When motor cable is symmetrical and shielded and it has short parallel runs with other cables 1 5 m 5 ft distances between the motor ca...

Page 46: ...n level when safety switches contactors connection boxes or similar equipment are installed on the motor cable between the drive and the motor Install the equipment in a metal enclosure Use either a symmetrical shielded cable or install the cabling in a metal conduit Make sure that there is a good and continuous galvanic connection in the shield conduit between drive and motor Connect the shield c...

Page 47: ...the motor and motor cable in short circuits The drive protects the motor cable and motor in a short circuit situation when the motor cable is sized according to the nominal current of the drive No additional protection devices are needed Protecting the drive and the input power and motor cables against thermal overload If the cables have the correct size for the nominal current the drive protects ...

Page 48: ...the same manner as the overload relays are specified in standards IEC 60947 4 1 and NEMA ICS 2 The motor overload protection supports thermal memory retention and speed sensitivity For more information see drive firmware manual Implementing a motor temperature sensor connection WARNING IEC 60664 and IEC 61800 5 1 require double or reinforced insulation between live parts and accessible parts when ...

Page 49: ...on For safety reasons install the emergency stop devices at each operator control station and at other operating stations where emergency stop may be needed Design the emergency stop according to the applicable standards You can use the Safe torque off function of the drive to implement the Emergency stop function Note Pressing the stop off key on the control panel of the drive does not generate a...

Page 50: ...s Inductive loads relays contactors motors cause voltage transients when switched off It is highly recommended that inductive loads are equipped with noise attenuating circuits varistors RC filters AC or diodes DC in order to minimize the EMC emission at switch off If not suppressed the disturbances may connect capacitively or inductively to other conductors in the control cable and form a risk of...

Page 51: ... 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 short flat head screwdriver f...

Page 52: ... do not do installation or maintenance work 1 Stop the drive and do the steps in section Electrical safety precautions page 14 before you start the work 2 Make sure that the motor cable is disconnected from the drive output terminals 3 Measure the insulation resistance between each phase conductor and the protective earth conductor Use a measuring voltage of 1000 V DC The insulation resistance of ...

Page 53: ... symmetrically grounded TN S system If you install the drive to another system you may need to disconnect the EMC filter See When to disconnect EMC filter or ground to phase varistor page 53 Note If you disconnect the EMC filter the electromagnetic compatibility of the drive decreases Ground to phase varistor compatibility A drive with the ground to phase varistor connected can be installed to a s...

Page 54: ...remove Frames R1 R3 R4 Metal VAR Do not remove Do not remove Do not remove Frame R2 Plastic Drive PE N L3 L2 L1 Drive Drive PE L3 L2 L1 L3 L2 L1 Drive PE L3 L2 L1 B1 C A B2 PE L2 L3 L1 N Drive A Drive N L3 L2 L1 D Disconnecting the EMC filter or ground to phase varistor Before you proceed see When to disconnect EMC filter or ground to phase varistor page 53 Obey the guidelines 1 Stop the drive and...

Page 55: ...3 input voltage line 2 to ground UL2 G 4 input voltage line 3 to ground UL3 G The table below shows the line to ground voltages in relation to the line to line voltage for each earthing system Electrical power system type UL3 G UL2 G UL1 G UL L Symmetrically grounded TN system TN S sys tem 0 58 X 0 58 X 0 58 X X Corner grounded delta system nonsymmetrical 0 1 0 X 1 0 X X Midpoint grounded delta sy...

Page 56: ...mm2 8 AWG Cu conductor minimum size for individual PE conductor is 2 5 mm2 14 AWG Cu Separate PE cable line side Use it if the conductivity of the fourth conductor or shield is not sufficient for the protective grounding 4 Motor cable 5 Separate PE cable motor side Use it if the conductivity of the shield is not sufficient for the protective earth conductor or there is no symmetrically constructed...

Page 57: ...ounding 5 Twist the motor cable shield into a bundle mark it with yellow green insulation tape fit a cable lug and connect it to the grounding terminal 6 Connect the phase conductors of the motor cable to the T1 U T2 V and T3 W motor terminals 7 If you use a brake resistor connect the brake resistor cable to the R and UDC terminals Use shielded cable and ground the shield under the grounding clamp...

Page 58: ...ion diagrams ABB standard macro The connection diagrams below are valid for the standard drive variant ie drive equipped with the RIIO 01 I O EIA 485 module ABB standard macro parameter 96 04 is in use with the default parameter settings 2 Description Term 1 Connection Analog inputs and outputs Signal cable shield screen SCR SCR AI1 AGND 10 V AI2 AGND AO1 AO2 AGND 1 10 kohm Max 500 ohm Output freq...

Page 59: ... 250 V AC 30 V DC 2 A Common RO1C Norm closed RO1A Norm open RO1B Running 250 V AC 30 V DC 2 A Common RO2C Norm closed RO2A Norm open RO2B Fault 1 250 V AC 30 V DC 2 A Common RO3C Norm closed RO3A Norm open RO3B Embedded EIA 485 Embedded fieldbus EIA 485 B B A DGND A DGND Termination switch ON on 1 off TERM Safe torque off Safe torque off Factory connection Both circuits must be closed for the dri...

