—
ABB DRIVES FOR HVAC
ACH480 drives
Hardware manual
Hardware manual
ACH480 drives
2018 ABB Oy. All Rights Reserved.
3AXD50000245949 Rev A
EN
EFFECTIVE: 2018-11-22
3
4
Table of contents 5
Table of contents
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Use of warnings and notes in this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
General safety in installation, start-up and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Electrical safety in installation, start-up and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Precautions before electrical work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Additional instructions and notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Additional instructions for permanent magnet motor drives . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Safety in installation, start-up and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
General safety in operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Applicability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Target audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Purpose of the manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Contents of this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Related documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Categorization by frame (size) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Quick installation and commissioning flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
General description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Product variants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Hardware overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Control connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Standard unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Base unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Mounted options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
PC connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Drive labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Model information label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Software information label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Type designation label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Type designation key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Operation principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6 Table of contents
Examining the installation site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Required tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Unpacking the delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Installing the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
To install the drive with screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
To install the drive to a DIN installation rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Selecting the supply disconnecting device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
European Union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Other regions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Checking the compatibility of the motor and drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Selecting the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Typical power cable sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Recommended power cable types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Power cable types for limited use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Not allowed power cable types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Motor cable shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Additional US requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Selecting the control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Shielding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Signals in separate cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Signals that can be run in the same cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Relay cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Control panel to PC connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Control panel to drive connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Modbus RTU cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Routing the cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Separate control cable ducts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Continuous motor cable shield or conduit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Implementing short-circuit protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Protecting the drive and input power cable in short-circuits . . . . . . . . . . . . . . . . . . . . . . . 50
Protecting the motor and motor cable in short-circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Implementing thermal overload protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Protecting the motor against thermal overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Protecting the drive against ground faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Residual current device compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Implementing the emergency stop function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Implementing the Safe torque off function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Using a safety switch between the drive and motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Using a contactor between the drive and motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Protecting the contacts of relay outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Table of contents 7
Measuring insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Input power cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Motor and motor cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Brake resistor assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Compatibility with IT (ungrounded) and corner-grounded TN systems . . . . . . . . . . . . . . . . . . 57
EMC filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
EMC filter disconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Ground-to-phase varistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Connecting the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Connection procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Connecting the control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
I/O connections (HVAC default) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Connecting EIA-485 embedded fieldbus terminal to the drive . . . . . . . . . . . . . . . . . . . . . 65
Control cable connection procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Auxiliary voltage connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Option modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
To install a front option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
To remove a front option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
To install a side option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
To remove a side option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Cleaning the heat sink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Replacing the cooling fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
To replace the cooling fan for frame sizes R1, R2 and R3 . . . . . . . . . . . . . . . . . . . . . . . . 78
To replace the cooling fan for frame R4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Servicing the capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Capacitor reforming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
IEC ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
NEMA ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
8 Table of contents
Altitude derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Fuses (IEC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
gG fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
gR fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
UL fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Alternate short-circuit protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Miniature circuit breakers (IEC environment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Self-protected combination manual controller – Type E
USA (UL) environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Dimensions and weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Free space requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Losses, cooling data and noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Terminal data for the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Terminal data for the control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
External EMC filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Electric power network specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Motor cable length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Motor connection data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Control connection data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Brake resistor connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Degrees of protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Applicable standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
CE marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Compliance with the European Low Voltage Directive . . . . . . . . . . . . . . . . . . . . . . . . . 104
Compliance with the European EMC Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Compliance with the European RoHS Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Compliance with the European WEEE Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Compliance with the European Machinery Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Compliance with EN 61800-3:2004 + A1:2012 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Category C1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Category C2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Category C3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
UL marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
UL checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
CSA marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
RCM marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
EAC marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
WEEE marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
China RoHS marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
TÜV marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Disclaimers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Generic disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Table of contents 9
Frame R1 (400 V) (bottom & rear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Frame R2 (400 V) (front & side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Frame R2 (400 V) (bottom & rear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Frame R3 (front & side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Frame R3 (bottom & rear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Frame R4 (front & side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Frame R4 (bottom & rear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Operation principle and hardware description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Selecting the brake resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Reference brake resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Selecting and routing the brake resistor cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Minimizing electromagnetic interference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Maximum cable length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
EMC compliance of the complete installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Brake resistor installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Protecting the system in brake circuit fault situations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Protecting the system in cable and brake resistor short-circuit situations . . . . . . . . . . . . 125
Protecting the system against thermal overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Mechanical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Electrical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Measuring the insulation of the assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Connection procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Compliance with the European Machinery Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Connection principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Connection with internal +24 V DC power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Connection with external +24 V DC power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Wiring examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Activation switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Cable types and lengths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Grounding of protective shields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Operation principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Start-up including acceptance test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Competence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Acceptance test reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Acceptance test procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Competence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
10 Table of contents
Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Declaration of conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
TÜV certificate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Hardware description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Product overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Mechanical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Electrical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Voltage and current rating for the auxiliary power supply . . . . . . . . . . . . . . . . . . . . . . . 146
Power loss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Hardware description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Product overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Mechanical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Electrical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Control connection data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Safety instructions 11
1
Safety instructions
Contents of this chapter
This chapter contains the safety instructions which you must obey when you install
and operate the drive and do maintenance on the drive. Obey the safety instructions
to prevent injury or death, or damage to the equipment.
Use of warnings and notes in this manual
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:
Electricity warning tells you about hazards from electricity which can
cause injury or death, or damage to the equipment.
General warning tells you about conditions, other than those caused by
electricity, which can cause injury or death, or damage to the equipment.
Electrostatic sensitive devices warning tells you about the risk of
electrostatic discharge which can cause damage to the equipment.
12 Safety instructions
General safety in installation, start-up and maintenance
These instructions are for all personnel that install the drive and do maintenance work
on it.
WARNING! Obey these instructions. If you ignore them, injury or death, or
damage to the equipment can occur.
•
•
•
Handle the drive carefully.
Use safety shoes with a metal toe cap.
Keep the drive in its package or protect it otherwise from dust and burr from
drilling and grinding until you install it.
•
•
Vacuum clean the area below the drive before the start-up to prevent the drive
cooling fan from drawing the dust inside the drive.
Protect also the installed drive against dust and burr. Electrically conductive
debris inside the drive may cause damage or malfunction.
•
•
•
Do not cover the air inlet and outlet when the drive runs.
Make sure that there is sufficient cooling.
Before you connect voltage to the drive, make sure that the drive covers are on.
Keep the covers on during operation.
•
•
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 61800-5-1, subclause 6.5.3, for example, “THIS
MACHINE STARTS AUTOMATICALLY”.
•
•
The maximum number of drive power-ups is two per minute. Too frequent power-
ups can damage the charging circuit of the DC capacitors. The maximum total
number of chargings is 15000.
If you have connected safety circuits to the drive (for example, emergency stop
and Safe torque off), validate them at the start up.
Note:
•
•
•
If you select an external source for the start command and it is on, the drive starts
immediately after a fault reset, unless you configure the drive for pulse start.
When the control location is not set to local, the stop key on the control panel
does not stop the drive.
Drives can be repaired only by an authorized person.
Safety instructions 13
Electrical safety in installation, start-up and maintenance
Precautions before electrical work
These warnings 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 electrician, do
not do electrical installation or maintenance work. Do these steps before you begin
any installation or maintenance work.
1. Clearly identify the work location.
2. Disconnect all possible voltage sources.
•
•
Open the main disconnector at the power supply of the drive.
Make sure that reconnection is not possible. Lock the disconnector to open
position and attach a warning notice to it.
•
•
Disconnect any external power sources from the control circuits before you do
work on the control cables.
After you disconnect the drive, always wait for 5 minutes to let 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 multimeter with an impedance of at least 1 Mohm.
Make sure that the voltage between the drive input power terminals (L1, L2,
L3) and the grounding terminal (PE) is close to 0 V.
•
Make sure that the voltage between the drive DC terminals (UDC+ and UDC-)
and the grounding terminal (PE) is close to 0 V.
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.
14 Safety instructions
Additional instructions and notes
WARNING! Obey these instructions. If you ignore them, injury or death, or
damage to the equipment can occur.
•
If you install the drive on an IT system (an ungrounded power system or a high-
resistance-grounded [over 30 ohms] power system), disconnect the internal EMC
filter; otherwise the system will be connected to ground potential through the EMC
filter capacitors. This can cause danger or damage the drive.
Note: Disconnecting the internal EMC filter increases the conducted emission
and reduces the drive EMC compatibility considerably.
•
•
If you connect the drive to an IT system (an ungrounded power system or a high-
resistance-grounded [over 30 ohms] power system), disconnect the varistor from
ground. Failure to do so can cause damage to the varistor circuit.
If you install the drive on a corner-grounded TN system, disconnect the internal
EMC filter; otherwise the system will be connected to ground potential through the
EMC filter capacitors. This will damage the drive.
Note: Disconnecting the internal EMC filter increases the conducted emission
and reduces the drive EMC compatibility considerably.
•
Use all ELV (extra low voltage) circuits connected to the drive only within a zone
of equipotential bonding, that is, within a zone where all simultaneously
accessible conductive parts are electrically connected to prevent hazardous
voltages appearing between them. You can accomplish this by a proper factory
grounding, that is, make sure that all simultaneously accessible conductive parts
are grounded to the protective earth (PE) bus of the building.
•
Do not do insulation or voltage withstand tests on the drive.
Note:
•
The motor cable terminals of the drive are at a dangerous voltage when the input
power is on, regardless of whether the motor is running or not.
•
The DC and brake resistor terminals (UDC+, UDC-, R+ and R-) are at a
dangerous voltage.
•
•
External wiring can supply dangerous voltages to the terminals of relay outputs.
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.
WARNING! Use a grounding wrist band when you handle the printed circuit
boards. Do not touch the boards unnecessarily. The components on the boards
are sensitive to electrostatic discharge.
Safety instructions 15
Grounding
These instructions are for all personnel who are responsible for the electrical
installation, including 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 electrician, do not do grounding work.
Always ground the drive, the motor and adjoining equipment to the protective
earth (PE) bus of the power supply. This is necessary for the personnel safety.
Proper grounding also reduces electromagnetic emission and interference.
•
•
In a multiple-drive installation, connect each drive separately to the protective
earth (PE) bus of the power supply.
Make sure that the conductivity of the protective earth (PE) conductors is
regulations.
•
•
Connect the power cable shields to the protective earth (PE) terminals of the
drive.
Make a 360° grounding of the power and control cable shields at the cable entries
to suppress electromagnetic disturbances.
Note:
•
You can use power cable shields as grounding conductors only when their
conductivity is sufficient.
•
Standard IEC/EN 61800-5-1 (section 4.3.5.5.2.) requires that as the normal touch
current of the drive is higher than 3.5 mA AC or 10 mA DC, you must use a fixed
protective earth (PE) connection. In addition,
•
install a second protective earth conductor of the same cross-sectional area
as the original protective earthing conductor,
or
•
2
install a protective earth conductor with a cross-section of at least 10 mm Cu
or 16 mm Al,
2
or
•
install a device which automatically disconnects the supply if the protective
earth conductor breaks.
16 Safety instructions
Additional instructions for permanent magnet motor drives
Safety in installation, start-up and maintenance
These are additional warnings that apply to 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 and
damage to the equipment can occur.
•
Do not work on a drive when a rotating permanent magnet motor is connected
to it. A rotating permanent magnet motor energizes the drive including its input
power terminals.
Before installation, start-up and maintenance work on the drive:
•
•
•
Stop the motor.
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 felt, nip, rope, etc.
•
Measure that the installation is de-energized.
•
•
Use a multimeter with an impedance of at least 1 Mohm.
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.
•
•
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 (UDC+, UDC-) and
the grounding (PE) terminal is close to 0 V.
•
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.
Start-up and operation:
•
Make sure that the operator cannot run the motor over the rated speed. Motor
overspeed causes overvoltage that can damage or explode the capacitors in the
intermediate circuit of the drive.
Safety instructions 17
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.
•
•
Do not control the motor with the disconnector at the drive power supply. Use the
control panel start and stop keys or the start/stop commands from an external
control device connected through the I/O or fieldbus interface.
Give a stop command to the drive before you reset a fault. If you have an external
source for the start command and the start is on, the drive will start immediately
after the fault reset, unless you configure the drive for pulse start. See the
firmware manual.
•
Before you activate automatic fault reset 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.
Note: When the control location is not set to Local, the stop key on the control panel
will not stop the drive.
18 Safety instructions
Introduction to the manual 19
2
Introduction to the manual
Contents of this chapter
The chapter describes the applicability, target audience and purpose of this manual. It
describes the contents of this manual. The chapter also has a flowchart for the
delivery, installation and commissioning of the drive.
Applicability
The manual applies to ACH480 drives.
Target audience
The reader must know the fundamentals of electricity, wiring, electrical components
and electrical schematic symbols.
Purpose of the manual
This manual has the information needed to plan the installation, and install,
commission and service the drive.
20 Introduction to the manual
Contents of this manual
•
•
•
•
•
•
when you install, commission, operate and service the drive.
audience, purpose and contents of this manual.
power connections and control interfaces, type designation information.
site, unpack, examine the delivery and install the drive mechanically.
electrical installation of the drive.
assembly and the compatibility with IT (ungrounded) and corner-grounded TN
systems. It shows how to connect the power and control cables, install optional
modules and connect a PC.
•
•
electrical installation of the drive before start-up.
LED indicator descriptions.
•
•
•
•
and technical data.
•
•
01 module.
module.
Related documents
Categorization by frame (size)
The drive is manufactured in frame sizes, for example, R0, R1, R2 and so on.
Information that is applicable only to certain frames shows the frame size. Some
instructions only apply to specific frame sizes. You can read the frame size from the
Introduction to the manual 21
Quick installation and commissioning flowchart
Task
Refer to
Identify the frame size: R0, R1, R2, etc.
Plan the installation.
Check the ambient conditions, ratings and
required cooling air flow.
Unpack and check the drive.
sure that the internal EMC filter is not
connected.
Install the drive.
Route the cables.
Measure the insulation of the input cable,
motor and motor cable.
Connect the power cables.
Connect the control cables.
Examine the installation.
Commission the drive.
Refer to the ACH480 drives quick installation
guide (3AXD50000247141 [English]) and the
ACH480 drives firmware manual
(3AXD50000247134 [English]).
22 Introduction to the manual
Terms and abbreviations
Term/abbreviation Explanation
ACX-AP-X
BACnet™
Assistant control panel. An advanced operator keypad for
communication with the drive.
BACnet™ is a registered trademark of American Society of Heating,
Refrigerating and Air-Conditioning Engineers (ASHRAE).
Brake chopper
Conducts the surplus energy from the intermediate circuit of the drive to
the brake resistor when necessary. The chopper operates when the DC
link voltage exceeds a certain maximum limit. The voltage rise is
typically caused by deceleration (braking) of a high inertia motor.
Brake resistor
Dissipates the drive surplus braking energy conducted by the brake
chopper to heat. Essential part of the brake circuit. Refer to Brake
Capacitor bank
CDPI-02
Control board
BAPO-01
BCBL-01
BIO-01
Communication adapter module
Circuit board in which the control program runs.
