ABB ACS280 User manual

—
ABB MACHINERY DRIVES
ACS280 coldplate drives
Hardware manual

ACS280 coldplate drives
Hardware manual
Table of contents
1. Safety instructions
4. Mechanical installation
6. Electrical installation
3AXD50001017705 Rev A
EN
Original instructions
EFFECTIVE: 2023-11-30

Table of contents
1 Safety instructions
11Contents of this chapter .........................................................................................
11Use of warnings and notes .....................................................................................
12General safety in installation, start-up and maintenance ................................
14Electrical safety in installation, start-up and maintenance .............................
14Electrical safety precautions ..........................................................................
15Additional instructions and notes .................................................................
15Printed circuit boards ..........................................................................
16Grounding ...........................................................................................................
17General safety in operation ....................................................................................
17Additional instructions for permanent magnet motor drives ........................
17Safety in installation, start-up, maintenance ..............................................
18Safety in operation ...........................................................................................
2 Introduction to the manual
19Contents of this chapter .........................................................................................
19Applicability ...............................................................................................................
19Target audience ........................................................................................................
19Purpose of the manual ............................................................................................
19Categorization by frame size .................................................................................
20Quick installation and commissioning flowchart ..............................................
21Terms and abbreviations ........................................................................................
22Related documents ..................................................................................................
22Manuals on internet .................................................................................................
3 Operation principle and hardware description
23Contents of this chapter .........................................................................................
24Operation principle ..................................................................................................
24Simplified main circuit diagram .....................................................................
24Product variants .......................................................................................................
25Layout .........................................................................................................................
25Frame sizes R1 ...................................................................................................
26Frame sizes R2 ...................................................................................................
27Control connections ................................................................................................
27Frame size R1 and R2 ........................................................................................
28Control panel options ..............................................................................................
28Drive labels .................................................................................................................
28Model information label ...................................................................................
Table of contents 5

29Type designation label .....................................................................................
29Type designation key ...............................................................................................
30Control panel .............................................................................................................
4 Mechanical installation
31Contents of this chapter .................................................................................
31Installation alternatives ..........................................................................................
32Examining the installation site ..............................................................................
32Required tools ...........................................................................................................
33Unpacking the delivery ............................................................................................
34Planning the cooling of the drive ..........................................................................
35Design the external heatsink ..........................................................................
36Installing the drive ....................................................................................................
5 Guidelines for planning the electrical installation
39Contents of this chapter .........................................................................................
39Limitation of liability ...............................................................................................
39North America ....................................................................................................
39Selecting the main supply disconnecting device ...............................................
40Selecting the main contactor .................................................................................
40Examining the compatibility of the motor and drive ........................................
40Selecting the power cables ....................................................................................
40General guidelines ............................................................................................
41Typical power cable sizes ................................................................................
41Power cable types .............................................................................................
41Preferred power cable types ..............................................................
42Alternate power cable types ...............................................................
43Not allowed power cable types ..........................................................
43Additional guidelines – North America .........................................................
44Metal conduit .........................................................................................
44Power cable shield ............................................................................................
45Grounding ..................................................................................................................
45Selecting the control cables ...................................................................................
45Shielding .............................................................................................................
46Signals in separate cables ...............................................................................
46Signals that can be run in the same cable ....................................................
46Relay cable ..........................................................................................................
46Control panel to drive cable ............................................................................
46PC tool cable ......................................................................................................
46Routing the cables ...................................................................................................
46General guidelines – IEC ...................................................................................
47General guidelines – North America ..............................................................
48
Continuous motor cable shield/conduit and metal enclosure for
equipment on the motor cable .......................................................................
6 Table of contents