Page 60: ... been done yet 2 Description Term 1 Connection Auxiliary voltage output and digital inputs Aux voltage output 24 V DC max 250 mA 24V 24 V DGND DCOM DI1 DI2 24 V DGND DCOM DI1 DI2 Aux voltage output common DGND Digital input common for all DCOM Stop 0 Start 1 DI1 Forward 0 Reverse 1 DI2 Relay outputs Aux voltage output 24 V DC max 250 mA 24V RO1C RO1A RO1B 24 V DGND DCOM Aux voltage output common D...

Page 61: ...sted 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 a qualified electrical professional do not do installation or maintenance work 1 Stop the drive and do the steps in Electrical safety precautions page 14 before you start the work 2 Strip a p...

Page 62: ...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 ON 1 ON 1 ON 1 B A DGND ON 1 ON 1 ON 1 B A DGND ON 1 ON 1 ON 1 B A DGND 1 2 1 2 1 2 3 4 Drive 1 Termination switch Termination must be on at both ends on the fieldbus For the drive the termination switch position is ON 2 Fieldbus controller 3 Fi...

Page 63: ...ensor to the drive If the motor temperature sensor has a reinforced insulation vs the motor windings you can connect it directly to the drive IO interface This section shows two connection alternatives for the direct I O connection If the sensor has no reinforced insulation you must use another type of connection to fulfill the safety requirements See Implementing a motor temperature sensor connec...

Page 64: ...digital input voltage via the analog input and calculates the PTC resistance T T T DIn AIn 10 V 1 2 3 DGND DCOM 1 3 PTC sensors 1 Digital input and analog input Set the analog input type to V volt in parameter group 12 Standard AI Define the temperature sensor type signal source etc with parameters 35 11 to 35 24 For the sensor type select PTC AI DI Voltage Divider tree Make sure that the digital ...

Page 65: ...citation mode for the analog output in parameter group 13 Standard AO 3 Auxiliary voltage connection The drive has an auxiliary 24 V DC 10 auxiliary power supply terminals both on the base unit and on the RIIO 01 module You can use it to supply auxiliary power from the drive to external control circuits or option modules to supply external auxiliary power to the drive in order to keep the control ...

Page 66: ...see BAPO 01 auxiliary power extension module page 165 BIO 01 I O extension module page 169 BREL 01 relay output extension module page 173 Installing a front option WARNING Obey the safety instructions of the drive If you ignore them injury or death or damage to the equipment can occur If you are not a qualified electrical professional do not do installation or maintenance work 1 Stop the drive and...

Page 67: ...fied electrical professional do not do installation or maintenance work 1 Stop the drive and do the steps in section Electrical safety precautions page 14 before you start the work 2 Remove the two screws from the front most grounding clamp at the bottom of the drive 3 Carefully align the side option with the connectors on the right side of the drive 4 Fully push the option module into position 5 ...

Page 68: ...unding bar to the bottom of the side option and to the front ground tab on the drive 7 Connect the applicable control cables according to control cable connection instructions 5 6 7 2 3 4 68 Electrical installation IEC ...

Page 69: ... 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 short flat head screwdriver f...

Page 70: ...ot do installation or maintenance work 1 Stop the drive and do the steps in section Electrical safety precautions page 14 before you start the work 2 Make sure that the motor cable is disconnected from the drive output terminals 3 Measure the insulation resistance between each phase conductor and the protective earth conductor Use a measuring voltage of 1000 V DC The insulation resistance of an AB...

Page 71: ...e concerned with EMC issues and install the drive to a symmetrically grounded TN S system you can connect the internal EMC filter See Disconnecting ground to phase varistor or connecting EMC filter Note When the internal EMC filter is disconnected the electromagnetic compatibility of the drive is reduced Ground to phase varistor The drive is equipped with an internal ground to phase varistor as st...

Page 72: ...stems Symmetrically groun ded TN S systems i e center grounded wye A Maintain the plastic screw Maintain the plastic screw Can install the metal screw 1 Plastic EMC Remove the metal screw Maintain the metal screw Maintain the metal screw Frames R1 R3 R4 metal VAR Maintain the plastic screw Maintain the plastic screw Maintain the plastic screw Frame R2 plastic Drive PE N L3 L2 L1 Drive Drive PE L3 ...

Page 73: ...ical 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 Proceed only if you are an electrical professional certified for the work Obey the local regulations If you ignore them injury or death can occur To identify the earthing system find out the supply transfo...

Page 74: ...mmetrical 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 elec trode and there is another independently installed at the generator Varying level versus time Varying level versus time Varying level versus time X Connecting the power cables North America wiring in conduits Use insu...

Page 75: ...WARNING Obey the safety instructions of the drive If you ignore them injury or death or damage to the equipment can occur If you are not a qualified electrical professional do not do installation or maintenance work 1 Stop the drive and do the steps in section Electrical safety precautions page 14 before you start the work 2 Install the conduits and attach them to the cable entry plate of the encl...