Optional side-mounted auxiliary power extension module
Optional USB to RJ45 cable
Optional I/O extension module underneath the fieldbus option
Optional cold configuration adapter
CCA-01
DC link
DC circuit between rectifier and inverter
Energy storage which stabilizes the intermediate circuit DC voltage
Mounting platform for ACX-AP control panel (flange mounting)
Mounting platform for ACX-AP control panel (surface mounting)
Frequency converter for controlling AC motors
Embedded fieldbus
DC link capacitors
DPMP-01
DPMP-02
Drive
EFB
EMC
Electromagnetic compatibility
FBA
Fieldbus adapter
FBIP-21
FCAN-01
FCNA-01
FDNA-01
FECA-01
FENA-21
Optional BACnet/IP adapter module
Optional CANopen adapter module
Optional ControlNet adapter module
Optional DeviceNet adapter module
Optional EtherCAT adapter module
Optional Ethernet adapter module for EtherNet/IP, Modbus TCP and
PROFINET IO protocols
FEPL-02
FLON-01
FPBA-01
FSCA-01
Optional Ethernet POWERLINK adapter module
Optional LONWORKS adapter module
Optional PROFIBUS DP adapter module
Optional RS-485 adapter module
Introduction to the manual 23
Term/abbreviation Explanation
Frame (size)
Refers to drive physical size, for example, R0 and R1. The type
designation label attached to the drive shows the frame of the drive,
I/O
Input/Output
IGBT
Insulated gate bipolar transistor
Inverter
Macro
Converts direct current and voltage to alternating current and voltage.
Pre-defined default set of parameters in a drive control program. Each
macro is intended for a specific application.
NETA-21
Optional remote monitoring tool
Network control
With fieldbus protocols based on the Common Industrial Protocol
(CIPTM), such as DeviceNet and Ethernet/IP, denotes the control of the
drive using the Net Ctrl and Net Ref objects of the ODVA AC/DC Drive
Profile. For more information, refer to www.odva.org, and to FDNA-01
DeviceNet adapter module user’s manual (3AFE68573360 [English])
and FENA-01/-11/-21 Ethernet adapter module user’s manual
(3AUA0000093568 [English]).
Parameter
PLC
User-adjustable operation instruction to the drive, or signal measured or
calculated by the drive
Programmable logic controller
PROFIBUS,
Registered trademarks of PI - PROFIBUS & PROFINET International
PROFIBUS DP,
PROFINET IO
R0, R1, R2, R3…
RCD
Rectifier
RFI
Residual current device
Converts alternating current and voltage to direct current and voltage.
Radio-frequency interference
SIL
STO
24 Introduction to the manual
Hardware description 25
3
Hardware description
Contents of this chapter
This chapter describes the operation principle, layout, type designation label and type
designation information. It shows a general diagram of the power connections and
control interfaces.
General description
The ACH480 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.
Product variants
The drive has two primary products:
•
Standard unit (for example, ACH480-04-02A7) with the Assistant control panel
ACH-AP-H and an I/O module with integrated EIA-485 RIIO-01.
•
Base unit (for example, ACH480-04-02A7+0J400+0L540) without a control panel
and without an I/O module RIIO-01 with EIA-485.
26 Hardware description
Hardware overview
11
2
4
1
6
5
7
3
12
8
16
13
14
9
15
10
17
No. Description
No. Description
1
2
3
4
5
6
7
8
9
Type designation label
Model information label
10 Motor and braking resistor terminals
11 Cooling fan (not on R0)
Software information label
Control panel connection
Control panel
12 Front cover
13 Fixed control terminals
14 Cold configuration connection (CCA-01)
EMC filter grounding screw
Varistor grounding screw
PE connection (motor)
Input power terminal
15 Slot for front option modules
(I/O module or fieldbus module)
16 I/O or fieldbus module
17 Side option slot for side-mounted options
Hardware description 27
Control connections
There are fixed control connections on the base unit and optional control connections
based on the installed option module.
Standard unit
Connections of the base unit:
1. Auxiliary voltage outputs
2. Digital inputs
3. Safe torque-off connections
4. Relay output connection
5. Cold configuration connection for CCA-01
Connections of the standard I/O module
RIIO-01:
2
+24V
DGND
DCOM
SGND
OUT1
D 1
1
3
4
6. Digital inputs
DI2
IN1
IN2
5
RO C
RO1A
RO1B
7. Analog inputs and outputs
8. Relay output connections
9. Embedded fieldbus EIA-485 (BACnet
MS/TP, Modbus RTU, N2)
8
10. Auxiliary voltage output
RELAYS MAX
250V AC 30 DC 2A
11.Termination switch and bias resistor switch
ON
10
7
6
11
1
9
28 Hardware description
Base unit
Connections of the base unit:
1. Auxiliary voltage outputs
2. Digital inputs
3. Safe torque-off connections
4. Relay output connection
5. Cold configuration connection for CCA-01
6. Front option module slot 1
+24V
D 1
1GND
2
4
DI2
IN1
IN2
5
RO C
DCOM
RO1A
RO1B
SGND
3
OUT1
6
Hardware description 29
Mounted options
For information on mounted optional modules, refer to:
•
•
Control panel
The drive supports these assistant control panels:
•
•
•
ACH-AP-H (included in the standard delivery)
ACH-AP-W
CDPI-02 communication adapter module
For information on the assistant control panels, refer to the ACX-AP-x Assistant
control panels user’s manual (3AUA0000085685 [EN]).
For information on how to start up the drive, and modify the settings and parameters,
refer to the ACH480 drives firmware manual (3AXD50000247134 [English]).
PC connection
To connect a PC to the drive, there are two alternatives:
1. Use an ACH-AP-H/ACH-AP-W assistant control panel as a converter with a USB
Mini-B type cable.
2. Use a USB to RJ45 converter BCBL-01 (3AXD50000032449) with CDPI-02
(3AXD50000009929).
For information on the Drive composer PC tool, refer to Drive composer PC tool
user's manual (3AUA0000094606 [English]).
30 Hardware description
Drive labels
The drive has these labels:
•
•
•
Model information label on the top of the drive
Software information label on the front cover
Type designation label on the left side of the drive
Model information label
1
AC,480-04-04A1-4
2
3
S/N: 1170301940
No. Description
1
2
3
Drive type
Bar code
Serial number
Software information label
1
AC,480-04-04A1-4
2
3~400V/480 V (frame R1)ꢀ
3
Pld: 1.5 kW (2 hp)
Phd: 1.1 kW (1.5 hp)ꢀ
SW v2.02.0.8
4
5
No. Description
1
2
3
4
5
Drive type
Input voltage rating and frame size
Typical motor power in light-duty use (10% overload)
Typical motor power in heavy-duty use (50% overload)
Drive software version
Hardware description 31
Type designation label
This is a sample type designation label.
ꢁꢂ,ϰϴϬͲϬϰͲϬϰꢁϭͲϰ
1
5
IND.CONT.EQ.
1PDS
/ŶƉƵƚ hϭ ϯΕꢀϰϬϬͬϰϴϬꢀsꢁꢂ
Ĩϭ 50/60 Hz
/ŶƉƵƚꢀĐƵƌƌĞŶƚꢀŝƐꢀƐĐĂůĞĚꢀďLJ
ŵŽƚŽƌꢀŽƵƚƉƵƚꢀĐƵƌƌĞŶƚ
ABB Oy
,ŝŽŵŽƟĞꢀϭϯ
ϬϬϯϴϬꢀ,ĞůƐŝŶŬŝ
&ŝŶůĂŶĚ
4
/ŶƉƵƚꢀ;ǁŝƚŚ
KƵƚƉƵƚ
U2 ϯΕꢀϬ͘͘͘hϭ
/ůĚꢀ ϯ͘ϴͬϯ͘ϰꢀꢁ
/ŚĚ ϯ͘ϯͬϯꢀꢁ
KƵƚƉƵƚ /ŶƉƵƚ
ϱйꢀĐŚŽŬĞͿ
4
ϲ͘ϰͬϱ͘ϰ
ϰͬϯ͘ϰ
FRAME
2
ϯ͘ϴͬϯ͘ϰ ϲ͘ϭͬϱ͘ϰ
ϯ͘ϴͬϯ͘ϰ
ϯ͘ϯͬϯ
ϯ͘ϯͬϯ
ϱ͘ϯͬϰ͘ϴ
Zϭ
f2
Ϭ͘͘͘ϱϵϵ,nj
e
ꢁŝƌꢀĐŽŽůŝŶŐ
3
IP20
/ĐĐꢀꢀϭϬϬꢀŬꢁ
6
h>ꢀŽƉĞŶꢀƚLJƉĞ
^ͬE͗ꢀϭϭϳϬϯϬϭϵϰϬ
No. Description
1
2
3
4
5
6
Frame (size)
Degree of protection
Valid markings
S/N:
M:
Serial number of format MYYWWXXXX, where
Manufacturer
Year of manufacture: 15, 16, 17, … for 2015, 2016, 2017, …
Week of manufacture: 01, 02, 03, … for week 1, week 2, week 3, …
Running item number that starts each week from 0001.
YY:
WW:
XXXX:
32 Hardware description
Type designation key
The type designation tells you the specifications and configuration of the drive. For
Sample type code: ACH480-04-12A7-4+XXXX
Segment
A
B
C
D
ACH480
-
04 - 02A7 - 4 + Option codes
Code
Description
Basic codes
A Construction
04 = Module, IP20
04
When there aro no options: cabinet optimized module, IP20, assistant
control panel with USB, I/O module with embedded Modbus RTU, EMC
C2 filter (internal EMC filter), safe torque off, braking chopper, coated
boards, quick installation and start-up guide.
B Drive size
e.g. 12A7
Nominal output current rating of the inverter.
3-phase 380...480 V AC
C Voltage rating
4
D Option codes (plus codes)
Control panel and panel options
J400
J429
0J400
I/O
ACH-AP-H Assistant control panel
ACH-AP-W Assistant control panel with Bluetooth interface
Without control panel
L515
BIO-01 I/O extension module (front option, can be used with a fieldbus
module)
L534
L540
BAPO-01 External 24 V DC (side option)
Standard I/O module RIIO-01 with embedded EIA-485 (front option,
cannot be used with a fieldbus module)
0L540
Fieldbus adapters
K451
Without standard I/O module RIIO-01 with embedded EIA-485
FDNA-01 DeviceNetTM adapter module
FPBA-01 PROFIBUS DP adapter module
FCAN-01 CANopen adapter module
FSCA-01 RS-485 adapter module
K454
K457
K458
K462
FCNA-01 ControlNetTM adapter module
FBIP-21 BACnet/IP adapter module
FECA-01 EtherCAT adapter module
FEPL-02 Ethernet POWERLINK adapter module
K465
K469
K470
Hardware description 33
Code
Description
K475
FENA-21 Ethernet adapter module
FMBT-21 Modbus/TCP adapter module
FPNO-21 Profinet adapter module
K491
K492
Documentation
+R700 English
+R701 German
+R702 Italian
+R703 Dutch
+R704 Danish
+R705 Swedish
+R706 Finnish
+R707 French
+R708 Spanish
Full set of printed manuals in
the selected language. An
English manual is included, if a
translation is not available.
+R709 Portuguese
(in Portugal)
The product package includes
the Quick installation and start-
up guide.
+R711 Russian
+R714 Turkish
34 Hardware description
Operation principle
The figure shows the simplified main circuit diagram of the drive.
1
2
3
L1
L2
L3
T1/U
T2/V
T3/W
4
R-
R+
No. Description
1
2
3
4
Rectifier. Converts alternating current and voltage to direct current and voltage.
DC link. DC circuit between rectifier and inverter.
Inverter. Converts direct current and voltage to alternating current and voltage.
Brake chopper. Conducts the surplus energy from the intermediate DC circuit of the
drive to the brake resistor when it is necessary and if an external brake resistor is
connected to the drive. The chopper operates when the DC link voltage exceeds a
certain maximum limit. The voltage rise is typically caused by deceleration (braking) of
a motor. The user obtains and installs the brake resistor when needed.
Mechanical installation 35
4
Mechanical installation
Contents of this chapter
The chapter tells you how to examine the installation site, unpack, check the delivery
and install the drive mechanically.
Installation alternatives
You can install the drive:
•
•
•
With screws on to a wall
With screws on to an assembly plate
On to a DIN installation rail (with the integrated lock)
Installation requirements:
•
Make sure that there is a minimum of 75 mm 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 of space on the right side of the drive.
•
•
Install R0 drives upright. R0 drives do not have a cooling fan.
You can install R1, R2, R3 and R4 drives tilted by up to 90 degrees from vertical to
fully horizontal orientation.
•
Make sure that the cooling air exhaust at the top of the drive is not below the
cooling air inlet at the bottom of the drive.
36 Mechanical installation
•
•
Make sure that the hot exhaust air from a drive does not flow into the cooling inlet
of other drives or equipment.
The drive has an IP20 ingress protection classification for cabinet installation.
Examining the installation site
Make sure that:
•
•
•
The installation surface is as close to vertical as possible, of non-flammable
material and strong enough to support the drive. Refer to Dimensions and weights
•
•
The material above and below the drive is non-flammable.
There is sufficient free space above and below the drive for service and
maintenance.
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)
(For motor cable terminals, the recommended shaft length is 150 mm)
•
•
A tape measure and spirit level
Personal protective equipment
Mechanical installation 37
Unpacking the delivery
Make sure that all of the items are present and that there are no signs of damage.
Standard drive package contents:
•
•
•
Drive
Assistant control panel (not installed)
I/O module RIIO-01 with EIA-485 (BACnet MS/TP, Modbus RTU, N2) (not
installed)
•
•
•
Mounting template (for R3 and larger drives)
Installation accessories (cable clamps, cable ties, hardware, etc.)
Options, if ordered with a plus code. Note that if a fieldbus adapter is ordered, it
replaces the I/O module RIIO-01 with EIA-485 of the standard delivery.
•
•
•
•
Multilingual warning sticker sheet (residual voltage warning)
Safety instructions
Quick installation and start-up guide
Hardware and Firmware manuals, if ordered with a plus code
38 Mechanical installation
Installing the drive
You can install the drive:
•
•
With screws to a suitable surface
To a DIN installation rail with the integrated lock
To install the drive with screws
1. Mark the surface for the mounting holes.
template for the R3 and R4 frames.
2
1
H
2. Drill the holes for the mounting screws.
W
3. Start to tighten the screws into the
mounting holes.
3
4. Install the drive onto the mounting
screws.
5
5. Tighten the mounting screws.
4
Mechanical installation 39
To install the drive to a DIN installation rail
1. Move the locking part to the left.
2. Push and hold the locking button down.
3. Put the top tabs of the drive onto the top
edge of the DIN installation rail.
4. Put the drive against the bottom edge of
the DIN installation rail.
5. Release the locking button.
6. Move the locking 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.
40 Mechanical installation
Planning the electrical installation 41
5
Planning the electrical
installation
Contents of this chapter
This chapter contains the instructions to plan the electrical installation of the drive, for
example, to check the compatibility of the motor and drive, and select the cables,
protections as well as cable routing.
Make sure that the installation is designed and done according to the applicable local
laws and regulations. ABB does not assume any liability whatsoever for any
installation which breaches the local laws and/or other regulations. If the
recommendations given by ABB are not followed, the drive may experience problems
that the warranty does not cover.
Selecting the supply disconnecting device
Install a hand-operated input disconnecting device between the AC power source
and the drive. 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 of utilization category AC-23B (EN 60947-3).
Disconnector that has an auxiliary contact that in all cases causes switching
devices to break the load circuit before the opening of the main contacts of the
disconnector (EN 60947-3).
