ABB ACS480-04-09A8-1 User manual

—
ABB GENERAL PURPOSE DRIVES
ACS480 drives
Hardware manual

ACS480 drives
Hardware manual
Table of contents
1. Safety instructions
4. Mechanical installation
6. Electrical installation – IEC
7. Electrical installation – North
America
3AXD50000047392 Rev E
EN
Original instructions
EFFECTIVE: 2021-10-04

Table of contents
1 Safety instructions
15Contents of this chapter ......................................................................................
15Use of warnings and notes .................................................................................
16General safety in installation, start-up and maintenance ....................................
17General safety in operation ..........................................................................
18Electrical safety in installation, start-up and maintenance ..................................
18Electrical safety precautions ........................................................................
19Additional instructions and notes .................................................................
19Printed circuit boards ........................................................................
20Grounding ....................................................................................................
20Additional instructions for permanent magnet motor drives ................................
20Safety in installation, start-up, maintenance ................................................
21Safety in operation .......................................................................................
2 Introduction to the manual
23Contents of this chapter ......................................................................................
23Applicability .........................................................................................................
23Target audience ..................................................................................................
23Categorization by frame size ..............................................................................
24Quick installation and commissioning flowchart .................................................
25Terms and abbreviations .....................................................................................
26Related manuals .................................................................................................
3 Operation principle and hardware description
29Contents of this chapter ......................................................................................
29Operation principle ..............................................................................................
30Simplified main circuit diagram ....................................................................
30Product variants ..................................................................................................
30IEC and UL (NEC) product types .................................................................
31Layout .................................................................................................................
32Control connections ............................................................................................
32Standard unit (with RIIO-01) ........................................................................
33Base unit ......................................................................................................
33Option modules ...................................................................................................
34Control panel options ..........................................................................................
34UL Type 1 kits .....................................................................................................
35Drive labels .........................................................................................................
35Type designation label .................................................................................
Table of contents 5

36Software information label ...........................................................................
36Type designation key ..........................................................................................
36Basic code ....................................................................................................
36Option codes ................................................................................................
4 Mechanical installation
39Contents of this chapter ......................................................................................
39Installation alternatives .......................................................................................
40Examining the installation site ............................................................................
40Required tools .....................................................................................................
41Unpacking the delivery ........................................................................................
41Installing the drive ...............................................................................................
41To install the drive with screws .....................................................................
42To install the drive to a DIN installation rail ..................................................
5 Guidelines for planning the electrical installation
45Contents of this chapter ......................................................................................
45Limitation of liability .............................................................................................
45Selecting the main supply disconnecting device ................................................
46European Union and United Kingdom .........................................................
46North America ..............................................................................................
46Other regions ...............................................................................................
46Selecting the main contactor ..............................................................................
46North America ..............................................................................................
46Other regions ...............................................................................................
47Checking the compatibility of the motor and drive ..............................................
47Selecting the power cables .................................................................................
47General guidelines .......................................................................................
47Typical power cable sizes ............................................................................
48Power cable types ........................................................................................
48Preferred power cable types .............................................................
49Alternate power cable types .............................................................
50Not allowed power cable types .........................................................
51Additional guidelines, North America ...........................................................
51Metal conduit ....................................................................................
52Power cable shield .......................................................................................
52Grounding requirements .....................................................................................
53Additional grounding requirements – IEC ....................................................
54Additional grounding requirements – UL (NEC) ...........................................
54Selecting the control cables ................................................................................
54Shielding ......................................................................................................
54Signals in separate cables ...........................................................................
54Signals that can be run in the same cable ...................................................
55Relay cable ..................................................................................................
6 Table of contents