Page 76: ...on diagrams below are valid for the standard drive variant ie drive equipped with the RIIO 01 I O EIA 485 module ABB standard macro parameter 96 04 is in use with the default parameter settings 2 Description Term 1 Connection Analog inputs and outputs Signal cable shield screen SCR SCR AI1 AGND 10 V AI2 AGND AO1 AO2 AGND 1 10 kohm Max 500 ohm Output frequency 0 10 V AI1 Analog input circuit common...

Page 77: ...V AC 30 V DC 2 A Common RO1C Norm closed RO1A Norm open RO1B Running 250 V AC 30 V DC 2 A Common RO2C Norm closed RO2A Norm open RO2B Fault 1 250 V AC 30 V DC 2 A Common RO3C Norm closed RO3A Norm open RO3B Embedded EIA 485 Embedded fieldbus EIA 485 B B A DGND A DGND Termination switch ON on 1 off TERM Safe torque off Safe torque off Factory connection Both circuits must be closed for the drive to...

Page 78: ... done yet 2 Description Term 1 Connection Auxiliary voltage output and digital inputs Aux voltage output 24 V DC max 250 mA 24V 24 V DGND DCOM DI1 DI2 24 V DGND DCOM DI1 DI2 Aux voltage output common DGND Digital input common for all DCOM Stop 0 Start 1 DI1 Forward 0 Reverse 1 DI2 Relay outputs Aux voltage output 24 V DC max 250 mA 24V RO1C RO1A RO1B 24 V DGND DCOM Aux voltage output common DGND D...

Page 79: ...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 a qualified electrical professional do not do installation or maintenance work 1 Stop the drive and do the steps in Electrical safety precautions page 14 before you start the work 2 Strip a part o...

Page 80: ...pF per foot Distributed capacitance between conductors and shield is less than 200 pF per meter 60 pF per foot Foil or braided shields are acceptable ON 1 ON 1 ON 1 B A DGND ON 1 ON 1 ON 1 B A DGND ON 1 ON 1 ON 1 B A DGND 1 2 1 2 1 2 3 4 Drive 1 Termination switch Termination must be on at both ends on the fieldbus For the drive the termination switch position is ON 2 Fieldbus controller 3 Fieldbu...

Page 81: ... to the drive If the motor temperature sensor has a reinforced insulation vs the motor windings you can connect it directly to the drive IO interface This section shows two connection alternatives for the direct I O connection If the sensor has no reinforced insulation you must use another type of connection to fulfill the safety requirements See Implementing a motor temperature sensor connection ...

Page 82: ...al input voltage via the analog input and calculates the PTC resistance T T T DIn AIn 10 V 1 2 3 DGND DCOM 1 3 PTC sensors 1 Digital input and analog input Set the analog input type to V volt in parameter group 12 Standard AI Define the temperature sensor type signal source etc with parameters 35 11 to 35 24 For the sensor type select PTC AI DI Voltage Divider tree Make sure that the digital input...

Page 83: ...ion mode for the analog output in parameter group 13 Standard AO 3 Auxiliary voltage connection The drive has an auxiliary 24 V DC 10 auxiliary power supply terminals both on the base unit and on the RIIO 01 module You can use it to supply auxiliary power from the drive to external control circuits or option modules to supply external auxiliary power to the drive in order to keep the control and c...

Page 84: ...APO 01 auxiliary power extension module page 165 BIO 01 I O extension module page 169 BREL 01 relay output extension module page 173 Installing a front option WARNING Obey the safety instructions of the drive If you ignore them injury or death or damage to the equipment can occur If you are not a qualified electrical professional do not do installation or maintenance work 1 Stop the drive and do t...

Page 85: ...electrical professional do not do installation or maintenance work 1 Stop the drive and do the steps in section Electrical safety precautions page 14 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 Tight...

Page 86: ...g bar to the bottom of the side option and to the front ground tab on the drive 7 Connect the applicable control cables according to control cable connection instructions 5 6 7 2 3 4 86 Electrical installation North America ...

Page 87: ...steps in section Electrical safety precautions page 14 before you start the work Make sure that The ambient operating conditions meet the drive ambient conditions specification and enclosure rating IP code or UL enclosure type The supply voltage matches the nominal input voltage of the drive See the type designation label The drive is attached securely on an even vertical and non flammable wall Th...

Page 88: ...o the correct terminal and the terminals are tightened to the correct torque Proper grounding has also been measured according to the regulations If an external brake resistor is connected to the drive The brake resistor is connected to the correct terminals and the terminals are tightened to the correct torque If an external brake resistor is connected to the drive The brake resistor cable is rou...

Page 89: ...on the Internet www abb com drivesservices For more information consult your local ABB Service representative www abb com searchchannels Annually Recommended action Connections and environment P Quality of the supply voltage Spare parts I Spare parts P Reform DC circuit capacitors spare modules Inspections I Tightness of the cable and busbar terminals I Ambient conditions dustiness moisture and te...

Page 90: ...nk fins pick up dust from the cooling air The drive runs into overtemperature warnings and faults if the heatsink is not clean When necessary clean the heatsink as follows WARNING Obey the safety instructions of the drive If you ignore them injury or death or damage to the equipment can occur If you are not a qualified electrical professional do not do installation or maintenance work WARNING Use ...

Page 91: ... 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 Before you start the work do the steps in Electrical safety precautions page 14 2 Use a suitable flat screwdriver to open the fan cover 3 Carefully lift the fan cover out of the drive Note that the fan cover holds the cooling fan 2 3 4 Re...