•
Circuit breaker suitable for isolation in accordance with EN 60947-2.
42 Planning the electrical installation
Other regions
The disconnecting device must conform to the applicable local safety regulations.
Checking the compatibility of the motor and drive
Use an asynchronous AC induction motor, permanent magnet motor or synchronous
reluctance motor (SynRM) with the drive. Several induction motors can be connected
to the drive at a time.
Make sure that the motor and the drive are compatible according to the rating table in
Selecting the power cables
•
Select the input power and motor cables according to the local regulations
•
Make sure that the input power and the motor cables can carry the corresponding
•
Make sure that the cable is rated for at least 70 °C maximum permissible
temperature of the conductor in continuous use. For the US, refer to Additional
•
•
•
The conductivity of the PE conductor must be sufficient, see below.
A 600 V AC cable is accepted for up to 500 V AC.
To comply with the EMC requirements of the CE mark, use an approved cable
Use a symmetrical shielded cable to decrease:
•
•
•
The electromagnetic emissions of the drive system.
The stress on the motor insulation.
The bearing currents.
Make sure that the protective conductor has adequate conductivity.
Unless local wiring regulations state otherwise, the cross-sectional area of the
protective conductor must agree with the conditions that require automatic
disconnection of the supply required in 411.3.2. of IEC 60364-4-41:2005, and be
capable of withstanding the prospective fault current during the disconnection time of
the protective device.
You can select the cross-sectional area of the protective conductor from the table
below or calculate it according to 543.1 of IEC 60364-5-54.
This table shows the minimum cross-sectional area related to the phase conductor
size according to IEC 61800-5-1 when the phase conductor and the protective
conductor are made of the same metal. If this is not so, select the cross-sectional
area of the protective earthing conductor in a manner that produces a conductance
equivalent to that which results from the application of this table:
Planning the electrical installation 43
Cross-sectional area of the phase
conductors S (mm2)
Minimum cross-sectional area of the
protective conductor Sp (mm2)
S < 16
16 < S < 35
35 < S
S
16
S/2
Typical power cable sizes
These are the typical cross-sectional area of the power cables at the nominal drive
current.
Type
Frame
mm2 (Cu) (1
AWG
ACH480-04-…
1-phase UN= 200…240 V
02A4-1
R0
R0
R1
R1
R1
R2
R2
3×1.5 + 1.5
3×1.5 + 1.5
3×1.5 + 1.5
3×1.5 + 1.5
3×1.5 + 1.5
3×2.5 + 2.5
3×2.5 + 2.5
16
16
16
16
16
14
14
03A7-1
04A8-1
06A9-1
07A8-1
09A8-1
12A2-1
3-phase UN= 200…240 V
02A4-2
R1
R1
R1
R1
R1
R1
R2
R3
R3
R4
R4
R4
3×1.5 + 1.5
3×1.5 + 1.5
3×1.5 + 1.5
3×1.5 + 1.5
3×1.5 + 1.5
3×2.5 + 2.5
3×2.5 + 2.5
3×6 + 6
16
16
16
16
16
03A7-2
04A8-2
06A9-2
07A8-2
09A8-2
14
14
14
10
8
12A2-2
17A5-2
25A0-2
3×6 + 6
032A-2
3×10 + 10
3×25 + 16
3×25 + 16
048A-2
4
055A-2
4
3-phase UN= 380…480 V
02A7-4
R1
R1
3×1.5 + 1.5
3×1.5 + 1.5
16
16
03A4-4
44 Planning the electrical installation
Type
Frame
mm2 (Cu) (1
AWG
ACH480-04-…
04A1-4
05A7-4
07A3-4
09A5-4
12A7-4
018A-4
026A-4
033A-4
039A-4
046A-4
050A-4
R1
R1
R1
R1
R2
R3
R3
R4
R4
R4
R4
3×1.5 + 1.5
3×1.5 + 1.5
3×1.5 + 1.5
3×2.5 + 2.5
3×2.5 + 2.5
3×6 + 6
16
16
16
14
14
10
10
8
3×6 + 6
3×10 + 10
3×16 + 16
3×25 + 16
3×25 + 16
6
4
4
1) This is the size of a typical power cable (symmetrical, shielded, three-phase copper cable). Note that for the
input power connection, you typically must have two separate PE conductors, that is, the shield alone is not
Planning the electrical installation 45
Recommended power cable types
Symmetrical shielded cable with three phase conductors and a
concentric PE conductor as the shield. The shield must meet the
local/state/country electrical codes permit this cable type.
PE
Symmetrical shielded cable with three phase conductors and a
concentric PE conductor as the shield. A separate PE conductor is
required if the shield does not meet the requirements of IEC 61800-5-1
PE
Symmetrical shielded cable with three phase conductors and
symmetrically constructed PE conductor, and a shield. The PE conductor
PE
Power cable types for limited use
A four-conductor system (three phase conductors and a protective
conductor on a cable tray) is not permitted for motor cabling (it is
permitted for input cabling).
PE
A four-conductor system (three phase conductors and a PE conductor in
a PVC conduit) is permitted for input cabling with a phase conductor
cross-section less than 10 mm2 (8 AWG) or for motors < 30 kW (40 hp).
Not permitted in the USA.
PVC
EMT
Corrugated or EMT cable with three phase conductors and a protective
conductor is permitted for motor cabling with a phase conductor cross
section less than 10 mm2 (8 AWG) or for motors < 30 kW (40 hp).
Not allowed power cable types
Symmetrical shielded cable with individual shields for each phase
conductor is not permitted in any cable size for input or motor cabling.
PE
46 Planning the electrical installation
Motor cable shield
If the motor cable shield is the only protective earth conductor of the motor, make
sure that the conductivity of the shield is sufficient. Refer to Selecting the power
To effectively suppress radiated and conducted radio-frequency emissions, the cable
shield conductivity must be at least 1/10 of the phase conductor conductivity. To meet
the requirements, use a copper or an aluminum shield. The figure shows the
minimum requirements for the motor cable shield. It has a concentric layer of copper
wires with an open helix of copper tape or copper wire. The better and tighter the
shield, the lower the emissions and bearing currents.
3
4
5
1
2
No. Description
1
2
3
4
5
Insulation jacket
Helix of copper tape or copper wire
Copper wire shield
Inner insulation
Cable conductors
Additional US requirements
Use type MC continuous corrugated aluminum armor cable with symmetrical grounds
or shielded power cable for the motor cables if metallic conduit is not used. For the
North American market, 600 V AC cable is accepted for up to 500 V AC. A 1,000 V
AC cable is required above 500 V AC (below 600 V AC). The power cables must be
rated for 75 °C (167 °F).
Conduit
Couple separate parts of a conduit together: Bridge the joints with a ground conductor
that is bonded to the conduit on each side of the joint. Also bond the conduits to the
drive enclosure and motor frame. Use separate conduits for input power, motor, brake
resistor and control wiring. When a conduit is used, type MC continuous corrugated
aluminum armor cable or shielded cable is not required. A dedicated ground cable is
always required.
Do not run motor wiring from more than one drive in the same conduit.
Planning the electrical installation 47
Armored cable or shielded power cable
Six-conductor (three phase and three ground conductors) type MC continuous
corrugated aluminum armor cable with symmetrical grounds is available from the
following suppliers (trade names in parentheses):
•
•
•
Anixter Wire & Cable (VFD)
RSCC Wire and Cable (Gardex)
Okonite (CLX)
Shielded power cables are available from the following suppliers:
•
•
•
Belden
LAPPKABEL (ÖLFLEX)
Pirelli
48 Planning the electrical installation
Selecting the control cables
Shielding
Only use shielded control cables.
Use a double-shielded twisted pair cable (a) for analog signals. Use one individually
shielded pair for each signal. Do not use a common return for different analog
signals.
A double-shielded cable (a) is the best alternative for low-voltage digital signals, but a
single-shielded (b) twisted pair cable is acceptable.
a
b
Signals in separate cables
Put analog and digital signals in separate, shielded cables.
Do not mix 24 V and 115/230 V AC signals in the same cable.
Signals that can be run in the same cable
If their voltage does not exceed 48 V, relay-controlled signals can be in the same
cables as digital input signals. The relay-controlled signals should be run as twisted
pairs.
Relay cable
The cable type with braided metallic screen (for example ÖLFLEX by LAPPKABEL,
Germany) has been tested and approved by ABB.
Control panel to PC connection
Use a USB type A (PC) – type B (control panel) cable. The maximum permitted
length of the cable is 3 m (9.8 ft).
Control panel to drive connection
Use EIA-485 with male RJ-45 connector, cable type CAT 5e or better. The maximum
permitted length of the cable is 100 m (328 ft).
Modbus RTU cable
Planning the electrical installation 49
Routing the cables
Select the cable routes as follows:
• Put the input power cable (I), motor
cable (M) and control cables (C) into
separate trays.
• Put the motor cable (M) away from
the other cables.
• Make sure that there is a minimum of
200 mm between the input power
cable (I) and the control cables (C).
• Make sure that there is a minimum of
500 mm between the motor cable (M)
and the control cables (C).
• Make sure that there is a minimum
300 mm between the input power
cable (I) and the motor cable (M).
• If the control cables cross the input
power or motor cables, put the cables
at 90 degrees to each other.
• You can put several motor cables in
parallel.
C
I
• Do not install other cables in parallel
with the motor cables.
M
• Make sure that the cable trays are
electrically bonded to each other and
to the electrical ground.
•
Make sure that the control cables are approriately supported outside the drive to
relieve stress on the cables.
WARNING! Make sure that there 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. If there is interference, move the source of the magnetic field away
from the drive.
50 Planning the electrical installation
Separate control cable ducts
Put 24 V and 230 V (120 V) control cables in separate ducts unless the 24 V cable is
insulated for 230 V (120 V) or insulated with an insulation sleeving for 230 V (120 V).
Continuous motor cable shield or conduit
To minimize the emission level when there are safety switches, contactors,
connection boxes or similar equipment on the motor cable between the drive and the
motor: Install the equipment in a metal enclosure with 360 degree grounding for the
shields of both the incoming and outgoing cables, or connect the shields otherwise
together. If cabling is put into conduits, make sure that they are continuous.
Implementing short-circuit protection
Protecting the drive and input power cable in short-circuits
damage to adjoining equipment if there is a short-circuit.
For information on circuit breakers, contact ABB for more information.
Protecting the motor and motor cable in short-circuits
If the motor cable has the correct size for the nominal current, the drive protects the
motor cable and motor if there is a short-circuit.
Planning the electrical installation 51
Implementing thermal overload protection
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 itself and
the input and motor cables against thermal overload.
WARNING! If the drive is connected to several motors, use a separate circuit
breaker or fuses to protect each motor cable and motor against overload. The
drive overload protection is tuned for the total motor load. It may not trip due to an
overload in one motor circuit only.
Protecting the motor against thermal overload
According to the regulations, the motor must be protected against thermal overload
and the current must be switched off when an overload is detected. The drive has a
motor thermal protection function that protects the motor and switches off the current
when necessary. Depending on a drive parameter value, the function either monitors
a calculated temperature value or an actual temperature indication given by motor
temperature sensors. The user can tune the thermal model by feeding in additional
motor and load data.
The most common temperature sensors are:
•
•
For motor sizes IEC180…225: a thermal switch, for example, a Klixon.
For motor sizes IEC200…250 and larger: a PTC or Pt100 sensor.
Note: PTC can be used by connecting it through analog input and output. Configure
supervision parameters to give a warning and fault.
Protecting the drive against ground faults
The drive has a ground fault protection function that protects the unit against ground
faults in the motor and motor cable. It is not a personnel safety or a fire protection
feature.
Residual current device compatibility
The drive can be used with residual current devices of Type B.
Note: The EMC filter of the drive has capacitors between the main circuit and the
frame. These capacitors and long motor cables increase the ground leakage current
and can cause the fault current circuit breakers to function.
52 Planning the electrical installation
Implementing the emergency stop function
For safety reasons, install the emergency stop devices at each operator control
station and at other operating stations where an emergency stop may be needed.
Design the emergency stop according to the applicable standards.
Note: The stop key on the control panel of the drive does not generate an emergency
stop or separate the drive from dangerous potential.
Implementing the Safe torque off function
Using a safety switch between the drive and motor
Install a safety switch between the permanent magnet motor and the drive output.
The safety switch isolates the motor from the drive during maintenance work.
Using a contactor between the drive and motor
The control of the output contactor depends on how you use the drive.
When you use the vector control mode and motor ramp stop, open the contactor as
follows:
1. Give a stop command to the drive.
2. Wait until the drive stops the motor.
3. Open the contactor.
When you use the vector control mode and motor coast stop or the scalar control
mode, open the contactor as follows:
1. Give a stop command to the drive.
2. Open the contactor.
WARNING! In the vector control mode, do not open the output contactor when
the drive controls the motor. The vector control operates faster than the
contactor opens its contacts. If the contactor starts to open when the drive controls
the motor, the vector control tries to maintain the load current and increases the
output voltage to the maximum. This can cause damage to the contactor.
Planning the electrical installation 53
Protecting the contacts of relay outputs
Inductive loads (relays, contactors and motors) cause voltage transients when
switched off. The voltage transients can connect capacitively or inductively to other
conductors and cause a malfunction in the system.
Use a noise attenuating circuit (varistors, RC filters [AC] or diodes [DC]) to minimize
the EMC emission of inductive loads at switch-off. Install the noise attenuating circuit
as close to the inductive load as possible. Do not install a noise attenuating circuit at
the relay output.
1
No. Description
1
2
3
4
Relay output
Varistor
230 V AC
RC filter
Diode
2
230 V AC
3
+ 24 V DC
4
54 Planning the electrical installation
Electrical installation 55
6
Electrical installation
Contents of this chapter
The chapter describes how to check the insulation of the installation and the
compatibility with IT (ungrounded) and corner-grounded TN systems. It shows how to
connect the power and control cables, install optional modules and connect a PC.
Warnings
ignore them, injury or death, or damage to the equipment can occur.
WARNING! Make sure that the drive is disconnected from the input power
during installation. Before you do work on the drive, wait for 5 minutes after you
disconnect the input power.
Required tools
To perform the electrical installation, you need the following tools:
•
•
•
•
•
Wire stripper
Screwdriver or wrench with a set of suitable bits
Short flat head screwdriver for the I/O terminals
Multimeter and voltage detector
Personal protective equipment
56 Electrical installation
Measuring insulation
Drive
Do not do voltage tolerance or insulation resistance tests on the drive. The drive was
tested for insulation between the main circuit and the chassis at the factory. The drive
has voltage-limiting circuits which decrease the testing voltage automatically.
Input power cable
Before you connect the input power cable, measure its insulation according to the
local regulations.
Motor and motor cable
Measure the insulation of the motor and motor cable as follows:
1. Make sure that the motor cable is disconnected from the drive output terminals
T1/U, T2/V and T3/W.
2. Measure the insulation resistance
between the phase conductors and
between each phase conductor and the
protective earth conductor. Use a
measuring voltage of 1,000 V DC. The
insulation resistance of an ABB motor
must be more than 100 Mohm (reference
value at 25 °C or 77 °F). For the
U1
M
3~
V1
W1
ohm
PE
insulation resistance of other motors,
refer to the manufacturer’s instructions.
Moisture in the motor casing decreases the insulation resistance. If you think that
there is moisture in the motor, dry the motor and measure again.
Brake resistor assembly
Measure the insulation of the brake resistor assembly as follows:
1. Make sure that the resistor cable is
connected to the resistor, and disconnected
from the drive output terminals R+ and R-.