49Separate control cable ducts ..........................................................................
49Implementing short-circuit and thermal overload protection ........................
49Protecting the drive and input power cable in short-circuits ..................
49Protecting the motor and motor cable in short-circuits ..........................
50
Protecting the drive, and the input power and motor cables against
thermal overload ...............................................................................................
50Protecting the motor against thermal overload ........................................
50
Protecting the motor against overload without thermal model or
temperature sensors ........................................................................................
51Implementing motor temperature sensor connection .....................................
51Protecting the drive against ground faults .........................................................
51Residual current device compatibility ..........................................................
52Implementing the Emergency stop function ......................................................
52Implementing the Safe torque off function ........................................................
52Using a safety switch between the drive and the motor .................................
52Implementing the control of a contactor between drive and motor .............
53Protecting the contacts of relay outputs ............................................................
6 Electrical installation
55Contents of this chapter .........................................................................................
55Warnings ....................................................................................................................
55Required tools ...........................................................................................................
56Measuring the insulation ........................................................................................
56Measuring the insulation resistance of the drive .......................................
56Measuring the insulation resistance of the input power cable ...............
56Measuring the insulation resistance of the motor and motor cable ......
57Grouding system compatibility check .................................................................
57EMC filter ............................................................................................................
57When to disconnect the EMC filter ................................................................
58Disconnecting the EMC filter ..........................................................................
59Guidelines for installing the drive to a TT system ......................................
59Identifying the grounding system of the electrical power network .......
61Connecting the power cables ................................................................................
61Connection diagram .........................................................................................
62Connection procedure .....................................................................................
63Connecting the control cables ...............................................................................
64Default I/O connection diagram (ABB standard macro) ..........................
64Control cable connection procedure .............................................................
66Additional information on the control connections ..........................................
66Connecting EIA-485 fieldbus cable to the drive ..........................................
67PNP configuration for digital inputs .............................................................
67Connection examples of two-wire and three-wire sensors .....................
68Safe torque off ..................................................................................................
68Connecting a PC .......................................................................................................
Table of contents 7

7 Installation checklist
69Contents of this chapter .........................................................................................
69Checklist .....................................................................................................................
8 Maintenance
73Contents of this chapter .........................................................................................
73Maintenance intervals .............................................................................................
73Description of symbols ....................................................................................
74Recommended maintenance intervals after start-up ...............................
74Replacing the cooling fans .....................................................................................
75Replacing the cooling fan ................................................................................
76Capacitors ..................................................................................................................
77Reforming the capacitors ................................................................................
9 Technical data
79Contents of this chapter .........................................................................................
79Ratings ........................................................................................................................
79IEC ratings ..........................................................................................................
80UL (NEC) ratings ................................................................................................
81Definitions ..........................................................................................................
82Sizing ...................................................................................................................
82Output derating ........................................................................................................
82Altitude derating ...............................................................................................
82Switching frequency derating ........................................................................
84Fuses ...........................................................................................................................
84gG fuses (IEC) ....................................................................................................
85gR or aR -type fuses (IEC) ................................................................................
85UL fuses (UL(NEC)) ...........................................................................................
86Alternate short-circuit protection .........................................................................
86Miniature circuit breakers (IEC) .....................................................................
87Miniature circuit breakers (UL) ......................................................................
89Dimensions and weights ........................................................................................
90Free space requirements ........................................................................................
90Losses, cooling data and noise .............................................................................
91Terminal data for the power cables ......................................................................
93Typical power cable sizes .......................................................................................
94Terminal data for the control cables ....................................................................
94Electrical power network specification ...............................................................
95Motor connection data ............................................................................................
95Motor cable length ............................................................................................
95Operational functionality and motor cable length ........................
96EMC compatibility and motor cable length .....................................
96Control connection data .........................................................................................
8 Table of contents