Page 92: ... 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 To replace the cooling fan for frame R4 WARNING Obey the safety instructions of the drive If you ignore them injury or death or damage to the equipment can occur If you are not a qualified electrical professional do no...

Page 93: ...lug the fan power cable from the extension cable connector 4 5 6 Replace the old fan carefully Pay attention to the correct installation direction of the fan by following the arrow markings on the fan they must point up and to the left When installed correctly the fan creates suction within the drive and blows it outwards 7 Attach the fan power cable to the connector 6 7 8 Place the fan cover back...

Page 94: ...y followed by damage to the unit and an input cable fuse failure or a fault trip If you think that any capacitors in the drive have failed contact ABB Reforming the capacitors The capacitors must be reformed if the drive has not been powered either in storage or unused for a year or more The manufacturing date is on the type designation label For information on reforming the capacitors see Convert...

Page 95: ...s chapter The chapter contains the technical specifications of the drive such as ratings sizes and technical requirements as well as provisions for fulfilling the requirements for CE UL and other approval marks 10 Technical data 95 ...

Page 96: ...A1 4 R1 1 5 4 0 2 2 5 3 2 2 5 6 7 2 5 6 9 0 05A7 4 R1 2 2 5 6 3 0 6 8 3 0 7 2 10 1 7 2 11 5 07A3 4 R1 3 0 7 2 4 0 8 9 4 0 9 4 13 0 9 4 15 0 09A5 4 R2 4 0 9 4 5 5 12 0 5 5 12 6 16 9 12 6 20 2 12A7 4 R3 5 5 12 6 7 5 16 2 7 5 17 0 22 7 17 0 27 2 018A 4 R3 7 5 17 0 11 0 23 8 11 0 25 0 30 6 25 0 40 0 026A 4 R4 11 0 25 0 15 0 30 5 15 0 32 0 45 0 32 0 45 0 033A 4 R4 15 0 32 0 18 5 36 0 18 5 38 0 57 6 38 ...

Page 97: ...0 3 5 5 4 3 5 5 6 03A5 4 R1 2 0 3 4 2 0 4 8 3 0 4 8 6 1 4 8 7 7 04A8 4 R1 2 0 4 0 3 0 6 0 3 0 6 0 7 2 6 0 9 6 06A0 4 R1 3 0 4 8 5 0 7 6 5 0 7 6 8 6 7 6 12 2 07A6 4 R2 5 0 7 6 7 5 11 0 7 5 11 0 13 7 11 0 17 6 011A 4 R3 7 5 11 0 10 0 14 0 10 0 14 0 19 8 14 0 22 4 014A 4 R3 10 0 14 0 15 0 21 0 15 0 21 0 25 2 21 0 33 6 021A 4 R4 15 0 12 0 20 0 27 0 20 0 27 0 37 8 27 0 37 9 027A 4 R4 20 0 27 0 25 0 34 ...

Page 98: ...s 460 V 60 Hz IHd Continuous rms output current Allows 50 overload for 1 minute every 10 minutes PHd Typical motor power in heavy duty use 50 overload The kilowatt ratings apply to most IEC 4 pole 400 V 50 Hz motors The horsepower ratings apply to most NEMA 4 pole motors 460 V 60 Hz Sizing ABB recommends the DriveSize PC tool for selecting the drive motor and gear combination http new abb com driv...

Page 99: ...ng The derating factor for 131 F surrounding air temperature is The derated drive output current becomes Example 2 IEC How to calculate the required drive If your application requires a nominal motor current of 6 0 A at 8 kHz switching frequency the supply voltage is 400 V and the drive is situated at 1800 m altitude and at 35 C surrounding air temperature calculate the required drive size Altitud...

Page 100: ...nge Frame No derating Up to 50 C All Up to 122 F Output current decreases by 1 for every additional 1 C 1 8 F 50 60 C R1 R3 122 140 F Output current decreases by 1 for every additional 1 C 1 8 F on 50 60 C R4 ACS480 04 033A 4 ACS480 04 046A 4 122 140 F Output current decreases by 2 for every additional 1 C on ACS480 04 039A 4 ACS480 04 050A 4 ACS480 04 055A 2 Switching frequency derating The outpu...

Page 101: ...A 4 0 49 0 65 1 0 034A 4 0 49 0 66 1 0 042A 4 Altitude derating 400 480 V units In altitudes 1000 4000 m 3281 13123 ft above sea level the derating is 1 for every 100 m 328 ft In addition A maximum altitude of 4000 m 13123 ft is permitted for these earthing systems neutral grounded TN and TT systems and non corner grounded IT systems A maximum altitude of 2000 m 6562 ft is permitted for these eart...

Page 102: ... Min short circuit cur rent1 Drive in put cur rent IEC type ACS480 04 IEC 60269 size ABB type Voltage rating I2t Nom cur rent V A2s A A A 3 phase UN 400 V 000 OFAF000H6 500 110 6 48 4 2 02A7 4 000 OFAF000H6 500 110 6 48 5 3 03A4 4 000 OFAF000H10 500 360 10 80 6 4 04A1 4 000 OFAF000H10 500 360 10 80 9 0 05A7 4 000 OFAF000H16 500 740 16 128 11 5 07A3 4 000 OFAF000H16 500 740 16 128 15 0 09A5 4 000 O...