R+
2. At the drive, connect the R+ and R-
conductors of the resistor cable together.
Measure the insulation resistance between
the combined conductors and the PE
conductor with a measuring voltage of
1000 V DC. The insulation resistance must
be more than 1 Mohm.
R-
ohm
PE
Electrical installation 57
Compatibility with IT (ungrounded) and corner-grounded
TN systems
EMC filter
WARNING! Do not use the internal EMC filter of the drive in an IT system (an
ungrounded power system or a high-resistance-grounded [over 30 ohms]
power system). If you use the internal EMC filter, the system is connected to the
ground potential through the EMC filter capacitors. This can cause danger or damage
to the drive.
WARNING! Do not use the internal EMC filter of the drive in a corner-grounded
TN system. If you use the internal EMC filter, this can cause damage to the
drive.
When the internal EMC filter is disconnected, the EMC compatibility of the drive
EMC filter disconnection
This is applicable only to product
variants with an internal EMC filter
(EMC C2). Variants with a C4 rating do
not have an internal EMC filter.
26.
To disconnect the EMC filter, remove
the EMC filter grounding screw. In
some product variants, the EMC circuit
is disconnected from electrical ground
at the factory with a non-conducting
(plastic) screw. The EMC filter is
disconnected on drives with a plastic
screw in the EMC filter location. To connect the filter, remove the plastic screw and
insert the metal screw and washer from the hardware bag shipped with the drive.
58 Electrical installation
The EMC grounding screw is
located on the bottom of the
frame in R3 and R4 frames.
Ground-to-phase
varistor
The metallic varistor screw
(VAR) connects the varistor
protection circuit to electrical
ground.
To disconnect the varistor
protection circuit from ground,
remove the varistor screw.
Refer to Hardware overview
In some product variants the
varistor protection circuit is
disconnected from electrical
ground at the factory with a
non-conducting (plastic)
screw.
WARNING! If you connect the drive to an IT system (an ungrounded power
system or a high-resistance-grounded [over 30 ohms] power system),
disconnect the varistor from ground. Failure to do so can cause damage to the
varistor circuit.
Electrical installation 59
Connecting the power cables
Connection diagram
d
d
c
b
a
a. Two grounding conductors. Use two conductors, if the cross-section of grounding
2
2
conductor is less than 10 mm Cu or 16 mm Al (IEC/EN 61800-5-1). For example,
use the cable shield in addition to the fourth conductor.
b. Separate grounding cable (line side). Use it if the conductivity of the fourth
conductor or shield is not sufficient for the protective grounding.
c. Separate grounding cable (motor side). Use it if the conductivity of the shield is not
sufficient for the protective grounding, or there is no symmetrically constructed
grounding conductor in the cable.
d. 360-degree grounding of the cable shield. Required for the motor cable and brake
resistor cable, recommended for the input power cable.
60 Electrical installation
Connection procedure
or death, or damage to the equipment can occur.
WARNING! If the drive is connected to an IT (non-grounded) system or to a
corner-grounded TN system, disconnect the EMC filter grounding screw.
If the drive is connected to an IT (non-grounded) system, disconnect the
varistor grounding screw.
1. Open the locking screw of the front cover
and lift the front cover up.
2. Strip the motor cable.
3. Ground the motor cable shield under the
grounding clamp.
4. 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.
5. Connect the phase conductors of the motor
cable to the T1/U, T2/V and T3/W motor
terminals.
6. If it is applicable, connect the brake resistor
cable to the R- and UDC+ terminals. Use a
shielded cable and ground the shield under
the grounding clamp.
Electrical installation 61
7. Strip the input power cable.
8. If the input power cable has a shield, twist it
into a bundle, mark it with yellow-green
insulation tape, fit a cable lug, and connect
it to the grounding terminal.
9. Connect the PE conductor of the input
power cable to the grounding terminal.
10. If the combined cross-sectional area of the
cable shield and PE conductor is not
sufficient, use an additional PE conductor.
11. Connect the phase conductors of the input
power cable to the L1, L2 and L3 input
terminals.
12. Mechanically attach all of the cables on the
outside of the drive.
62 Electrical installation
Connecting the control cables
Before you connect the control cables, make sure that all option modules are
the ABB standard macro. For other macros and information, refer to ACH480 drives
firmware manual (3AXD50000247134 [English]).
or death, or damage to the equipment can occur.
Electrical installation 63
I/O connections (HVAC default)
This connection diagram is valid for drives with the standard I/O extension module
in the base unit are marked in the table.
Terminal
Description
Terminals in
base unit
Reference voltage and analog I/O
Signal cable shield (screen)
Output frequency/speed reference: 0...10 V
Analog input circuit common
Reference voltage 10 V DC
Actual feedback: 0...20 mA
SCR
AI1
AGND
+10 V
AI2
1...10 kohm
AGND
AO1
AO2
Analog input circuit common
Output frequency: 0...20 mA
Output current: 0...20 mA
AGND
Analog output circuit common
max. 500 ohm
Aux. voltage output and programmable digital inputs
+24 V
DGND
DCOM
DI1
Aux. voltage output +24 V DC, max. 200 mA
Aux. voltage output common
Digital input common for all
Stop (0)/Start (1)
Not configured
X
X
X
X
X
DI2
DI3
DI4
DI5
Constant frequency/speed selection
Start interlock 1 (1 = allow start)
Not configured
DI6
Not configured
Relay outputs
RO1C
RO1A
RO1B
RO2C
RO2A
RO2B
RO3C
RO3A
RO3B
Damper control
250 V AC/30 V DC
2 A
Running
250 V AC/30 V DC
2 A
Fault (-1)
250 V AC/30 V DC
2 A
X
X
X
Damper actuator
Run status
Fault status
Embedded fieldbus
B+
A-
Embedded fieldbus, EFB (EIA-485)
DGND
TERM&BIAS Termination switch and bias resistor switch
Safe torque off
SGND
X
X
X
X
IN1
IN2
Safe torque off. Factory connection. Both
circuits must be closed for the drive to start.
OUT1
+24V
DGND
DCOM
Auxiliary voltage output. The alternative terminals
have the same supply as the base unit.
64 Electrical installation
Fieldbus connection diagram
This connection diagram is valid for drives with a fieldbus adapter module. Refer to
Terminal
Description
Aux. voltage output and digital connections
Aux. voltage output +24 V DC, max. 200 mA
Aux. voltage output common
Digital input common for all
Stop (0) / Start (1)
+24 V
DGND
DCOM
DI1
DI2
Not configured
Relay output
RO1C
RO1A
RO1B
Ready run
250 V AC/30 V DC
2 A
Safe torque off
SGND
IN1
IN2
Safe torque off. Factory connection. Both
circuits must be closed for the drive to start.
OUT1
Extension module options
RJ45 x2
RJ45 x2
+K465 FBIP-21 BACnet/IP adapter module
+K491 FMBT-21 Modbus/TCP adapter module
Terminal block +K451 FDNA-01 DeviceNet adapter module
DSUB9
DSUB9
+K454 FPBA-01 PROFIBUS DP adapter module
+K457 FCAN-01 CANopen adapter module
Terminal block +K458 FSCA-01 RS-485 adapter module
8P8C x2
RJ45 x2
RJ45 x2
RJ45 x2
RJ45 x2
+K462 FCNA-01 ControlNet adapter module
+K469 FECA-01 EtherCAT adapter module
+K470 FEPL-02 Ethernet POWERLINK adapter module
+K475 FENA-21 Ethernet adapter module
+K492 FPNO-21 Profinet adapter module
Electrical installation 65
Connecting EIA-485 embedded fieldbus terminal to the drive
Connect the fieldbus to the EIA-485 terminal on the RIIO-01 module. The connection
diagram is shown below.
Fieldbus controller
(1
Termination ON
Data flow
Fieldbus
Control Word (CW)
References
Process I/O (cyclic)
Status Word (SW)
Actual values
Parameter R/W
Service messages (acyclic)
requests/responses
ON
ON
ON
ON
ON
ON
...
1
1
1
1
1
1
(1
Termination OFF
Drive
Termination OFF
Drive
Termination ON
Drive
1) The device at both ends on the fieldbus must have termination set to ON.
66 Electrical installation
Connection examples of two-wire and three-wire sensors
The figures give examples of connections for a two-wire or three-wire
sensor/transmitter that is supplied by the auxiliary voltage output of the drive.
Note: Do not exceed the maximum capability of the auxiliary 24 V (200 mA) output.
Two-wire sensor/transmitter
4…20 mA
-
AI2
Process actual value measurement or reference,
P
0(4)…20 mA, Rin = 137 ohm
AGND
+
I
+24V Auxiliary voltage output, non-isolated,
+24 V DC, max. 200 mA
DGND
Note: The sensor is supplied through its current output and the drive feeds the supply
voltage (+24 V). The output signal must be 4…20 mA, not 0…20 mA.
Three-wire sensor/transmitter
(0)4…20 mA
OUT
AI2
Process actual value measurement or reference,
0(4)…20 mA, Rin = 137 ohm
P
-
+
AGND
I
+24V Auxiliary voltage output, non-isolated,
+24 V DC, max. 200 mA
DGND
Electrical installation 67
Control cable connection procedure
Do the connections according to the macro in use. The default macro connections
macro.
Keep the signal wire pairs twisted as near to the terminals as possible to prevent
inductive coupling.
1. Strip a part of the outer shield of the
control cable for grounding.
2. Use a cable tie to ground the outer
shield to the grounding tab. For 360-
degree grounding, use metallic cable
ties.
3. Strip the control cable conductors.
4. Connect the conductors to the
correct control terminals. Torque the
terminals to 0.5 N·m (0.4 lbf·ft).
5. Connect the shields of the twisted
pairs and grounding wires to the
SCR terminals. Torque the terminals
to 0.5 N·m (0.4 lbf·ft).
6. Mechanically attach the control
cables on the outside of the drive.
68 Electrical installation
Auxiliary voltage connection
The drive has an auxiliary 24 V DC (±10%)
voltage connection. Depending on the
application, you can use the connection
DI1
DI2
RC
RA
RB
•
To supply external power to the drive
control board
S1
S2
•
To supply power from the drive to external
option modules
Connect the external supply or module to the
+24V and DGND terminals.
For more information on how to feed auxiliary power to the drive, refer to BAPO-01
There is a DC to DC flyback converter power supply in BAPO-01 module. This power
supply has an input voltage of 24 V DC and an output voltage of 5 V DC. It supplies
the drive control board to keep its processor and the communication links on at all
times.
ACH480
External supply
BAPO-01
24VDC (+)
GND (-)
+24V
DGND
+24 V internal
+5 V internal
Main PSU
The power supply in BAPO-01 operates with the main power supply of the drive and
starts only when the main power supply shuts down.
Note: When you use the auxiliary +24 V DC voltage connection of the drive to supply
external power to the drive control board, make sure that the auxiliary power cable is
not chained to several drives and that each drive is powered by individual +24 V DC
Electrical installation 69
outputs of the auxiliary power source or by multiple auxiliary power sources with a
single +24 V DC output.
Option modules
or death, or damage to the equipment can occur.
The drive has two option module slots:
•
•
Front option: I/O or fieldbus module slot under the front cover.
Side option: Multifunction extension module slot on the side of the drive.
For more information, refer to the option module manual for installation and wiring
instructions. For information on specific options, refer to:
•
•
70 Electrical installation
To install a front option
1. Open the locking screw of the front cover
and lift the front cover up.
1
2. If the option module has a locking tab, pull
it up.
3. Carefully align the option module with the
option module slot in the front of the drive.
3
2
4. Fully push the option module into
position.
4
5. If applicable, push the locking tab down
until it locks.
6. Tighten the locking screw to fully attach
and electrically ground the front option.
7. Connect the applicable control cables
according to Connecting the control
5
6
Electrical installation 71
To remove a front option
1. Disconnect the control cables from the option module.
2. Loosen the locking screw.
3. If the option module has a locking tab, pull it out.
4. Carefully pull the option module to disconnect and remove it. Note that the option
module can be tight.
To install a side option
1. Remove the two screws from the front-
most grounding clamp at the bottom of
the drive.
3
2. Carefully align the side option with the
connectors on the right side of the drive.
2
1
3. Fully push the option module into position.
4. Tighten the locking screw of the option
module.
5. Attach the grounding bar to the bottom of
the side option and to the front ground tab
on the drive.
5
4
6. Connect the applicable control cables
according to Connecting the control
6
To remove a side option
1. Disconnect the control cables from the side option.
2. Open the grounding bar screws.
3. Loosen the locking screw.
Carefully remove the side option from the drive. Note that the option module can be
tightly in position.
72 Electrical installation
Installation checklist 73
7
Installation checklist
Contents of this chapter
This chapter contains an installation checklist which you must complete before you
start up the drive.
Warnings
ignore them, injury or death, or damage to the equipment can occur.
Checklist
Read the checklist together with another person.
Make sure that …
If the drive is connected to an IT (non-grounded) or corner-grounded TN supply
network: Internal EMC filter is disconnected.
If the drive is connected to an IT (non-grounded) system, disconnect the varistor
grounding screw.
57.
If the drive is stored over one year: The electrolytic DC capacitors in the DC link of the
74 Installation checklist
Make sure that …
There is an adequately sized protective earth (ground) conductor between the drive
and the switchboard.
There is an adequately sized protective earth (ground) conductor between the motor
and the drive.
All protective earth (ground) conductors are connected to the correct terminals and the
terminals are tightened (pull the conductors to check).
The supply voltage matches the nominal input voltage of the drive. Read the type
designation label.
The input power cable is connected to the correct terminals, the phase order is right,
and the terminals are tightened. (Pull the conductors to check.)
Appropriate supply fuses and disconnector are installed.
The motor cable is connected to the correct terminals, the phase order is right, and the
terminals are tightened. (Pull the conductors to check.)
The brake resistor cable (if present) is connected to the correct terminals, and the
terminals are tightened. (Pull the conductors to check.)
The motor cable (and brake resistor cable, if present) is routed away from other
cables.
The control cables (if any) are connected.
If a drive bypass connection is used: The direct-on-line contactor of the motor and the
drive output contactor are mechanically or electrically interlocked (cannot be closed
simultaneously).
There are no tools, foreign objects or dust inside the drive. There is no dust near the
air inlet of the drive.
The drive cover is in place.
The motor and the driven equipment are ready for start-up.
76 Maintenance
Maintenance intervals
The table shows the maintenance tasks which can be done by the user. The full
maintenance schedule is available at www.abb.com/drivesservices. For more
information, speak to your local ABB Service representative
(www.abb.com/searchchannels).
Maintenance and component replacement intervals are based on the assumption that
the equipment is operated within the specified ratings and ambient conditions. Long
term operation near the specified maximum ratings or ambient conditions may
require shorter maintenance intervals for certain components. ABB recommends
annual drive inspections to ensure the highest reliability and optimum performance.
Recommended action
Annually
Connections and environment
Quality of the supply voltage
Spare parts
P
Spare parts
I
Reform DC circuit capacitors (spare modules).
Inspections
P
Tightness of the cable and busbar terminals.
Ambient conditions (dustiness, moisture and temperature)
I
I
P
Years from start-up
Maintenance task/object
3
6
9
12 15 18 21
Cooling fans
R
R
R
R
Batteries
Control panel battery
R
Symbols
I
Inspection and maintenance action, if it is necessary.
P
R
Other work (commissioning, tests, measurements, etc.)