55Control panel to drive cable .........................................................................
55PC tool cable ................................................................................................
55Routing the cables ..............................................................................................
55General guidelines – IEC .............................................................................
56General guidelines – North America ............................................................
57
Continuous motor cable shield/conduit or enclosure for equipment on the
motor cable ..................................................................................................
58Separate control cable ducts .......................................................................
58Implementing short-circuit and thermal overload protection ...............................
58Protecting the drive and input power cable in short-circuits .........................
58Protecting the motor and motor cable in short-circuits .................................
58
Protecting the drive, and the input power and motor cables against thermal
overload .......................................................................................................
59Protecting the motor against thermal overload ............................................
59
Protecting the motor against overload without thermal model or temperature
sensors .........................................................................................................
59Implementing a motor temperature sensor connection ......................................
60Protecting the drive against ground faults ..........................................................
60Residual current device compatibility ...........................................................
60Implementing the Emergency stop function ........................................................
61Implementing the Safe torque off function ..........................................................
61Using a safety switch between the drive and the motor .....................................
61Implementing the control of a contactor between drive and motor .....................
61Protecting the contacts of relay outputs ..............................................................
6 Electrical installation – IEC
63Contents of this chapter ......................................................................................
63Warnings .............................................................................................................
63Required tools .....................................................................................................
64Measuring the insulation resistance - IEC ..........................................................
64Measuring the insulation resistance of the drive ..........................................
64Measuring the insulation resistance of the input power cable .....................
64Measuring the insulation resistance of the motor and motor cable ..............
65Measuring the insulation resistance of the brake resistor circuit .................
65Grounding system compatibility check – IEC .....................................................
65EMC filter .....................................................................................................
66Ground-to-phase varistor .............................................................................
66
Compatibility of EMC filter and ground-to-phase varistor with the grounding
system ..........................................................................................................
68Disconnecting the EMC filter or ground-to-phase varistor ...........................
68EMC/VAR screw location ..................................................................
69Guidelines for installing the drive to a TT system ........................................
69Identifying the grounding system of the electrical power network ................
71Connecting the power cables – IEC (shielded cables) .......................................
71Connection diagram .....................................................................................
Table of contents 7

72Connection procedure ..................................................................................
74Connecting the control cables - IEC ...................................................................
74Default I/O connection diagrams (ABB standard macro) .............................
76Default fieldbus connection diagram ............................................................
77Control cable connection procedure ............................................................
78Additional information on the control connections .......................................
78Embedded EIA-485 fieldbus connection ..........................................
80PNP configuration for digital inputs ..................................................
80NPN configuration for digital inputs ..................................................
81Connection for obtaining 0 … 10 V from analog output 2 (AO2) ......
81Connection examples of two-wire and three-wire sensors ...............
82
AI and AO (or AI, DI and +10 V) as PTC motor temperature sensor
interface ............................................................................................
83
AI1 and AI2 as Pt100, Pt1000, Ni1000, KTY83 and KTY84 sensor
inputs ................................................................................................
84Safe torque off ..................................................................................
84Auxiliary voltage connection ...............................................................................
85Connecting a PC .................................................................................................
85Installing options .................................................................................................
86Installing a front option .................................................................................
87Installing a side option .................................................................................
7 Electrical installation – North America
89Contents of this chapter ......................................................................................
89Warnings .............................................................................................................
89Required tools .....................................................................................................
90Measuring the insulation resistance - North America .........................................
90Measuring the insulation resistance of the drive ..........................................
90Measuring the insulation resistance of the input power cable .....................
90Measuring the insulation resistance of the motor and motor cable ..............
91Measuring the insulation resistance of the brake resistor circuit .................
91Grounding system compatibility check – North America ....................................
92EMC filter .....................................................................................................
92Ground-to-phase varistor .............................................................................
92
Compatibility of EMC filter and ground-to-phase varistor with the grounding
system ..........................................................................................................
94Disconnecting the ground-to-phase varistor, or connecting the EMC filter ...
94EMC/VAR screw location ..................................................................
95Guidelines for installing the drive to a TT system ........................................
95Identifying the grounding system of the electrical power network ................
97Connecting the power cables – North America (wiring in conduits) ...................
97Connection diagram .....................................................................................
98Connection procedure ..................................................................................
100Connecting the control cables - North America ..................................................
100Default I/O connection diagrams (ABB standard macro) .............................
8 Table of contents