Page 103: ...class Bussmann Edison type Voltage rating Nominal current A V A A A 3 phase UN 480 V 25 T JJS TJS6 600 6 48 4 2 02A1 4 25 T JJS TJS6 600 6 48 5 3 03A0 4 25 T JJS TJS10 600 10 80 6 4 03A5 4 25 T JJS TJS10 600 10 80 9 0 04A8 4 25 T JJS TJS20 600 20 128 11 5 06A0 4 25 T JJS TJS20 600 20 128 15 0 07A6 4 30 T JJS TJS25 600 25 200 20 2 011A 4 40 T JJS TJS35 600 35 256 27 2 014A 4 40 T JJS TJS40 600 40 4...

Page 104: ...n and placement of the breakers Obey the manufacturer s instructions You can use the circuit breakers specified by ABB You can also use other circuit breakers with the drive if they provide the same electrical characteristics ABB does not assume any liability whatsoever for the correct function and protection of the circuit breakers not specified by ABB Furthermore if the specifications given by A...

Page 105: ...132 6 3 S1 M3 25 5 R1 03A0 4 1482 24 3 MS132 10 S1 M3 25 5 R1 03A5 4 1482 24 3 MS132 10 S1 M3 25 5 R1 04A8 4 1482 24 3 MS165 16 R1 06A0 4 1482 24 3 MS165 16 R1 07A6 4 1482 24 3 MS165 20 R2 011A 4 1482 24 3 MS165 32 R3 014A 4 1482 24 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 protectors listed are Type E ...

Page 106: ...d weights Dimensions and weights IP20 UL type open 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 1 7 7 52 191 1 97 50 8 2 208 2 9 73 6 7 170 8 8 223 8 1 205 R1 4 9 2 2 7 52 191 2 95 75 8 2 208 3 9 97 6 7 170 8 8 223 8 1 205 R2 5 6 2 5 7 52 191 5 83 148 8 2 208 6 8 172 6 7 170 8 7 220 8 1 205 R3 12 4 5 6 7 52 191 9 21 234 8 2 213 10 3 262 6 7 170 9 5 240 8 1 20...

Page 107: ...a side mounted option module to the drive take the extra width needed on the right into account Losses cooling data and noise The air flow direction is from bottom to top The tables below specify the heat dissipation in the main circuit at nominal load and in the control circuit with minimum load I O and panel not in use and maximum load all digital inputs in the on state and the panel fieldbus an...

Page 108: ...A 4 Noise Air flow Heat dissipation UL NEC type ACS480 04 Main and con trol circuit max Control cir cuit max Control cir cuit min Main circuit at rated cur rent dB A ft3 min m3 h BTU h W BTU h W BTU h W BTU h W 3 phase UN 480 V 63 33 57 189 55 69 20 29 9 121 35 02A1 4 63 33 57 213 62 69 20 29 9 145 42 03A0 4 63 33 57 240 70 69 20 29 9 172 50 03A5 4 63 33 57 302 88 69 20 29 9 233 68 04A8 4 63 33 57...

Page 109: ...6 16 0 5 0 5 018A 4 1 2 1 2 1 5 16 16 0 5 0 5 026A 4 2 9 2 5 3 7 25 35 0 5 0 5 033A 4 2 9 2 5 3 7 25 35 0 5 0 5 039A 4 2 9 2 5 3 7 25 35 0 5 0 5 046A 4 2 9 2 5 3 7 25 35 0 5 0 5 050A 4 PE U1 V1 W1 T1 U T2V T3 W R R UDC UL NEC type ACS480 04 Torque Torque Max solid stranded Min solid stranded lbf in lbf in AWG AWG 3 phase UN 480 V 10 6 5 10 18 02A1 4 10 6 5 10 18 03A0 4 10 6 5 10 18 03A5 4 10 6 5 1...

Page 110: ...pical power cable symmetrical shielded three phase copper cable Note that for the input power connection you may have to use two separate PE conductors IEC 61800 5 1 Frame Wire size Cu AWG UL NEC type ACS480 04 3 phase UN 480 V R1 16 02A1 4 R1 16 03A0 4 R1 16 03A5 4 R1 16 04A8 4 R1 16 06A0 4 R1 14 07A6 4 R2 14 011A 4 R3 10 014A 4 R3 10 021A 4 R4 8 027A 4 R4 6 034A 4 R4 4 042A 4 Terminal data for t...

Page 111: ...x FN 3268 30 33 RFI 32 018A 4 x x x FN 3268 30 33 RFI 33 026A 4 x x x FN 3258 100 35 RFI 34 033A 4 x x x FN 3258 100 35 RFI 34 039A 4 x x x FN 3258 100 35 RFI 34 046A 4 x x x FN 3258 100 35 RFI 34 050A 4 Category EMC filter type UL NEC type ACS480 04 C3 C2 C1 Schaffner order code ABB type code 3 phase UN 480 V x x x FN 3268 16 44 RFI 32 02A1 4 x x x FN 3268 16 44 RFI 32 03A0 4 x x x FN 3268 16 44 ...