Replacement of component
Maintenance 77
Cleaning the heat sink
The fins of the drive heat sink become dusty from the cooling air. If the heat sink is not
clean, this can cause the drive to give overtemperature warnings and faults.
ignore them, injury or death, or damage to the equipment can occur.
WARNING! Use a vacuum cleaner with an antistatic hose and nozzle. A
normal vacuum cleaner can cause static discharges which can cause damage
to circuit boards.
To clean the heat sink:
1. Stop the drive and disconnect it from the input power.
2. Wait for 5 minutes and measure to make sure that there is no voltage. Refer to
4. Blow clean, dry and oil free compressed air from the bottom of the heat sink to the
top and use a vacuum cleaner at the air outlet to trap the dust.
If there is a risk that dust can go into other equipment, clean the heat sink in
another room.
5. Install the cooling fan.
78 Maintenance
Replacing the cooling fans
This instruction is applicable only to frame sizes R1, R2, R3 and R4. Frame R0 units
do not have a cooling fan.
operating conditions. Parameter 05.04 Fan on-time counter shows the running time
of the cooling fan. After you replace the fan, reset the fan counter. Refer to the
ACH480 drives firmware manual (3AXD50000247134 [English]).
You can get replacement fans from ABB. Use only ABB specified spare parts.
To replace the cooling fan for frame sizes R1, R2 and R3
ignore them, injury or death, or damage to the equipment can occur.
1. Stop the drive and disconnect it from the power line.
2. Wait for 5 minutes and measure to make sure that there is no voltage. Refer to
3. Use a suitable flat screwdriver to open
the fan cover.
4
4. Carefully lift the fan cover out of the drive.
Note that the fan cover holds the cooling
3
fan.
5. Remove the fan power cable from the
cable slot in the drive.
5
6. Disconnect the fan power cable.
6
Maintenance 79
7. Free the fan clips and remove the fan
from the fan cover.
7
8
8. Install the new fan into the fan cover.
Make sure that the air flow is in the
correct direction. The air flows in from the
bottom of the drive and out from the top
of the drive.
9. Connect the fan power cable.
10. Put the fan power cable into the cable
slot in the drive.
10
9
11. Carefully put the fan cover into position in
the drive. Make sure that the fan power
cable is routed correctly.
11
12. Push the cover to lock into position.
12
80 Maintenance
To replace the cooling fan for frame R4
WARNING! Obey the instructions in
ignore them, injury or death, or damage to
the equipment can occur.
2
1. Stop the drive and do the steps in
section Precautions before electrical
work.
2. Use a suitable flat screwdriver to open
the fan cover.
3. Lift out the fan cover and set it aside.
4. Lift and pull the fan from its base.
3
5. Unplug the fan power cable from the
extension cable connector.
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.
4
7. Attach the fan power cable to the
connector.
5
8. Place the fan cover back on the frame.
9. Push the cover to lock into position.
6
7
9
8
Maintenance 81
Servicing the capacitors
The intermediate DC circuit of the drive has electrolytic capacitors. Their lifespan
depends on the operating time and loading of the drive, and the surrounding air
temperature.
Capacitor failure can cause damage to the drive and an input cable fuse failure, or a
fault in the drive. Contact ABB if you think that a capacitor failed.
Capacitor reforming
To reform the capacitors, refer to Converter module capacitor reforming instructions
(3BFE64059629), available on the Internet (go to www.abb.com and enter the code in
the Search field).
82 Maintenance
84 Technical data
Ratings
IEC ratings
Type
ACH480- rating
04-…
Input
Input
with
choke
Output ratings
Light-duty use
Frame
size
Max.
current
Nominal use
Heavy-duty use
I
I
I
I
P
I
P
I
P
Hd
1N
1N
max
A
N
N
Ld
Ld
Hd
A
A
A
A
kW
A
kW
kW
3-phase U = 380…480 V
N
02A7-4
03A4-4
04A1-4
05A7-4
07A3-4
09A5-4
12A7-4
018A-4
026A-4
033A-4
039A-4
046A-4
050A-4
4.2
5.3
2.6
3.3
3.2
4.7
2.6
3.3
0.75
1.1
2.5
3.1
0.75
1.1
1.8
2.6
0.55
0.75
1.1
R1
R1
R1
R1
R1
R1
R2
R3
R3
R4
R4
R4
R4
6.4
4.0
5.9
4.0
1.5
3.8
1.5
3.3
9.0
5.6
7.2
5.6
2.2
5.3
2.2
4.0
1.5
11.5
15.0
20.2
27.2
40.0
45.0
50.0
56.0
60.0
7.2
10.1
13.0
16.9
22.7
30.6
45.0
57.6
68.4
81.0
7.2
3.0
6.8
3.0
5.6
2.2
9.4
9.4
4.0
8.9
4.0
7.2
3.0
12.6
17.0
25.0
32.0
38.0
45.0
50.0
12.6
17.0
25.0
32.0
38.0
45.0
50.0
5.5
12.0
16.2
23.8
30.5
36.0
42.8
48.0
5.5
9.4
4.0
7.5
7.5
12.6
17.0
25.0
32.0
38.0
45.0
5.5
11.0
15.0
18.5
22.0
22.0
11.0
15.0
18.5
22.0
22.0
7.5
11.0
15.0
18.5
22.0
3AXD10000299801.xls
NEMA ratings
Type
ACH480-04-…
Input
rating
Inputwith
choke
Output ratings
Frame
size
Light-duty use
Heavy-duty use
I
I
I
P
I
P
Hd
1N
A
1N
Ld
Ld
Hd
A
A
hp
A
hp
3-phase U = 460 V (440…480 V)
N
02A7-4
03A4-4
04A1-4
05A7-4
07A3-4
3.4
4.8
5.4
7.7
9.6
2.1
3.0
2.1
3.0
1.0
1.5
1.6
2.1
0.75
1.0
R1
R1
R1
R1
R1
R1
R2
R3
R3
R4
R4
R4
R4
3.5
3.5
2.0
3.0
1.5
4.8
4.8
2.0
3.4
2.0
6.0
6.0
3.0
4.0
2.0
09A5-4
12A7-4
018A-4
026A-4
033A-4
039A-4
046A-4
050A-4
12.2
17.6
22.4
33.6
37.9
44.7
49.8
50.4
7.6
7.6
5.0
4.8
3.0
11.0
14.0
21.0
27.0
34.0
40.0
42.0
11.0
14.0
21.0
27.0
34.0
40.0
42.0
7.5
7.6
5.0
10.0
15.0
20.0
25.0
30.0
30.0
11.0
14.0
12.0
27.0
34.0
40.0
7.5
10.0
15.0
20.0
25.0
30.0
3AXD10000299801.xls
Technical data 85
Definitions
UN
I1N
Nominal supply voltage
Nominal input current. Continuous rms input current (for dimensioning cables
and fuses).
Imax
IN
Maximum output current. Available for two seconds at start.
Nominal output current. Maximum continuous rms output current allowed (no
overload).
PN
Nominal power of the drive. Typical motor power (no overloading). The kilowatt
ratings apply to most IEC 4-pole motors. The horsepower ratings apply to most
NEMA 4-pole motors.
ILd
Maximum current with 10% overload, allowed for one minute every ten minutes
Typical motor power in light-duty use (10% overload)
PLd
IHd
Maximum current with 50% overload, allowed for one minute every ten minutes
Typical motor power in heavy-duty use (50% overload)
PHd
Sizing
Drive sizing is based on the rated motor current and power. To achieve the rated
motor power, the rated current of the drive must be more than or equal to the rated
motor current. Also, the rated power of the drive must be more than or equal to the
rated motor power. The power ratings are the same regardless of the supply voltage
in one voltage range.
The ratings are valid at a surrounding air temperature of 50 °C (122 °F) for I . When
N
the temperature increases, derating is required.
Derating
The load capacity (I , I , I ; note that I is not derated) decreases in certain
max
N
Ld Hd
situations. In such situations, where full motor power is required, oversize the drive so
that the derated value provides sufficient capacity.
If several situations are present at a time, the effects of derating are cumulative.
Example:
If your application requires continuous 6.0 A of motor current (I ) at 8 kHz switching frequency,
N
the supply voltage is 400 V and the drive is situated at 1500 m, calculate the appropriate drive
size requirement as follows:
From the table, the minimum size required is IN = 9.4 A.
The derating factor for 1500 m is 1 - 1/10 000 m · (1500 - 1000) m = 0.95.
The minimum size required becomes then IN = 9.4 A / 0.95 = 9.9 A.
exceeds the IN requirement of 9.9 A.
86 Technical data
Surrounding air temperature derating, IP20
Frame size
Temperature
Derating
R0…R4
up to +50 °C
up to +122 °F
+50…+60 °C
+122…+140 °F
+50…+60 °C
No derating
R1…R3
R4
Output current is decreased by 1% for every additional
1 °C (1.8 °F).
Output current is decreased by 1% for every additional
1 °C on:
+122…+140 °F
• ACH480-04-033A-4
• ACH480-04-046A-4
Output current is decreased by 2% for every additional
1 °C on:
• ACH480-04-039A-4
• ACH480-04-050A-4
• ACH480-04-055A-2
Switching frequency derating
Type
Current with different switching frequencies (I at 50 °C)
2N
ACH480-04-…
2 kHz
4 kHz
8 kHz
12 kHz
3-phase U = 380…480 V
N
02A7-4
03A4-4
04A1-4
05A7-4
07A3-4
09A5-4
12A7-4
018A-4
026A-4
033A-4
039A-4
046A-4
050A-4
2.6
3.3
2.6
3.3
1.7
2.1
1.2
1.6
4.0
4.0
2.6
1.9
5.6
5.6
3.6
2.7
7.2
7.2
4.7
3.5
9.4
9.4
6.1
4.5
12.6
17.0
25.0
32.0
38.0
45.0
50.0
12.6
17.0
25.0
32.0
38.0
45.0
50.0
8.5
6.4
11.5
16.8
21.7
24.6
29.4
32.9
8.6
12.6
16.7
18.5
21.9
24.5
3AXD10000299801.xls
For frame R4: Keep the minimum switching frequency in its default value (parameter
97.02 = 1.5 kHz) if the application is cyclic and the ambient temperature is constantly
over +40 °C. Adjusting the parameter decreases the product life time and/or limits the
performance in the temperature range +40...60 °C.
Technical data 87
Altitude derating
At 1000…4000 m (3300…13120 ft) above sea level, the derating is 1% for every
100 m (330 ft). An altitude of up to 4000 m is permitted for 400 V units when the
following boundary conditions are taken into account:
•
•
•
The maximum switching voltage for integrated Relay Output 1 is 30 V at 4000 m.
If the conditions are not met, the maximum installation altitude is 2000 m.
For a 3-phase 400 V drive at 4000 m, you can connect the drive only to the
following power systems: TN-S, TN-c, TN-CS, TT (not corner earthed).
To calculate the output current, multiply the current in the rating table with the
derating factor k, which for x meters (1000 m <= x <= 4000 m) is:
1
.
k = 1 -
(x - 1000) m
10 000 m
Examine the network compatibility restrictions above 1000 m (3281 ft) and the PELV
limitation on relay output terminals above 1000 m (3281 ft).
88 Technical data
Fuses (IEC)
The tables list the gG and gR fuses for protection against short circuits in the input
power cable or drive. Either fuse type can be used if it operates rapidly enough. The
operating time depends on the supply network impedance, and the cross-sectional
Do not use fuses with a higher current rating than that given in the table. You can use
fuses from other manufacturers, if they meet the ratings, and if the melting curve of
the fuse does not exceed the melting curve of the fuse mentioned in the table.
gG fuses
Make sure that the operating time of the fuse is less than 0.5 seconds. Obey the local
regulations.
2
Type
Input
Min. short- Nominal
I t
Voltage
rating
ABB type
IEC 60269
size
ACH480-04-… current
circuit
current
current
2
A
A
A
A s
V
3-phase U = 380…480 V
N
02A7-4
03A4-4
04A1-4
05A7-4
07A3-4
09A5-4
12A7-4
018A-4
026A-4
033A-4
039A-4
046A-4
050A-4
4.2
5.3
48
48
6
6
110
110
500
500
500
500
500
500
500
500
500
500
500
500
500
OFAF000H6
OFAF000H6
000
000
000
000
000
000
000
000
000
000
000
000
000
6.4
80
10
10
16
16
25
32
50
63
80
100
100
360
OFAF000H10
OFAF000H10
OFAF000H16
OFAF000H16
OFAF000H25
OFAF000H32
OFAF000H50
OFAF000H63
OFAF000H80
OFAF000H100
OFAF000H100
9.0
80
360
11.5
15.0
20.2
27.2
40.0
45.0
50.0
56.0
60.0
128
128
200
256
400
504
640
800
800
740
740
2500
4500
15500
20000
36000
65000
65000
3AXD10000299801.xls
Technical data 89
gR fuses
2
Type
Input
Min. short- Nominal
I t
Voltage
rating
Bussmann
type
IEC 60269
size
ACH480-04-… current
circuit
current
current
2
A
A
A
A s
V
3-phase U = 380…480 V
N
02A7-4
03A4-4
04A1-4
05A7-4
07A3-4
09A5-4
12A7-4
018A-4
026A-4
033A-4
039A-4
046A-4
050A-4
4.2
5.3
48
48
25
25
125
125
690
690
690
690
690
690
690
690
690
690
690
690
690
170M2694
00
00
00
00
00
00
00
00
00
00
00
00
00
170M2694
170M2695
170M2695
170M2696
170M2696
170M2697
170M2698
170M2699
170M2700
170M2701
170M2702
170M2702
6.4
80
32
275
9.0
80
32
275
11.5
15.0
20.2
27.2
40.0
45.0
50.0
56.0
60.0
128
128
200
256
400
504
640
800
800
40
490
40
490
50
1000
1800
3600
6650
12000
22500
22500
63
80
100
125
160
160
3AXD10000299801.xls
UL fuses
Type
Input
Min. short-
circuit
Nominal
current
Voltage
rating
Bussmann/
Edison type
Type
ACH480-04-… current
current
A
A
A
V
3-phase U = 380…480 V
N
02A7-4
03A4-4
04A1-4
05A7-4
07A3-4
09A5-4
12A7-4
018A-4
026A-4
033A-4
039A-4
046A-4
050A-4
4.2
5.3
48
48
6
6
600
600
600
600
600
600
600
600
600
600
600
600
600
JJS/TJS6
JJS/TJS6
UL class T
UL class T
6.4
80
10
10
20
20
25
35
50
60
80
100
100
JJS/TJS10
JJS/TJS10
JJS/TJS20
JJS/TJS20
JJS/TJS25
JJS/TJS35
JJS/TJS50
JJS/TJS60
JJS/TJS80
JJS/TJS100
JJS/TJS100
UL class T
UL class T
UL class T
UL class T
UL class T
UL class T
UL class T
UL class T
UL class T
UL class T
UL class T
9.0
80
11.5
15.0
20.2
27.2
40.0
45.0
50.0
56.0
60.0
128
128
200
256
400
504
640
800
800
3AXD10000299801.xls
90 Technical data
Alternate short-circuit protection
Miniature circuit breakers (IEC environment)
The protective characteristics of the circuit breakers depend on their type,
construction and settings. There are also limitations pertaining to the short-circuit
capacity of the supply network. Your local ABB representative can help you to select
the circuit breaker when the supply network characteristics are known.
WARNING! Obey the installation instructions of the circuit breaker
manufacturer. If there is a short circuit, hot ionized gases can escape from the
circuit breaker.