97Brake resistor connection data .............................................................................
98Energy efficiency data (ecodesign) ......................................................................
98Degrees of protection .............................................................................................
98Ambient conditions .................................................................................................
99Materials .....................................................................................................................
99Disposal ......................................................................................................................
100Applicable standards ...............................................................................................
100Markings .....................................................................................................................
101Compliance with EN 61800-3 .................................................................................
101Definitions ..........................................................................................................
102Category C1 ........................................................................................................
102Category C2 ........................................................................................................
102Category C3 ........................................................................................................
103Category C4 ........................................................................................................
104UL checklist ................................................................................................................
105Compliance with the European Machinery Directive ........................................
105Disclaimers ................................................................................................................
105Generic disclaimer ............................................................................................
105Cyber security disclaimer ................................................................................
10 Dimension drawings
107Contents of this chapter .........................................................................................
108Frame R1 .....................................................................................................................
109Frame R2 .....................................................................................................................
11 Resistor braking
111Contents of this chapter .........................................................................................
111Safety ..........................................................................................................................
111Operation principle ..................................................................................................
111Selecting the brake resistor ...................................................................................
113Reference brake resistors ...............................................................................
113Definitions ..............................................................................................
113Selecting and routing the brake resistor cables ................................................
114Minimizing electromagnetic interference ....................................................
114Maximum cable length .....................................................................................
114Selecting the installation location for the brake resistors ..............................
114Protecting the system in brake circuit fault situations ....................................
114
Protecting the system in cable and brake resistor short-circuit
situations ............................................................................................................
115Protecting the system against thermal overload .......................................
116Mechanical and electrical installation of brake resistor ...................................
116Mechanical installation ....................................................................................
116Electrical installation ........................................................................................
116Measuring the insulation .....................................................................
Table of contents 9

116Connecting power cables ....................................................................
116Connection the control cables ...........................................................
116Start-up ......................................................................................................................
12 The Safe torque off function
119Contents of this chapter .........................................................................................
119Description ................................................................................................................
120
Compliance with the European Machinery Directive and the UK Supply
of Machinery (Safety) Regulations ................................................................
121Wiring ..........................................................................................................................
121Connection principle ........................................................................................
121Single ACS280 drive, internal power supply ....................................
122Single ACS280 drive, external power supply ...................................
123Wiring examples ................................................................................................
123Single ACS280 drive, internal power supply ....................................
123Single ACS280 drive, external power supply ...................................
124Multiple ACS280 drives, internal power supply ..............................
125Multiple ACS280 drives, external power supply .............................
125Activation switch ...............................................................................................
126Cable types and lengths ..................................................................................
126Grounding of protective shields ....................................................................
127Operation principle ..................................................................................................
128Start-up including validation test .........................................................................
128Competence .......................................................................................................
128Validation test reports .....................................................................................
128Validation test procedure ...............................................................................
130Use ...............................................................................................................................
132Maintenance ..............................................................................................................
132Competence .......................................................................................................
133Fault tracing ..............................................................................................................
134Safety data .................................................................................................................
136Terms and abbreviations .................................................................................
137TÜV certificate ...................................................................................................
138Declarations of conformity .............................................................................
Further information
10 Table of contents

Safety instructions
Contents of this chapter
This chapter contains the safety instructions which you must obey when you install,
start-up, operate and do maintenance work on the drive. If you ignore the safety
instructions, injury, death or damage can occur.
Use of warnings and notes
Warnings tell you about conditions which can cause injury or death, or damage to
the equipment. They also tell you how to prevent the danger. Notes draw attention
to a particular condition or fact, or give information on a subject.
The manual uses these warning symbols:
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 damage to the equipment.
WARNING!
Electrostatic sensitive devices warning tells you about the risk of electrostatic
discharge which can cause damage to the equipment.
1
Safety instructions 11

General safety in installation, start-up and maintenance
These instructions are for all personnel who do work on the drive.
WARNING!
Obey these instructions. If you ignore them, injury or death, or damage to
the equipment can occur.
• Keep the drive in its package until you install it. After unpacking, protect the
drive from dust, debris and moisture.
• Use the required personal protective equipment: safety shoes with metal toe
cap, safety glasses, protective gloves and long sleeves, etc. Some parts have
sharp edges.
• Beware of hot surfaces. Some parts, such as heatsinks of power
semiconductors, and brake resistors, remain hot for a while after disconnection
of the electrical supply.
• Vacuum clean the area around the drive before the start-up to prevent the
drive cooling fan from drawing dust inside the drive.
• Make sure that debris from drilling, cutting and grinding does not go into the
drive during installation. Electrically conductive debris inside the drive can
cause damage or malfunction.
• Make sure that 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
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/UL 61800-5-1, subclause 6.5.3,
for example, "THIS MACHINE STARTS AUTOMATICALLY".
• The maximum number of drive power-ups is five in ten minutes. Too frequent
power-ups can damage the charging circuit of the DC capacitors.
• If you have connected safety circuits to the drive (for example, Safe torque off
or emergency stop), validate them at start-up. See separate instructions for
the safety circuits.
• Beware of hot air exiting from the air outlets.
• Do not cover the air inlet or outlet when the drive is running.
12 Safety instructions
3