102Default fieldbus connection diagram ............................................................
103Control cable connection procedure ............................................................
104Additional information on the control connections .......................................
104Embedded EIA-485 fieldbus connection ..........................................
106PNP configuration for digital inputs ..................................................
106NPN configuration for digital inputs ..................................................
107Connection for obtaining 0 … 10 V from analog output 2 (AO2) ......
107Connection examples of two-wire and three-wire sensors ...............
108
AI and AO (or AI, DI and +10 V) as PTC motor temperature sensor
interface ............................................................................................
109
AI1 and AI2 as Pt100, Pt1000, Ni1000, KTY83 and KTY84 sensor
inputs ................................................................................................
110Safe torque off ..................................................................................
110Auxiliary voltage connection ...............................................................................
111Connecting a PC .................................................................................................
111Installing options .................................................................................................
112Installing a front option .................................................................................
113Installing a side option .................................................................................
8 Installation checklist
115Contents of this chapter ......................................................................................
115Checklist .............................................................................................................
9 Maintenance
119Contents of this chapter ......................................................................................
119Maintenance intervals .........................................................................................
119Description of symbols .................................................................................
120Recommended maintenance intervals after start-up ...................................
120Functional safety components ............................................................................
121Cleaning the heatsink .........................................................................................
121Replacing the cooling fans ..................................................................................
122Replacing the cooling fan, frames R1…R3 ..................................................
124Replacing the cooling fan, frame R4 ............................................................
125Capacitors ...........................................................................................................
125Reforming the capacitors .............................................................................
10 Technical data
127Contents of this chapter ......................................................................................
127Electrical ratings ..................................................................................................
127IEC ratings ...................................................................................................
129UL (NEC) ratings ..........................................................................................
130Definitions ....................................................................................................
130Sizing ...........................................................................................................
Table of contents 9

131Output derating ...................................................................................................
133Surrounding air temperature derating ..........................................................
133Altitude derating ...........................................................................................
134Switching frequency derating .......................................................................
136Fuses ..................................................................................................................
136IEC fuses ......................................................................................................
136gG fuses (IEC) ..................................................................................
137gR fuses (IEC) ..................................................................................
139UL (NEC) fuses ............................................................................................
140UL (NEC) fuse alternatives ...............................................................
144Input chokes ........................................................................................................
146Alternative short-circuit protection ......................................................................
146Miniature circuit breakers (IEC) ...................................................................
148
Manual self-protected combination motor controller – Type E USA
(UL (NEC)) ...................................................................................................
150Dimensions and weights .....................................................................................
151Free space requirements ....................................................................................
151Losses, cooling data and noise ..........................................................................
153Typical power cable sizes ...................................................................................
156Terminal data for the power cables .....................................................................
158Terminal data for the control cables ....................................................................
158External EMC filters ............................................................................................
160Electrical power network specification ................................................................
161Motor connection data ........................................................................................
161Motor cable length ........................................................................................
161Operational functionality and motor cable length .............................
162EMC compatibility and motor cable length .......................................
163Brake resistor connection data ...........................................................................
163Control connection data ......................................................................................
164Energy efficiency data (ecodesign) .....................................................................
165Protection classes ...............................................................................................
165Ambient conditions ..............................................................................................
166Materials .............................................................................................................
166Disposal ..............................................................................................................
167Applicable standards ...........................................................................................
167Markings .............................................................................................................
168EMC compliance (IEC/EN 61800-3:2004 + A1:2012) ........................................
168Definitions ....................................................................................................
169Category C1 .................................................................................................
169Category C2 .................................................................................................
170Category C3 .................................................................................................
170Category C4 .................................................................................................
171UL checklist .........................................................................................................
172Disclaimers .........................................................................................................
172Generic disclaimer .......................................................................................
10 Table of contents

172Cybersecurity disclaimer ..............................................................................
11 Dimension drawings
175Contents of this chapter ......................................................................................
176Frame R0 ............................................................................................................
176Frame R0 (front & side) - IP20 / UL open type ............................................
177Frame R0 (bottom & rear) - IP20 / UL open type .........................................
178Frame R1 ............................................................................................................
178Frame R1 (front & side) - IP20 / UL open type ............................................
179Frame R1 (bottom & rear) - IP20 / UL open type .........................................
180Frame R1 (front & side) - UL Type 1 kit installed .........................................
181Frame R1 (bottom & rear) - UL Type 1 kit installed .....................................
182Frame R2 ............................................................................................................
182Frame R2 (front & side) - IP20 / UL open type ............................................
183Frame R2 (bottom & rear) - IP20 / UL open type .........................................
184Frame R2 (front & side) - UL Type 1 kit installed .........................................
185Frame R2 (bottom & rear) - UL Type 1 kit installed .....................................
186Frame R3 ............................................................................................................
186Frame R3 (front & side) - IP20 / UL open type ............................................
187Frame R3 (bottom & rear) - IP20 / UL open type .........................................
188Frame R3 (front & side) - UL Type 1 kit installed .........................................
189Frame R3 (bottom & rear) - UL Type 1 kit installed .....................................
190Frame R4 ............................................................................................................
190Frame R4 (front & side) - IP20 / UL open type ............................................
191Frame R4 (bottom & rear) - IP20 / UL open type .........................................
192Frame R4 (front & side) - UL Type 1 kit installed .........................................
193Frame R4 (bottom & rear) - UL Type 1 kit installed .....................................
12 Resistor braking
195Contents of this chapter ......................................................................................
195Safety ..................................................................................................................
195Operation principle ..............................................................................................
195Selecting the brake resistor ................................................................................
197Reference brake resistors ............................................................................
199Definitions .........................................................................................
199Selecting and routing the brake resistor cables ..................................................
199Minimizing electromagnetic interference ......................................................
200Maximum cable length .................................................................................
200Placing the brake resistors .................................................................................
200Protecting the system in brake circuit fault situations .........................................
200Protecting the system in cable and brake resistor short-circuit situations ....
201Protecting the system against thermal overload ..........................................
202Mechanical and electrical installation of brake resistor .......................................
202Mechanical installation .................................................................................
Table of contents 11