You can use the circuit breakers listed below. You can also use other circuit breakers
with the same electrical characteristics. ABB does not assume any liability
whatsoever for the correct function and protection with circuit breakers not listed
below. If the recommendations given by ABB are not obeyed, the drive can
experience problems the warranty does not cover.
Note: Miniature circuit breakers with or without fuses have not been evaluated for
use as short circuit protection in USA (UL) environments.
Type
ACH480-04-…
ABB miniature circuit breaker
1)
Frame
kA
Type
3-phase U = 380...480 V (380, 400, 415, 440, 460, 480 V)
N
02A7-4
03A4-4
04A1-4
05A7-4
07A3-4
09A5-4
12A7-4
018A-4
026A-4
033A-4
039A-4
046A-4
050A-4
R1
R1
R1
R1
R1
R1
R2
R3
R3
R4
R4
R4
R4
S 203P-B 6
S 203P-B 6
S 203P-B 8
S 203P-B 10
S 203P-B 16
S 203P-B 16
S 203P-B 25
S 203P-B 32
S 203P-B 50
Contact ABB
Contact ABB
Contact ABB
Contact ABB
5
5
5
5
5
5
5
5
5
1) Maximum allowed rated conditional short-circuit current (IEC 61800-5-1) of the electrical power network.
Technical data 91
Self-protected combination manual controller – Type E
USA (UL) environment
You can use the ABB Type E manual motor protectors MS132 & S1-M3-25, MS165-
xx and MS5100-100 as an alternate to the recommended fuses as a means of branch
circuit protection. This is in accordance with the National Electrical Code (NEC).
When the correct ABB Type E manual motor protector is selected from the table and
used for branch circuit protection, the drive is suitable for use in a circuit capable of
delivering no more than 65 kA RMS symmetrical amperes at the drive’s maximum
rated voltage. See the following table for the appropriate ratings. See the MMP rating
table for the minimum enclosure volume of IP20 open type drive mounted in an
enclosure.
5)
Type
ACH480-04-…
Minimum enclosure volume
1) 2)
Frame
MMP type
3
dm
cu in
4) 5)
3-phase U = 380...480 V (380, 400, 415, 440, 460, 480 V)
N
3)
02A7-4
03A4-4
04A1-4
05A7-4
07A3-4
09A5-4
12A7-4
018A-4
026A-4
033A-4
039A-4
046A-4
050A-4
R1
R1
R1
R1
R1
R1
R2
R3
R3
R4
R4
R4
R4
MS132-6.3 & S1-M3-25
MS132-6.3 & S1-M3-25
MS132-10 & S1-M3-25
MS132-10 & S1-M3-25
MS165-16
30.2
30.2
30.2
30.2
30.2
30.2
30.2
30.2
30.2
1842
1842
1842
1842
1842
1842
1842
1842
1842
3)
3)
3)
MS165-16
MS165-20
MS165-32
MS165-42
Contact ABB
Contact ABB
Contact ABB
Contact ABB
1) All manual motor protectors listed are Type E self-protected up to 65 kA. See the ABB publication
2CDC131085M0201 – Manual Motor Starters – North American Applications for complete technical data on
the ABB Type E manual motor protectors. In order for these manual motor protectors to be used for branch
circuit protection, they must be UL listed Type E manual motor protectors, otherwise they can be used only as
an At Motor Disconnect. “At Motor Disconnect” is a disconnect just ahead of the motor on the load side of the
panel.
2) Manual motor protectors may require adjusting the trip limit from the factory setting at or above the drive
input Amps to avoid nuisance tripping. If the manual motor protector is set to the maximum current trip level
and nuisance tripping is occurring, select the next size MMP. (MS132-10 is the highest size in the MS132
frame size to meet Type E at 65 kA; the next size up is MS165-16.)
3) Requires the use of the S1-M3-25 line side feeder terminal with the manual motor protector to meet Type E
self-protection class.
4) 480Y/277V delta systems only: Short-circuit protective devices with slash voltage ratings (e.g.
480Y/277 V AC) can be applied only in solidly grounded networks where the voltage from line-to-ground does
not exceed the lower of the two ratings (e.g. 277 V AC), and the voltage from line-to-line does not exceed the
higher of the two ratings (e.g. 480 V AC). The lower rating represents the device’s interrupting capability per
pole.
5) For all drives, the enclosure must be sized to accommodate the specific thermal considerations of the
application as well as provide free space for cooling. Refer to Free space requirements on page 93. For UL
only: The minimum enclosure volume is specified in the UL listing when applied with the ABB Type E MMP
shown in the table. The drives are intended to be mounted in an enclosure, unless a NEMA-1 kit is added.
92 Technical data
Dimensions and weights
Frame
size
Dimensions and weights (IP20 / UL type open)
H1
H2
H3 M1
W
D
M2
Weight
kg lb
mm
205
205
205
205
205
in
mm
223
223
223
220
240
in
mm
in
mm
73
in
mm
208
208
208
208
in
mm
50
in
mm
in
R0
R1
R2
R3
R4
8.07
8.07
8.07
8.07
8.07
8.78 176 6.93
8.78 176 6.93
8.78 176 6.93
8.66 186 7.31
9.45 194 7.62
2.87
2.87
3.80
6.76
8.19
8.19
8.19
8.19
8.39
1.97 191 7.52 1.70 3.74
1.97 191 7.52 1.77 3.90
2.95 191 7.52 2.35 5.19
73
50
97
75
172
260
148 5.83 191 7.52 3.52 7.76
238 9.37 191 7.52 6.02 13.3
3AXD10000299801.xls
10.24 213
D
Symbols
H1
H2
H3
W
Back footprint height
Total height
Front height
Width
D
Depth
M1
M2
Mounting hole distance 1
Mounting hole distance 2
W
M1
Ø 5 [.21]
Ø 10 [.21]
M2
Ø 5 [.21]
Technical data 93
Free space requirements
Frame size Free space requirement
Above
Below
mm
On the sides (1
mm in
mm
in
in
R0...R4
75
3
75
3
0
0
3AXD10000299801.xls
1) You can install the modules side by side, but if you plan to install side-mounted options, leave 20 mm of
space to the right side of the module.
Losses, cooling data and noise
Frame size R0 has natural convection cooling. Frame sizes R1…R4 have a cooling
fan. The air flow direction is from bottom to top.
The table below specifies 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 and fan in use). The total heat
dissipation is the sum of the heat dissipation in the main and control circuits.
Type
ACH480-04-…
Heat dissipation
Air flow
Noise
Frame
size
Main
Control
Control
circuit
Main and
control
circuit at circuit
rated I1N minimum maximum boards
and I2N
maximum
W
W
W
W
m3/h
dB(A)
3-phase U = 380…480 V
N
02A7-4
03A4-4
04A1-4
05A7-4
07A3-4
09A5-4
12A7-4
018A-4
026A-4
033A-4
039A-4
046A-4
050A-4
35
42
9
9
20
20
20
20
20
20
20
22
22
30
30
30
30
55
62
57
57
63 dB
63 dB
63 dB
63 dB
63 dB
63 dB
59 dB
66 dB
66 dB
69 dB
69 dB
69 dB
69 dB
R1
R1
R1
R1
R1
R1
R2
R3
R3
R4
R4
R4
R4
50
9
70
57
68
9
88
57
88
9
108
135
178
230
344
465
566
668
668
57
115
158
208
322
435
537
638
638
9
57
9
63
11
11
18
18
18
18
128
128
216
216
216
216
3AXD10000299801.xls
94 Technical data
Terminal data for the power cables
Type
U1, V1, W1 / U2, V2, W2 / BRK+, BRK- / DC+, DC- terminals
PE terminal
ACH480-04-…
Torque
Min (solid/stranded) Max (solid/stranded) Torque
2
2
mm
AWG
mm
AWG
N·m
lbf·in
N·m
lbf·in
3-phase U = 380…480 V
N
02A7-4
03A4-4
04A1-4
05A7-4
07A3-4
09A5-4
12A7-4
018A-4
026A-4
033A-4
039A-4
046A-4
050A-4
0.2/0.2
0.2/0.2
0.2/0.2
0.2/0.2
0.2/0.2
0.2/0.2
0.2/0.2
0.5/0.5
0.5/0.5
0.5/0.5
0.5/0.5
0.5/0.5
0.5/0.5
18
18
18
18
18
18
18
20
20
20
20
20
20
6/6
6/6
10
10
10
10
10
10
10
6
0.5...0.6
0.5...0.6
0.5...0.6
0.5...0.6
0.5...0.6
0.5...0.6
0.5...0.6
1.2...1.5
1.2...1.5
2.5...3.7
2.5...3.7
2.5...3.7
2.5...3.7
5
1.2
1.2
1.2
1.2
1.2
1.2
1.2
1.2
1.2
2.9
2.9
2.9
2.9
10.6
10.6
10.6
10.6
10.6
10.6
10.6
10.6
10.6
25.7
25.7
25.7
25.7
5
5
6/6
6/6
5
6/6
5
6/6
5
6/6
5
16/16
16/16
16/16
25/35
25/35
25/35
11...13
11...13
22...32
22...32
22...32
22...32
6
6
2
2
2
3AXD10000299801.xls
Terminal data for the control cables
Type
All control cables
ACH480-04-…
Wire size
Torque
2
mm
AWG
N·m
lbf·in
3-phase U = 380…480 V
N
02A7-4
03A4-4
04A1-4
05A7-4
07A3-4
09A5-4
12A7-4
018A-4
026A-4
033A-4
039A-4
046A-4
050A-4
0.14...1.5
0.14...1.5
0.14...1.5
0.14...1.5
0.14...1.5
0.14...1.5
0.14...1.5
0.14...1.5
0.14...1.5
0.14...1.5
0.14...1.5
0.14...1.5
0.14...1.5
26...16
26...16
26...16
26...16
26...16
26...16
26...16
26...16
26...16
26...16
26...16
26...16
26...16
0.5...0.6
0.5...0.6
0.5...0.6
0.5...0.6
0.5...0.6
0.5...0.6
0.5...0.6
0.5...0.6
0.5...0.6
0.5...0.6
0.5...0.6
0.5...0.6
0.5...0.6
4.4...5.3
4.4...5.3
4.4...5.3
4.4...5.3
4.4...5.3
4.4...5.3
4.4...5.3
4.4...5.3
4.4...5.3
4.4...5.3
4.4...5.3
4.4...5.3
4.4...5.3
3AXD10000299801.xls
Technical data 95
External EMC filters
To comply with EMC limits in the European EMC Directive (standard IEC/EN 61800-
3) with longer maximum motor cable lengths, use an external EMC filter. The table
shows the EMC category that is met with the external EMC filter. For information on
Type
ACH480-04-…
EMC filter type
ABB order code Schaffner order code
Category
C1
C2
C3
3-phase U = 380…480 V
N
02A7-4
03A4-4
04A1-4
05A7-4
07A3-4
09A5-4
12A7-4
018A-4
026A-4
033A-4
039A-4
046A-4
050A-4
RFI-32
RFI-32
RFI-32
RFI-32
RFI-32
RFI-32
RFI-33
RFI-33
RFI-34
RFI-34
RFI-34
RFI-34
RFI-34
FN 3268-16-44
FN 3268-16-44
FN 3268-16-44
FN 3268-16-44
FN 3268-16-44
FN 3268-16-44
FN 3268-30-33
FN 3268-30-33
FN 3258-100-35
FN 3258-100-35
FN 3258-100-35
FN 3258-100-35
FN 3258-100-35
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
3AXD10000299801.xls
96 Technical data
Electric power network specification
Voltage (U1)
200/208/220/230/240 V AC 1-phase for 200 V AC drives
200/208/220/230/240 V AC 3-phase for 200 V AC drives
380/400/415/440/460/480 V AC 3-phase for 400 V AC drives
+10%/-15% variation from converter nominal voltage is allowed as
default.
Network type
Public low-voltage networks. TN (grounded), IT (ungrounded) and
corner-grounded TN systems.
Rated conditional
short-circuit current
(IEC 61800-5-1)
65 kA when protected by fuses given in the fuse tables.
Short-circuit current
protection
(UL 61800-5-1,
US and Canada: The drive is suitable for use on a circuit capable of
delivering not more than 100 kA symmetrical amperes (rms) at
480 V maximum when protected by fuses given in the fuse table.
CSA C22.2 No. 274-13)
Mains choke
Use a mains choke if the short-circuit capacity of the network at the
drive terminals is more than in the table:
Frame size/
Voltage rating
3-phase 380...480 V
R0, R1, R2
>5.0 kA
R3, R4
>10 kA
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.
Frequency (f1)
Imbalance
47 Hz to 63 Hz, maximum rate of change 17%/s
Max. ±3% of nominal phase to phase input voltage
0.98 (at nominal load)
Fundamental power
factor (cos phi)
Technical data 97
Motor connection data
Motor type
Asynchronous induction motor or permanent
magnet synchronous motor
0 to U1, 3-phase symmetrical, Umax at the field weakening point
Voltage (U2)
Short-circuitprotection The motor output is short-circuit proof by IEC 61800-5-1 and
(IEC 61800-5-1,
UL 61800-5-1)
UL 61800-5-1.
Frequency (f2)
0…599 Hz (On the type label, this is input frequency level f1.)
Frequency resolution 0.01 Hz
Current
Switching frequency
2, 4, 8 or 12 kHz
Operational functionality and motor cable length
Motor cable
The drive is designed to operate with optimum performance with the
following maximum motor cable lengths. The motor cable lengths may
be extended with output chokes as shown in the table.
length
Frame
size
Maximum motor cable length
m
ft
Standard drive, without external options
R0
30
100
492
492
R1, R2
150
150
R3, R4
With external output chokes
R0
R1…R3
R4
60
195
820
656
250
200
Note: In multimotor systems, the calculated sum of all motor cable lengths
must not exceed the maximum motor cable length given in the table.
98 Technical data
EMC compatibility and motor cable length
To comply with the EMC limits in the European EMC Directive
(standard IEC/EN 61800-3), use these maximum motor cable
lengths for the 4 kHz switching frequency.
Frame
size
Maximum motor cable length, 4 kHz
C1 C2 C3
m
ft
m
ft
m
ft
With internal EMC filter
3-phase 380...480 V
R0
R1
R2
R3
R4
-
-
-
-
-
-
-
-
-
-
10
10
10
10
10
30
30
30
30
30
30
30
20
30
30
100
100
66
100
100
With optional external EMC filter
3-phase 380...480 V
R0
R1
R2
R3
R4
30
30
30
30
-
100
100
100
100
-
50
50
50
50
30
150
150
150
150
100
50
50
50
50
50
150
150
150
150
150
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 installations for each case.
Notes:
• Remove the EMC screw to disconnect the internal EMC filter.
• Radiated emissions are according to C2 with and without an
external EMC filter. For 200 V frames, use a metal enclosure to
fulfill radiated emissions C2 limits with an external EMC filter.
• For 3-phase 380...400 V drives, the maximum motor cable lengths
are according to C3 in the above table with an internal EMC filter.
• For 1-phase and 3-phase 208...240 V drives, the maximum motor
cable lengths are according to the motor cable length table on
Technical data 99
Control connection data
Analog inputs
Voltage signal,
0…10 V DC (10% overrange, 11 V DC max.)
(AI1, AI2)
single-ended
Rin = 221.6 kohm
Current signal,
single-ended
0…20 mA (10% overrange, 22 mA max.)