Note:
• If you select an external source for the start command and it is on, the drive
will start immediately after fault reset unless you configure the drive for pulse
start. See the firmware manual.
• If the drive is in remote control mode, you cannot stop or start the drive with
the control panel.
• Only authorized persons are allowed to repair a malfunctioning drive.
Safety instructions 13

Electrical safety in installation, start-up and maintenance
￭Electrical safety precautions
These electrical safety precautions are for all personnel who do work on the drive,
motor cable or motor.
WARNING!
Obey these instructions. If you ignore them, injury or death, or damage to
the equipment can occur.
If you are not a qualified electrical professional, do not do installation or
maintenance work.
Do these steps before you begin any installation or maintenance work.
1. Prepare for the work.
• Make sure that you have a work order.
• Do an on-site risk assessment or job hazard analysis.
• Make sure that you have the correct tools available.
• Make sure that the workers are qualified.
• Select the correct personal protective equipment (PPE).
• Stop the motor(s).
2. Clearly identify the work location and equipment.
3. Disconnect all possible voltage sources. Make sure that re-connection is not
possible. Lock out and tag out.
• Open the main disconnecting device of the drive.
• If you have a permanent magnet motor connected to the drive, disconnect
the motor from the drive with a safety switch or by other means.
• Open the main isolating device of the drive.
• Disconnect 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.
4. Protect other energized parts in the work location against contact and take
special precautions when close to bare conductors.
5. Measure that the installation is de-energized. Use a quality voltage tester.
Before and after you measure the installation, verify the operation of the
voltage tester on a known voltage source.
•
• Make sure that the voltage between the drive input power terminals (L1,
L2, L3) and the grounding (PE) busbar is zero.
•Make sure that the voltage between the drive output terminals (T1/U, T2/V,
T3/W) and the grounding (PE) busbar is zero.
• Make sure that the voltage between the drive DC terminals (UDC+ and
UDC-) and the grounding (PE) terminal is zero.
14 Safety instructions
3

Note: If cables are not connected to the drive DC terminals, measuring the
voltage from the DC terminal screws can give incorrect results.
6. Install temporary grounding as required by the local regulations.
7. Ask for a permit to work from the person in control of the electrical installation
work.
￭Additional instructions and notes
WARNING!
Obey these instructions. If you ignore them, injury or death, or damage to
the equipment can occur.
If you are not a qualified electrical professional, do not do installation or
maintenance work.
• Make sure that the electrical power network, motor/generator, and
environmental conditions agree with the drive data.
• Do not do insulation or voltage withstand tests on the drive.
• If you have a cardiac pacemaker or other electronic medical device, keep away
from the area near motor, drive, and the drive power cabling when the drive
is in operation. There are electromagnetic fields 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.
After disconnecting the drive from the input power, these remain at a
dangerous voltage until the intermediate circuit capacitors have discharged.
• External wiring can supply dangerous voltages to the relay outputs of the
control units of the drive.
• The Safe torque off function does not remove the voltage from the main and
auxiliary circuits. The function is not effective against deliberate sabotage or
misuse.
Printed circuit boards
WARNING!
Use a grounding wristband when you handle printed circuit boards. Do not
touch the boards unnecessarily. The boards contain components sensitive
to electrostatic discharge.
Safety instructions 15