Page 112: ...y to use a mains choke Use a mains choke if the short circuit capacity of the network at the drive terminals is more than in the table Mains choke R3 R4 R1 R2 Frame Voltage rating 10 kA 5 0 kA 3 phase 380 480 V You can use one choke for several drives if the short circuit capacity at the drive terminals is reduced to the value in the table 47 to 63 Hz maximum rate of change 2 s Frequency f1 Max 3 ...

Page 113: ... R1 66 20 30 10 R2 100 30 30 10 R3 100 30 30 10 R4 With optional external EMC filter 3 phase 208 240 V 380 480 V 150 50 150 50 100 30 R1 150 50 150 50 100 30 R2 150 50 150 50 100 30 R3 150 50 100 30 100 30 R4 1 Category C1 with conducted emissions only Radiated emissions are not compatible when measured with the standard emission measurement setup and must be measured on cabinet and machine instal...

Page 114: ...y power output or input 24V DGND 24 V DC 10 max 1000 mA incl internal fan load As input optional BAPO 01 module required 12 24 V DC int or ext supply Max 30 V DC Voltage Digital inputs DI1 DI6 PNP and NPN Type Rin 2 kohm Input impedance 12 24 V DC int or ext supply max 30 V DC Voltage DI5 digital or frequency input PNP and NPN Type Rin 2 kohm Input impedance 10 16 kHz Max frequency 1 form C NO NC ...

Page 115: ...tput derat ing page 98 40 70 C 2 40 70 C 2 10 60 C 14 140 F Air temperature 40 158 F 2 40 158 F 2 Output is derated above 50 C 122 F See Output derating page 98 No frost allowed Max 95 Max 95 5 95 Relative humidity No condensation allowed Maximum allowed relative humidity is 60 in the presence of corrosive gases IEC 60721 3 2 1997 IEC 60721 3 1 1997 IEC 60721 3 3 2002 Contamination levels IEC 6072...

Page 116: ...formation on environmental aspects and recycling instructions for professional recyclers End of life treatment must follow international and local regulations Applicable standards The drive complies with the following standards Safety of machinery Safety related parts of the control systems Part 1 general principles for design EN ISO 13849 1 2015 Safety of machinery Safety related parts of the con...

Page 117: ...nce IEC EN 61800 3 EAC Eurasian Conformity mark Product complies with the technical regulations of the Eurasian Customs Union EAC mark is required in Russia Belarus and Kazakhstan Electronic Information Products EIP green mark The product complies with the People s Republic of China Electronic Industry Standard SJ T 11364 2014 The product does not contain toxic and hazardous substances or elements...

Page 118: ...gth page 113 4 The drive is installed according to the instructions IEC given in this manual This product can cause radio frequency inference In a residential or domestic environment supplementary mitigation measures may be required in addition to the requirements listed above for the CE compliance Category C2 This is applicable to drive with an internal EMC C2 filter The filter is included to all...

Page 119: ...ndary windings can be used 1 2 3 4 5 6 7 8 9 4 6 Medium voltage network 1 Neighboring network 2 Point of measurement 3 Low voltage 4 Equipment victim 5 Equipment 6 Supply transformer 7 Static screen 8 Drive 9 2 An EMC plan for preventing disturbances is drawn up for the installation A template is available in Technical guide No 3 EMC compliant installation and configuration for a power drive syste...

Page 120: ...tput current must be derated between 50 60 C 122 140 F The drive is suitable for use in a circuit capable of delivering not more than 100000 rms symmetrical amperes 480 V maximum 480 V drive types or 240 V maximum 240 V drive types when protected by the UL fuses specified by ABB The current rating is based on tests done according to the applicable UL standard See T fuses UL NEC page 103 The drive ...

Page 121: ...nary wear and tear Cybersecurity disclaimer This product is designed to be connected to and to communicate information and data via a network interface It is Customer s sole responsibility to provide and continuously ensure a secure connection between the product and Customer network or any other network as the case may be Customer shall establish and maintain any appropriate measures such as but ...

Page 122: ...122 ...

Page 123: ...Dimension drawings Contents of this chapter The chapter contains the dimension drawings of the drive The dimensions are in millimeters and inches 11 Dimension drawings 123 ...

Page 124: ...Frame R1 Frame R1 front side IP20 UL type open 124 Dimension drawings ...

Page 125: ... Frame R1 bottom rear IP20 UL type open Dimension drawings 125 ...

Page 126: ... Frame R1 front side UL type 1 kit installed 126 Dimension drawings ...

Page 127: ... Frame R1 bottom rear UL type 1 kit installed Dimension drawings 127 ...

Page 128: ...Frame R2 Frame R2 front side IP20 UL type open 128 Dimension drawings ...

Page 129: ... Frame R2 bottom rear IP20 UL type open Dimension drawings 129 ...

Page 130: ... Frame R2 front side UL type 1 kit installed 130 Dimension drawings ...

Page 131: ... Frame R2 bottom rear UL type 1 kit installed Dimension drawings 131 ...

Page 132: ...Frame R3 Frame R3 front side IP20 UL type open 132 Dimension drawings ...