202Electrical installation .....................................................................................
202Measuring the insulation ...................................................................
202Connecting power cables .................................................................
202Connection the control cables ..........................................................
202Start-up ...............................................................................................................
13 The Safe torque off function
203Contents of this chapter ......................................................................................
203Description ..........................................................................................................
204
Compliance with the European Machinery Directive and the UK Supply of
Machinery (Safety) Regulations ...................................................................
205Wiring ..................................................................................................................
205Connection principle ....................................................................................
205Single ACS480 drive, internal power supply ....................................
206Single ACS480 drive, external power supply ...................................
207Wiring examples ...........................................................................................
207Single ACS480 drive, internal power supply ....................................
207Single ACS480 drive, external power supply ...................................
208Multiple ACS480 drives, internal power supply ................................
209Multiple ACS480 drives, external power supply ...............................
209Activation switch ...........................................................................................
210Cable types and lengths ..............................................................................
210Grounding of protective shields ...................................................................
211Operation principle ..............................................................................................
212Start-up including validation test .........................................................................
212Competence .................................................................................................
212Validation test reports ...................................................................................
212Validation test procedure ..............................................................................
214Use ......................................................................................................................
216Maintenance .......................................................................................................
216Competence .................................................................................................
217Fault tracing ........................................................................................................
218Safety data ..........................................................................................................
219Terms and abbreviations ..............................................................................
220TÜV certificate ..............................................................................................
221Declarations of conformity ...........................................................................
14 BAPO-01 auxiliary power extension module
223Contents of this chapter ......................................................................................
223Safety instructions ...............................................................................................
223Hardware description ..........................................................................................
224Layout ..........................................................................................................
225Mechanical installation ........................................................................................
225Electrical installation ...........................................................................................
12 Table of contents

225Start-up ...............................................................................................................
226Technical data .....................................................................................................
15 BIO-01 I/O extension module
227Contents of this chapter ......................................................................................
227Safety instructions ...............................................................................................
227Hardware description ..........................................................................................
227Product overview ..........................................................................................
228Layout ..........................................................................................................
228Mechanical installation ........................................................................................
228Terminal configuration .........................................................................................
229Electrical installation ...........................................................................................
229Start-up ...............................................................................................................
229Technical data .....................................................................................................
16 BREL-01 relay output extension module
233Contents of this chapter ......................................................................................
233Safety instructions ...............................................................................................
233Hardware description ..........................................................................................
233Product overview ..........................................................................................
234Layout ..........................................................................................................
234Mechanical installation ........................................................................................
234Electrical installation ...........................................................................................
235Start-up ...............................................................................................................
235Configuration parameters ...................................................................................
237Technical data .....................................................................................................
Further information
Table of contents 13

14

1
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.
Safety instructions 15

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 the dust inside the drive.
•Make sure that debris from drilling, cutting and grinding does not enter the drive during
the installation. Electrically conductive debris inside the drive may 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 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 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.
16 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.
￭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 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 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.
Safety instructions 17

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.
Go through these steps before you begin any installation or maintenance work.
1. Clearly identify the work location and equipment.
2. 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.
•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.
3. Protect any other energized parts in the work location against contact.
4. Take special precautions when close to bare conductors.
5. Measure that the installation is de-energized. Use a quality voltage tester.
•Before and after measuring 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.
Note: If cables are not connected to the drive DC terminals, measuring the voltage
from the DC terminal screws can give incorrect results.
18 Safety instructions
3

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.
The brake circuit, including the brake chopper and brake resistor (if installed) are also
at a dangerous voltage.
After disconnecting the drive from the input power, these remain at a 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 19

￭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.
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.
•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.
20 Safety instructions
3