￭Grounding
These instructions are for all personnel who are responsible for the grounding of
the drive.
WARNING!
Obey these instructions. If you ignore them, injury or death, or equipment
malfunction can occur, and electromagnetic interference can increase.
If you are not a qualified electrical professional, do not do grounding work.
•Always ground the drive, the motor and adjoining equipment. This is necessary
for the personnel safety.
• Make sure that the conductivity of the protective earth (PE) conductors is
sufficient and that other requirements are met. See the electrical planning
instructions of the drive. Obey the applicable national and local regulations.
• When using shielded cables, make a 360° grounding of the cable shields at the
cable entries to reduce electromagnetic emission and interference.
• In a multiple-drive installation, connect each drive separately to the protective
earth (PE) busbar of the power supply.
16 Safety instructions
3

General safety in operation
These instructions are for all personnel that operate the drive.
WARNING!
Obey these instructions. If you ignore them, injury or death, or damage to
the equipment can occur.
• If you have a cardiac pacemaker or other electronic medical device, keep away
from the area near motor, drive, and the drive power cabling when the drive
is in operation. There are electromagnetic fields present which can interfere
with the function of such devices. This can cause a health hazard.
• Give a stop command to the drive before you reset a fault. If you have an
external source for the start command and the start is on, the drive will start
immediately after 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
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/UL 61800-5-1, subclause 6.5.3,
for example, "THIS MACHINE STARTS AUTOMATICALLY".
Note:
• The maximum number of drive power-ups is five in ten minutes. Too frequent
power-ups can damage the charging circuit of the DC capacitors. If you need
to start or stop the drive, use the control panel keys or commands through
the I/O terminals of the drive.
• If the drive is in remote control mode, you cannot stop or start the drive with
the control panel.
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.
WARNING!
Obey these instructions. 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.
Safety instructions 17

• Do not do work on the drive when a rotating permanent magnet motor is
connected to it. A rotating permanent magnet motor energizes the drive
including its input and output power terminals.
Before installation, start-up and maintenance work on the drive:
• Stop the drive.
• Disconnect the motor from the drive with a safety switch or by other means.
• If you cannot disconnect the motor, make sure that the motor cannot rotate
during work. Make sure that no other system, like hydraulic crawling drives,
can rotate the motor directly or through any mechanical connection like belt,
nip, rope, etc.
• Do the steps in section Electrical safety precautions (page 14).
• Install temporary grounding to the drive output terminals (T1/U, T2/V, T3/W).
Connect the output terminals together as well as to the PE.
During 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 the
load. Motor overspeed causes overvoltage that can damage or destroy the
capacitors in the intermediate circuit of the drive.
18 Safety instructions
3

Introduction to the manual
Contents of this chapter
This chapter describes the intended audience and contents of the manual. It
contains a flowchart of steps in examining the delivery, installing and
commissioning the drive. The flowchart refers to chapters/sections in this manual
and other manuals.
Applicability
This manual is applicable to ACS280 drives.
Target audience
The reader is expected to know the fundamentals 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 are manufactured in frame sizes R1 and R2. The instructions and
information that is applicable only to certain frames indicate the frame size. The
frame size is shown on the type designation label.
2
Introduction to the manual 19

Quick installation and commissioning flowchart
SeeTask
Type designation key (page 29)
Identify the frame size: R1 and R2.
Guidelines for planning the electrical
installation (page 39)
Technical data (page 79)
Plan the installation.
Examine the ambient conditions, ratings and required
cooling air flow.
Unpacking the delivery (page 33)
Unpack and examine the drive.
Grouding system compatibility
check (page 57)
If the drive will be connected to an IT (ungrounded)
system, make sure that the internal EMC filter is not
connected.
Installing the drive (page 36)
Install the drive mechanically.
Routing the cables (page 46)
Route the cables.
Measuring the insulation (page 56)
Measure the insulation of the input cable, motor and
motor cable.
Connecting the power
cables (page 61)
Connect the power cables.
Connecting the control
cables (page 63)
Connect the control cables.
Installation checklist (page 69)
Examine the installation.
Refer to the ACS280 Firmware
manual (3AXD50001017729 [Eng-
lish]).
Commission the drive.
20 Introduction to the manual