Page 133: ... Frame R3 bottom rear IP20 UL type open Dimension drawings 133 ...

Page 134: ... Frame R3 front side UL type 1 kit installed 134 Dimension drawings ...

Page 135: ... Frame R3 bottom rear UL type 1 kit installed Dimension drawings 135 ...

Page 136: ...Frame R4 Frame R4 front side IP20 UL type open 136 Dimension drawings ...

Page 137: ... Frame R4 bottom rear IP20 UL type open Dimension drawings 137 ...

Page 138: ... Frame R4 front side UL type 1 kit installed 138 Dimension drawings ...

Page 139: ... Frame R4 bottom rear UL type 1 kit installed Dimension drawings 139 ...

Page 140: ...140 ...

Page 141: ...a energy increases the DC link voltage The chopper connects the brake resistors 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 resistors can be disconnected Selecting the brake resistor Drives have a built in brake chopper as standard equipment The brake resis...

Page 142: ...240 V When the drive supply voltage is 380 415 V When the drive supply voltage is 415 480 V Equation 2 Equation 3 R Calculated brake resistor value ohm Make sure that Rmin R Rmax PRmax Maximum power during the braking cycle W PRave Average power during the braking cycle W ERpulse Energy conducted into the resistor during a single braking pulse J ton Braking time one cycle s T Braking cycle time s ...

Page 143: ...otherm hp kW hp kW ohm ohm CBH 360 C T 406 210R 1 10 0 83 0 75 0 55 628 99 02A1 4 or 1 50 1 13 1 00 0 75 428 99 03A0 4 CAR 200 D T 406 210R 2 20 1 65 1 50 1 10 285 99 03A5 4 3 00 2 25 2 00 1 50 206 99 04A8 4 CBR V 330 D T 406 78R UL 4 40 3 30 2 00 2 20 139 53 06A0 4 6 00 4 50 3 00 3 00 102 53 07A6 4 8 00 6 00 5 00 4 00 76 32 011A 4 CBR V 560 D HT 406 39R UL 11 00 8 25 7 50 5 50 54 32 014A 4 15 00 ...

Page 144: ...ustom brake resistors and cabling The customer must consider the EMC compliance of the complete installation Maximum cable length The maximum length of the resistor cable s is 10 m 33 ft Placing custom brake resistors Install the resistors outside the drive in a place where they are able to cool effectively Arrange the cooling of the resistor in a way that no danger of overheating is caused to the...

Page 145: ... 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 indication L1 L2 L3 1 2 3 4 5 6 13 14 3 4 1 2 K1 Θ OFF ON L1 L2 L3 4 10 24V x DIx 2 5 1 3 Drive input power connection with a main contactor ...

Page 146: ...rt up Set the following parameters 1 Disable the overvoltage control of the drive with parameter 30 30 Overvoltage control 2 Set the source of parameter 31 01 External event 1 source to point to the digital input where the thermal switch of the brake resistor is wired 3 Set parameter 31 02 External event 1 type to Fault 4 Enable the brake chopper by parameter 43 06 Brake chopper enable If Enabled ...

Page 147: ...utput stage A see the diagrams below thus preventing the drive from generating the torque required to rotate the motor If the motor is running when Safe torque off is activated it coasts to a stop The Safe torque off function has a redundant architecture that is both channels must be used in the safety function implementation The safety data given in this manual is calculated for redundant use and...

Page 148: ...C 61511 1 2016 Adjustable speed electrical power drive systems Part 5 2 Safety require ments Functional IEC 61800 5 2 2016 EN 61800 5 2 2007 Safety of machinery Functional safety of safety related electrical elec tronic and programmable electronic control systems IEC 62061 2005 A1 2012 A2 2015 EN 62061 2005 AC 2010 A1 2013 A2 2015 Safety of machinery Safety related parts of control systems Part 1 ...

Page 149: ...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 3 4 Drive 1 Control unit 2 Control logic 3 To motor 4 Activation switch K The Safe torque off function 149 ...

Page 150: ...24 V DC K 2 1 3 4 A Drive 1 Control unit 2 Control logic 3 To motor 4 Activation switch K Wiring examples Single ACS480 drive internal power supply 24 14 23 13 Y1 A2 Y2 A1 31 32 OUT GND IN1 OUT1 IN2 SGND K 1 2 Drive 1 Safety PLC 2 Safety relay K 150 The Safe torque off function ...

Page 151: ...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 151 ...

Page 152: ...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 152 The Safe torque off function ...

Page 153: ...s 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 In case a manually operated activation switch is used the switch must be of a type that can be locked out to the open position The contacts of the switch or relay must open close within 200 ms of each other Cable types and lengths Double shielded twisted ...

Page 154: ...cluding 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 tolerance of the input channels is 1 ms Grounding of protective shields Ground the shield in the cabling between the activation switch and...

Page 155: ... 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 156: ...formed due to changes or maintenance shall be logged into the logbook Acceptance test procedure After wiring the Safe torque off function validate its operation as follows Action WARNING Obey the safety instructions If you ignore them injury or death or damage to the equipment can occur Make sure that the drive can be run and stopped freely during start up Stop the drive if running switch the inpu...