Rin = 137 ohm
Inaccuracy
≤ 1.0%, of full scale
up to 30 V DC
Overvoltage
protection
Potentionmeter
reference value
10 V DC ±1%, max. load current 10 mA
Analog output
(AO1, AO2)
Current output
mode
0…20 mA (10% overrange, 22 mA max.) into 500 ohm
load (AO2 only supports output current)
Voltage output
mode
0…10 V DC (10% overrange, 11 V DC max.) into
200 kohm minimum load (resistive)
Inaccuracy
As output
≤ 2%, of full scale
Auxiliary voltage
output / optional
input (+24V)
+24 V DC ±10%, max. 200 mA
As input
(optional)
+24 V DC ±10%, max. 1000 mA (incl internal fan load)
Digital inputs
(DI1…DI6)
Voltage
Type
12…24 V DC (int. or ext. supply) Max. 30 V DC.
PNP and NPN
Input impedance Rin = 2 kohm
DI5 (digital or
frequency
input)
Voltage
12…24 V DC (int. or ext.
supply) max. 30 V DC.
Type
PNP and NPN
Input impedance
Max. frequency
1 form C (NO + NC)
250 V AC / 30 V DC
R
in = 2 kohm
16 kHz
Relay output
(RO1, RO2, RO3)
Type
Max. switching
voltage
Max. switching
current
2 A
Frequency input
(FI)
10 Hz…16 kHz
DI5 can be used as a digital or frequency input.
STO interface
EIA-485 Modbus
RTU (A+, B-,
DGND)
Connector pitch 5 mm, wire size 2.5 mm2
Physical layer: RS-485
Cable type: Shielded twisted pair cable with twisted pair for data and a
wire or pair for signal ground, nominal impedance 100…165 ohm, for
example, Belden 9842.
Transmission rate: 9.6…115.2 kbit/s
Termination by switch
100 Technical data
Brake resistor connection
Short-circuitprotection The brake resistor output is conditionally short-circuit proof by
(IEC 61800-5-1,
IEC 60439-1,
UL 61800-5-1)
IEC/EN 61800-5-1 and UL 61800-5-1. For correct fuse selection,
contact your local ABB representative. Rated conditional short-circuit
current as defined in IEC 60439-1.
Efficiency
Approximately 98% at nominal power level.
Degrees of protection
Degree of protection
IP20 (cabinet installation) / UL Open Type: Standard enclosure. The
(IEC/EN 60529)
drive must be installed in a cabinet to fulfill the requirements for
shielding from contact.
Enclosure types
(UL 61800-5-1)
UL Open Type. For indoor use only.
Overvoltage category III
(IEC 60664-1)
Protective classes
(IEC/EN 61800-5-1)
I
Technical data 101
Ambient conditions
Environmental limits for the drive are given below. The drive is to be used in a heated indoor
controlled environment.
Operation
installed for
stationary use
Storage
in the protective
package
Transportation
in the protective
package
Installation site altitude 0 to 4000 m above
-
-
sea level (with
derating above
1000 m)
For more information,
Surrounding air
temperature
-10…+60 °C
-40…+70 °C ±2%
(-40…+158 °F ±2%) (-40…+158 °F ±2%)
-40…+70 °C ±2%
(14…140 °F)(1
No frost allowed.
1) For frame R0,
-10…+50 °C
(14…122 °F).
Relative humidity
0…95%
Max. 95%
Max. 95%
No condensation allowed. Maximum allowed relative humidity is
60% in the presence of corrosive gases.
Contamination levels
(IEC 60721-3-3,
IEC 60721-3-2,
No conductive dust allowed.
According to
IEC 60721-3-3,
chemical gases:
Class 3C2
According to
IEC 60721-3-1,
chemical gases:
Class 1C2
According to
IEC 60721-3-2,
chemical gases:
Class 2C2
IEC 60721-3-1)
solid particles:
Class 3S2.
solid particles:
Class 1S2
solid particles:
Class 2S2
Install the drive
according to the
enclosure
classification.
Make sure that the
cooling air is clean,
and free from
corrosive materials
and electrically
conductive dust.
Pollution degree
(IEC 60950-1)
Pollution degree 2
-
-
102 Technical data
Sinusoidal vibration
(IEC 60721-3-3)
Tested according to
IEC 60721-3-3,
mechanical
-
-
conditions: Class 3M4
2…9 Hz, 3.0 mm
(0.12 in)
9…200 Hz, 10 m/s2
(33 ft/s2)
Shock
(IEC 60068-2-27,
ISTA 1A)
Not allowed
According to ISTA 1A. According to ISTA 1A.
Max. 100 m/s2
Max. 100 m/s2
(330 ft/s2), 11 ms.
(330 ft/s2), 11 ms.
Free fall
Not allowed
76 cm (30 in)
76 cm (30 in)
Materials
Drive enclosure
• PC/ABS 2 mm, PC+10%GF 2.5…3 mm and PA66+25%GF
1.5 mm, all in color NCS 1502-Y (RAL 9002 / PMS 420 C)
• Hot-dip zinc coated steel sheet 1.5 mm, thickness of coating
20 micrometers
• Extruded aluminum AlSi
Corrugated cardboard.
Package
Disposal
The main parts of the drive can be recycled to preserve natural
resources and energy. Product parts and materials should be
dismantled and separated.
Generally all metals, such as steel, aluminum, copper and its alloys,
and precious metals can be recycled as material. Plastics, rubber,
cardboard and other packaging material can be used in energy
recovery. Printed circuit boards and large electrolytic capacitors
need selective treatment according to IEC 62635 guidelines. To aid
recycling, plastic parts are marked with an appropriate identification
code.
Contact your local ABB distributor for further information on
environmental aspects and recycling instructions for professional
recyclers. End of life treatment must follow international and local
regulations.
Technical data 103
Applicable standards
The drive complies with the following standards:
EN ISO 13849-1:2015
EN ISO 13849-2:2012
Safety of machinery – Safety related parts of the control systems –
Part 1: general principles for design
Safety of machinery – Safety-related parts of the control systems –
Part 2: Validation
EN 60204-1:2006 +
A1:2009 + AC:2010
Safety of machinery. Electrical equipment of machines. Part 1:
General requirements. Provisions for compliance: The final
assembler of the machine must install:
• An emergency-stop device
• A supply disconnecting device
EN 62061:2005 +
AC:2010 + A1:2013 +
A2:2015
Safety of machinery – Functional safety of safety-related electrical,
electronic and programmable electronic control systems
EN 61800-3:2004 +
A1:2012
Adjustable speed electrical power drive systems. Part 3: EMC
requirements and specific test methods
IEC 61800-3:2004 +
A1:2011
IEC/EN 61800-5-1:2007 Adjustable speed electrical power drive systems – Part 5-1: Safety
requirements – Electrical, thermal and energy
ANSI/UL 61800-5-
1:2015
UL Standard for adjustable speed electrical power drive systems –
Part 5-1: Safety requirements – Electrical, thermal and energy
CSA C22.2 No. 274-13 Adjustable speed drives
104 Technical data
CE marking
A CE mark is attached to the drive to verify that the drive follows the provisions of the
European Low Voltage, EMC, RoHS and WEEE Directives.The CE marking also
verifies that the drive, in regard to its safety functions (such as Safe torque off),
conforms with the Machinery Directive as a safety component.
Compliance with the European Low Voltage Directive
The compliance with the European Low Voltage Directive has been verified according
to standard EN 61800-5-1:2007. Declaration is available on the Internet.
Compliance with the European EMC Directive
The EMC Directive defines the requirements for immunity and emissions of electrical
equipment used within the European Union. The EMC product standard (EN 61800-
3:2004 + A1:2012) covers requirements stated for drives. Refer to Compliance with
Internet.
Compliance with the European RoHS Directive
The RoHS Directive defines the restriction of the use of certain hazardous
substances in electrical and electronic equipment. The declaration is available on the
Internet.
Compliance with the European WEEE Directive
The WEEE Directive defines the regulated disposal and recycling of electric and
electrical equipment.
Technical data 105
Compliance with the European Machinery Directive
The drive includes the Safe torque off function and can be equipped with other safety
functions for machinery which, as safety components, are in the scope of the
Machinery Directive. These functions of the drive comply with European harmonized
106 Technical data
Compliance with EN 61800-3:2004 + A1:2012
Definitions
EMC stands for Electromagnetic Compatibility. It is the ability of electrical/electronic
equipment to operate without problems within an electromagnetic environment.
Likewise, the equipment must not disturb or interfere with any other product or
system within its locality.
First environment includes establishments connected to a low-voltage network which
supplies buildings used for domestic purposes.
Second environment includes establishments connected to a network not directly
supplying domestic premises.
Drive of category C1: drive of rated voltage less than 1000 V and intended for use in
the first environment.
Drive of category C2: drive of rated voltage less than 1000 V and intended to be
installed and started up only by an authorised professional when used in the first
environment.
Drive of category C3: drive of rated voltage less than 1000 V, intended for use in the
second environment and not intended for use in the first environment.
Category C1
The conducted emission limits are complied with the following provisions:
1. The optional EMC filter is selected according to the ABB documentation and
installed as specified in the EMC filter manual.
2. The motor and control cables are selected as specified in this manual.
3. The drive is installed according to the instructions given in this manual.
4. For the maximum motor cable length with 4 kHz switching frequency, refer to
In a domestic environment, this product can cause radio-frequency inference, in
which case supplementary mitigation measures may be required.
Category C2
Applicable to ACH480-04-xxxx-4 with an internal EMC C2 filter as standard.
The emission limits are complied with the following provisions:
1. The motor and control cables are selected as specified in this manual.
2. The drive is installed according to the instructions given in this manual.
3. For the maximum motor cable length with 4 kHz switching frequency, refer to
Technical data 107
If it is used in a residential or domestic environment, the drive can cause radio-
frequency interference. If it is necessary, take measures to prevent interference, in
addition to the requirements for the CE compliance.
WARNING! Do not install a drive with the internal EMC filter connected on IT
(ungrounded). The supply network becomes connected to ground potential
through the internal EMC filter capacitors which may cause danger or damage to the
WARNING! Do not install a drive with internal EMC filter connected on corner-
grounded TN systems; otherwise the drive will be damaged. To disconnect the
Category C3
The drive complies with the standard with these provisions:
1. The motor and control cables are selected as specified in this manual.
2. The drive is installed according to the instructions in this manual.
3. For the maximum motor cable length at a 4 kHz switching frequency, refer to
WARNING! Do not use a drive of category C3 on a low-voltage public network
which supplies domestic premises. Doing so can cause radio frequency
interference.
108 Technical data
UL marking
If the drive type label has the UL marking, the drive has UL certification.
UL checklist
•
Make sure that the drive type designation label includes the cULus Listed
marking.
•
CAUTION - Risk of electric shock. After you disconnect the input power, always
wait for 5 minutes to let the intermediate circuit capacitors discharge before you
start working on the drive, motor or motor cable.
•
The drive is to be used in a heated, indoor controlled environment. The drive must
be installed in clean air according to the enclosure classification. Cooling air must
be clean, free from corrosive materials and electrically conductive dust.
•
•
The maximum ambient air temperature is 50 °C (122 °F) at rated current.
The drive is suitable for use in a circuit capable of delivering not more than
100,000 rms symmetrical amperes, 480 V (or 240 V) maximum when protected
by UL-rated fuses. The ampere rating is based on tests done according to the
appropriate UL standard.
•
•
The cables located within the motor circuit must be rated for at least 75 °C
(167 °F) in UL-compliant installations.
Integral solid state short circuit protection does not provide branch circuit
protection. The input cable must be protected with UL-rated fuses. The fuses
provide branch circuit protection in accordance with the National Electrical Code
(NEC) and Canadian Electrical Code. For installation in the United States, also
obey any other applicable local codes. For installation in Canada, also obey any
applicable provincial codes.
Note: Circuit breakers must not be used without fuses in the USA. Contact your
local representative for suitable circuit breakers.
•
•
The drive provides motor overload protection. For the adjustments, refer to the
firmware manual.
101.
Technical data 109
CSA marking
If the drive type label has the CSA marking, the drive has CSA
certification. The CSA marking indicates that a product has been tested to
a Canadian or U.S. standard and meets the requirements of an applicable
CSA standard or another recognized document used as a basis for
certification.
RCM marking
If the drive type label has the RCM marking, the drive has RCM
certification.
The RCM marking is required in Australia and New Zealand. The RCM
mark is attached to the drive modules to verify compliance with the
relevant standard (IEC 61800-3:2004), mandated by the Trans-Tasman
Electromagnetic Compatibility Scheme.
For fulfilling the requirements of the standard, refer to Compliance with
EAC marking
If the drive type label has the EAC marking, the drive has EAC
certification. The EAC marking is required in Russia, Belarus and
Kazakhstan.
WEEE marking
The drive is marked with the wheelie bin symbol. It indicates that at the
end of life the drive should enter the recycling system at an appropriate
collection point and not placed in the normal waste stream. See section
China RoHS marking
If the drive type label has the China RoHS marking, the drive has China
RoHS certification. The People’s Republic of China Electronic Industry
Standard (SJ/T 11364-2014) specifies the marking requirements for
hazardous substances in electronic and electrical products. The green
mark is attached to the drive to verify that it does not contain toxic and
hazardous substances or elements above the maximum concentration
values, and that it is an environmentally-friendly product which can be
recycled and reused.
110 Technical data
TÜV marking
The TÜV marking is a recognized marking for electrical products. The
marking is used to designate that the product has undergone certification
measures on functional safety provided by a notified body TÜV (Technical
Inspection Association).
Disclaimers
Generic disclaimer
The manufacturer shall have no obligation hereunder with respect to any product
which (i) has been improperly repaired or altered; (ii) has been subjected to misuse,
negligence or accident; (iii) has been used in a manner contrary to the Manufacturer's
instructions; or (iv) has failed as a result of ordinary wear and tear.
Cyber security disclaimer
This product is designed to be connected to and to communicate information and
data via a network interface. It is Customer's 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 not limited to the installation of firewalls,
application of authentication measures, encryption of data, installation of anti-virus
programs, etc) to protect the product, the network, its system and the interface
against any kind of security breaches, unauthorized access, interference, intrusion,
leakage and/or theft of data or information. ABB and its affiliates are not liable for
damages and/or losses related to such security breaches, any unauthorized access,
interference, intrusion, leakage and/or theft of data or information.
120 Dimension drawings
Resistor braking 121
11
Resistor braking
Contents of this chapter
The chapter describes how to select the brake resistor and cables, protect the
system, connect the brake resistor and enable resistor braking.
Operation principle and hardware description
The brake chopper handles the energy generated by a decelerating motor. The
chopper connects the brake resistor to the intermediate DC circuit whenever the
voltage in the circuit exceeds the limit defined by the control program. Energy
consumption by the resistor losses lowers the voltage until the resistor can be
disconnected.
Selecting the brake resistor
Drives have in built-in brake chopper as standard equipment. The brake resistor is
selected using the table and equations presented in this section.
1. Determine the required maximum braking power P
for the application. P
Rmax
Rmax
must be smaller than P
BRmax
type.
2. Calculate resistance R with Equation 1.
3. Calculate energy E with Equation 2.
Rpulse
4. Select the resistor so that the following conditions are met:
•
•
The rated power of the resistor must be greater than or equal to P
.
Rmax
Resistance R must be between R
and R
given in the table for the used
min
max
drive type.
•
The resistor must be able to dissipate energy E
during the braking
Rpulse
cycle T.