Page 157: ...o IN1 If the motor was running it should coast to a stop The drive generates a FA81 Safe Torque Off 1 loss fault indication see the firmware manual Give a start command to verify that the STO function blocks the drive s operation The motor should not start Close the STO circuit Reset any active faults Restart the drive and check that the motor runs normally Open the 2nd channel of the STO circuit ...

Page 158: ...IGBT power semiconductor failure the drive can produce an alignment torque which maximally rotates the motor shaft by 180 p degrees with permanent magnet motors or 180 2p degrees with synchronous reluctance SynRM motors regardless of the activation of the Safe torque off function p denotes the number of pole pairs Notes If a running drive is stopped by using the Safe torque off function the drive ...

Page 159: ...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 160: ...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 161: ...508 2 Relevant failure modes The STO trips spuriously safe failure The STO does not activate when requested A fault exclusion on the failure mode short circuit on printed circuit board has been made EN 13849 2 table D 5 The analysis is based on an assumption that one failure occurs at one time No accumulated failures have been analyzed STO response times STO reaction time shortest detectable break...

Page 162: ...ability IEC 61508 SC Safe failure fraction IEC 61508 SFF Safety integrity level 1 3 IEC 61508 SIL Maximum 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 Per forming a proof test at a maximum...

Page 163: ... Declaration of conformity The Safe torque off function 163 ...

Page 164: ...164 ...

Page 165: ...e control board energized during a drive power outage The BAPO 01 module has internal connections to provide back up power to the control board I O fieldbus There is a DC to DC flyback converter power supply inside the module This power supply takes 24 V DC as input and outputs 5 V DC to the control board to keep the processor and communication links on at all times Note The BAPO 01 is not a batte...

Page 166: ... the drive Electrical installation Connect the external power supply to the 24 V and DGND terminals on the drive See the electrical installation instructions of the drive Do not chain an external 24 V DC power supply to several drives Each drive must be powered by a single 24 V DC power supply or a separate 24 V DC output of one auxiliary power source 166 BAPO 01 auxiliary power extension module ...

Page 167: ...o configure the BAPO 01 module 1 Power up the drive 2 Set the parameter 95 04 Control board supply to 1 External 24V Technical data Voltage and current rating for the auxiliary power supply 24 V DC 10 max 1000 mA including internal fan load Power loss Power losses with maximum load 4 W BAPO 01 auxiliary power extension module 167 ...

Page 168: ...d 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 Lang EN Cust Doc No Project name ACM380 Doc No 3AXD50000031166 Sheet 1 DMS Number 3AXD10000458992 Weight kg Total 1 T Huoso 500000681808 DIMENSION DRAWING FOR 3AXD50000022164 26 1 024 11 3 0 444...

Page 169: ...e description Product overview The BIO 01 option module option L515 is an I O extension module to be used with fieldbus adapter module The BIO 01 module can be installed between the drive and the fieldbus module The BIO 01 has three additional digital inputs DI3 DI4 and DI5 one analog input AI1 and one digital output DO1 that is referred as DIO1 in the firmware but works only in output mode You ca...

Page 170: ... bottom position The BIO 01 option module kit comes with a higher cable clamp plate Use this cable clamp plate to ground the wires that connect to the BIO 01 option module Electrical installation The BIO 01 module has removable spring clamp terminals Use ferrules on the multistranded conductor ends The connection diagram below is valid for the drive equipped with the BIO 01 I O extension module wh...

Page 171: ...og 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 Start up The BIO 01 module is automatically identified by the drive firmware To configure the inputs refer to the drive firmware manual Technical data Control connection data Spring type terminal blocks Conductor size accepted ...

Page 172: ...Dimensions 172 BIO 01 I O extension module ...

Page 173: ... 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 16 BREL 01 relay output extension module 173 ...

Page 174: ...05 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 to 2 5 mm2 20 to 14 AWG cable with a sufficient voltage rating If you connect an inductive load relay or contactor coil motor protect the relay contacts with varistor R...

Page 175: ...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 No 15 I O extension module None Sets the connected side mounted extension module Extension module type 15 01 5 Basenut relay extension module BREL None I O extension m...

Page 176: ...y output 3 is closed For complete parameter list refer to the drive firmware manual 0 0 s Sets the activation delay for relay output 3 RO3 ON delay 15 11 10 1 s Activation delay for relay output 3 0 0 3000 0 s 0 0 s Sets the deactivation delay for relay output 3 RO3 OFF delay 15 12 10 1 s Deactivation delay for relay output 3 0 0 3000 0 s Relay output 4 source selection RO4 source 15 13 0 Relay ou...

Page 177: ...ize pitch 5 0 mm Internal connectors Connector X102 provides relay control signals from the control board 1 8 pin header pitch 2 54 mm height 33 53 mm Connector X100 is not in use in BREL 01 2 4 pin header pitch 2 54 mm height 15 75 mm Dimensions 3AXD50000031148 rev A BREL 01 relay output extension module 177 ...

Page 178: ...178 ...

Page 179: ... 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 180: ...www abb com drives 3AXD50000047392D 2019 ABB Oy All Rights Reserved Specifications subject to change without notice 3AXD50000047392 Rev D EN EFFECTIVE 2019 09 23 ...

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