122 Resistor braking
Equations for selecting the resistor:
150000
ton
Eq. 1. UN = 200…240 V: R =
PRmax
PRave
PRmax
450000
UN = 380…415 V: R =
PRmax
T
615000
UN = 415…480 V: R =
PRmax
Eq. 2. ERpulse = PRmax
Eq. 3. PRave = PRmax
where
·
·
ton
ton
T
For conversion, use 1 hp = 746 W.
R
= calculated brake resistor value (ohm). Make sure that: Rmin < R < Rmxx.
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
T
= length of the braking pulse (s)
= length of the braking cycle (s).
WARNING! Do not use a brake resistor with a resistance below the minimum
value specified for the particular drive. The drive and the internal chopper are
not able to handle the overcurrent caused by the low resistance.
Resistor braking 123
Reference brake resistors
Type
ACH480-
04-…
Rmin Rmax PBRcont
PBRmax
kW hp
Example resistor types
Braking time (1
ohm ohm kW
hp
Danotherm
s
1-phase U = 200…240 V
N
02A4-1 32.5
03A7-1 32.5
04A8-1 32.5
06A9-1 32.5
468
316
213
145
0.25 0.33 0.38 0.50
0.37 0.50 0.56 0.74
0.55 0.75 0.83 1.10
0.75 1.00 1.10 1.50
CBH 360 C T 406 210R
or
CAR 200 D T 406 210R
Refer to braking
resistor
manufacturer’s
documentation
CBR-V 330 D T 406 78R UL
07A8-1 32.5 96.5 1.10 1.50 1.70 2.20
09A8-1 32.5 69.9 1.50 2.00 2.30 3.00 CBR-V 560 D HT 406 39R UL
12A2-1 19.5 47.1 2.20 3.00 3.30 4.40
3-phase U = 200…240 V
N
02A4-2
03A7-2
04A8-2
06A9-2
07A8-2
09A8-2
12A2-2
17A5-2
25A0-2
032A-2
048A-2
055A-2
39
39
39
39
39
20
20
16
16
3
474
319
217
145
105
71
0.25 0.33 0.38 0.50
0.37 0.50 0.56 0.74
0.55 0.75 0.83 1.10
0.75 1.00 1.13 1.50
1.10 1.50 1.65 2.20
CBH 360 C T 406 210R
or
CAR 200 D T 406 210R
Refer to braking
resistor
manufacturer’s
documentation
CBR-V 330 D T 406 78R UL
1.50 2.00 2.25 3.00 CBR-V 560 D HT 406 39R UL
2.20 2.00 3.30 4.40
52
38
3.00 3.00 4.50 6.00
4.00 5.00 6.00 8.00
5.50 7.50 8.25 11.00
7.50 10.00 11.25 15.00
11.00 15.00 16.50 21.99
CBT-H 560 D HT 406 19R
28
20
CBT-V 760 G H T 282 8R
3
14
3
10
3-phase U = 380…480 V
N
01A8-4
02A7-4
03A4-4
04A1-4
05A7-4
07A3-4
09A5-4
12A7-4
018A-4
026A-4
033A-4
039A-4
046A-4
050A-4
99
99
99
99
99
53
53
32
32
23
6
933
628
428
285
206
139
102
76
0.37 0.50 0.56 0.74
0.55 0.75 0.83 1.10
0.75 1.00 1.13 1.50
1.10 1.50 1.65 2.20
1.50 2.00 2.25 3.00
2.20 2.00 3.30 4.40
3.00 3.00 4.50 6.00
4.00 5.00 6.00 8.00
CBH 360 C T 406 210R
or
CAR 200 D T 406 210R
Refer to braking
resistor
manufacturer’s
documentation
CBR-V 330 D T 406 78R UL
54
5.50 7.50 8.25 11.00 CBR-V 560 D HT 406 39R UL
7.50 10.00 11.25 15.00
39
29
11.00 15.00 17 22.00
15.00 20.00 23 30.00
18.50 25.00 28 37.00
22.00 30.00 33 44.00
CBT-H 560 D HT 406 19R
CBT-H 760 D HT 406 16R
6
24
6
20
6
20
3AXD10000299801.xls
1) The maximum permitted braking cycle of the braking resistor differs from the that of the drive.
– The maximum braking capacity of the drive 1/10min (P * 150%), must exceed the desired
P
BRmax
BRcont
braking power.
P
– The maximum braking capacity of the drive, must exceed the desired braking power.
BRcont
R
– The maximum resistance value that can provide P
. The resistance of the brake resistor can be
BRcont
max
smaller if the application allows it.
124 Resistor braking
Selecting and routing the brake resistor cables
94.
Minimizing electromagnetic interference
Obey these rules to minimize electromagnetic interference caused by rapid current
changes in the resistor cables:
•
•
Install the cables away from other cable routes.
Avoid long parallel runs with other cables. The minimum parallel cabling
separation distance should be 0.3 meters.
•
•
Cross the other cables at right angles.
Keep the cable as short as possible to minimize the radiated emissions and stress
on chopper IGBTs. The longer the cable the higher the radiated emissions,
inductive load and voltage peaks over the IGBT semiconductors of the brake
chopper.
Maximum cable length
The maximum length of the resistor cable(s) is 10 m (33 ft).
EMC compliance of the complete installation
ABB has not verified that the EMC requirements are fulfilled with external user-
defined brake resistors and cabling. The EMC compliance of the complete installation
must be considered by the customer.
Brake resistor installation
Install the resistors outside the drive in a place where they will cool.
Arrange the cooling of the resistor in a way that:
•
•
There is no danger of overheating to the resistor or nearby materials.
The surrounding air temperature does not exceed the allowed maximum.
Supply the resistor with cooling air/water according to the resistor manufacturer’s
instructions.
WARNING! The materials near the brake resistor must be non-flammable. The
surface temperature of the resistor is high. Air flowing from the resistor is of
hundreds of degrees Celsius. If the exhaust vents are connected to a ventilation
system, ensure that the material withstands high temperatures. Protect the resistor
against physical contact.
Resistor braking 125
Protecting the system in brake circuit fault situations
Protecting the system in cable and brake resistor short-circuit
situations
The input fuses also protect the resistor cable when it is identical with the input cable.
Protecting the system against thermal overload
Equipping the drive with a main contactor is highly recommended for safety reasons.
Connect the contactor so that it opens if the resistor overheats. This is essential for
safety since the drive will not otherwise be able to interrupt the main supply if the
chopper remains conductive in a fault situation. Refer to the example wiring diagram
below. Use resistors that have a thermal switch (1) in the resistor assembly. The
switch indicates overtemperature and overload.
We recommend that you connect the thermal switch to a digital input of the drive.
L1 L2 L3
1
OFF
2
13
14
1
2
3
4
5
6
3
4
ON
Drive
10
1
Drive
L1 L2 L3
+24V
DIx
x
K1
Mechanical installation
Refer to the resistor manufacturer’s instructions.
126 Resistor braking
Electrical installation
Measuring the insulation of the assembly
Connection diagram
Connection procedure
Connect the thermal switch of the brake resistor as described in section Protecting
Resistor braking 127
Start-up
Set the following parameters:
1. Disable the overvoltage control of the drive with parameter 30.30 Overvoltage
control.
2. Set the source of parameter 31.01 External event 1 source to point to the digital
input where the thermal switch of the brake resistor is 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
with thermal model is selected, set also the brake resistor overload protection
parameters 43.08 and 43.09 according to the application.
5. Check the resistance value of parameter 43.10 Brake resistance.
With these parameter settings, the drive generates a fault and coasts to a stop on
brake resistor overtemperature.
WARNING! Disconnect the braking resistor, if it not enabled in the parameter
settings.
128 Resistor braking
Safe torque off function 129
12
Safe torque off function
Contents of this chapter
This chapter describes the Safe torque off (STO) function of the drive and gives
instructions for its use.
Description
The Safe torque off function can be used, for example, as the final actuator device of
safety circuits that stop the drive in case of danger (such as an emergency stop
circuit). Another typical application is a prevention of unexpected start-up function
that enables short-time maintenance operations like cleaning or work on non-
electrical parts of the machinery without switching off the power supply to the drive.
When activated, the Safe torque off function disables the control voltage of the power
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 does not apply if both channels are not used.
130 Safe torque off function
The Safe torque off function of the drive complies with these standards:
Standard
Name
IEC 60204-1:2016
EN 60204-1:2006 +
A1:2009 + AC:2010
Safety of machinery – Electrical equipment of machines – Part 1:
General requirements
IEC 61000-6-7:2014
Electromagnetic compatibility (EMC) – Part 6-7: Generic standards
– Immunity requirements for equipment intended to perform
functions in a safety-related system (functional safety) in industrial
locations
IEC/EN 61326-3-1:2017 Electrical equipment for measurement, control and laboratory use –
EMC requirements – Part 3-1: Immunity requirements for safety-
related systems and for equipment intended to perform safety-
related functions (functional safety) – General industrial
applications
IEC 61508-1:2010
Functional safety of electrical/electronic/programmable electronic
safety-related systems – Part 1: General requirements
IEC 61508-2:2010
Functional safety of electrical/electronic/programmable electronic
safety-related systems – Part 2: Requirements for
electrical/electronic/programmable electronic safety-related
systems
IEC 61511-1:2016
Functional safety – Safety instrumented systems for the process
industry sector
IEC 61800-5-2:2016
EN 61800-5-2:2007
Adjustable speed electrical power drive systems –
Part 5-2: Safety requirements – Functional
IEC 62061:2005 +
A1:2012 + A2:2015
EN 62061:2005 +
AC:2010 + A1:2013 +
A2:2015
Safety of machinery – Functional safety of safety-related electrical,
electronic and programmable electronic control systems
EN ISO 13849-1:2015
Safety of machinery – Safety-related parts of control systems –
Part 1: General principles for design
EN ISO 13849-2:2012
Safety of machinery – Safety-related parts of control systems – Part
2: Validation
The function also corresponds to Prevention of unexpected start-up as specified by
EN 1037:1995 + A1:2008 and Uncontrolled stop (stop category 0) as specified in
IEC/EN 60204-1.
Compliance with the European Machinery Directive
Safe torque off function 131
Connection principle
Connection with internal +24 V DC power supply
Drive
Control board
K
STO
+ 24 V DC
OUT1
SGND
IN1
IN2
UDC+
T1/U,
T2/V,
T3/W
Control logic
A
UDC-
Connection with external +24 V DC power supply
24 V DC
Drive
-
+
Control board
STO
K
OUT1
SGND
+ 24 V DC
IN1
IN2
UDC+
T1/U,
T2/V,
T3/W
Control logic
A
UDC-
132 Safe torque off function
Wiring examples
An example of a Safe torque off wiring with internal +24 V DC power supply is shown
below.
Safety PLC
OUT
Drive
OUT1
SGND
13 23 31
14 24 32
Y1 Y2
K
Safety relay
A1 A2
IN1
IN2
GND
An example of a Safe torque off wiring with external +24 V DC power supply is shown
below.
+24 V DC external
power supply
Safety PLC
OUT
Drive
-
+
OUT1
SGND
13 23 31
Y1 Y2
K
Safety relay
14 24 32
A1 A2
IN1
ÍN2
GND
Activation switch
This represents a component such as a manually operated switch, an emergency
stop push button switch, or the contacts of a safety relay or safety PLC.
•
If a manually operated activation switch is used, the switch must be of a type that
can be locked out to the open position.
•
The STO inputs must switch on/off within 200 ms of each other.
Safe torque off function 133
Cable types and lengths
•
•
Double-shielded twisted-pair cable is recommended.
Maximum cable length:
•
•
100 m (328 ft) between activation switch (K) and drive
60 m (200 ft) between external power supply and drive
Note: A short-circuit in the wiring between the switch and an STO terminal causes a
dangerous fault and therefore it is recommended to use a safety relay (including
wiring diagnostics), or a wiring method (shield grounding, channel separation) which
reduces or eliminates the risk caused by the short-circuit.
Note: The voltage at the STO input terminals of each 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 the control
board at the control board.
•
Ground the shield in the cabling between two control boards at one control board
only.
Operation principle
1. The Safe torque off activates (the activation switch is opened, or safety relay
contacts open).
2. The STO inputs on the drive control board de-energize.
3. The STO cuts off the control voltage from the output IGBTs.
4. The control program generates an indication as defined by parameter 31.22 STO
indication run/stop (refer to the drive firmware manual).
The parameter selects which indications are given when one or both STO signals
are switched off or lost. The indications also depend on whether the drive is
running or stopped when this occurs.
Note: This parameter does not affect the operation of the STO function itself. The
STO function operates 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 malfunction of STO hardware or wiring.
5. The motor coasts to a stop (if running). The drive cannot restart while the
activation switch or safety relay contacts are open. After the contacts close, a
reset may be needed (depending on the setting of parameter 31.22). A new start
command is required to start the drive.
134 Safe torque off function
Start-up including acceptance test
To ensure the safe operation of a safety function, validation is required. The final
assembler of the machine must validate the function by performing an acceptance
test. The acceptance test must be performed
•
•
at initial start-up of the safety function
after any changes related to the safety function (circuit boards, wiring,
components, settings, etc.)
•
after any maintenance work related to the safety function.
Competence
The acceptance test of the safety function must be carried out by a competent person
with adequate expertise and knowledge of the safety function as well as functional
safety, as required by IEC 61508-1 clause 6. The test procedures and report must be
documented and signed by this person.
Acceptance test reports
Signed acceptance test reports must be stored in the logbook of the machine. The
report shall include documentation of start-up activities and test results, references to
failure reports and resolution of failures. Any new acceptance tests performed due to
changes or maintenance shall be logged into the logbook.
Safe torque off function 135
Acceptance test procedure
After wiring the Safe torque off function, validate its operation as follows.
Action
injury or death, or damage to the equipment can occur.
Ensure that the drive can be run and stopped freely during start-up.
Stop the drive (if running), switch the input power off and isolate the drive from the
power line by a disconnector.
Check the Safe torque off circuit connections against the wiring diagram.
Close the disconnector and switch the power on.
Test the operation of the STO function when the motor is stopped.
• Give a stop command for the drive (if running) and wait until the motor shaft is at a
standstill.
Ensure that the drive operates as follows:
• Open the STO circuit. The drive generates an indication if one is defined for the
‘stopped’ state in parameter 31.22 (refer to the drive firmware manual).
• Give a start command to verify that the STO function blocks the drive’s operation.
The drive generates a warning. The motor should not start.
• Close the STO circuit.
• Reset any active faults. Restart the drive and check that the motor runs normally.
Test the operation of the STO function when the motor is running.
• Start the drive and ensure the motor is running.
• Open the STO circuit. The motor should stop. The drive generates an indication if
one is defined for the ‘running’ state in parameter 31.22 (refer to the drive firmware
manual).
• Reset any active faults and try to start the drive.
• Ensure that the motor stays at a standstill and the drive operates as described
above in testing the operation when the motor is stopped.
• Close the STO circuit.
• Reset any active faults. Restart the drive and check that the motor runs normally.
136 Safe torque off function
Action
Test the operation of the failure detection of the drive. The motor can be stopped or
running.
• Open the 1st channel of the STO circuit (wire coming to 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 inverter’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 (wire coming to IN2). If the motor was
running, it should coast to a stop. The drive generates a FA82 Safe torque off 2 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.
Document and sign the acceptance test report which verifies that the safety function is
safe and accepted for operation.
Use
1. Open the activation switch, or activate the safety functionality that is wired to the
STO connection.
2. The STO inputs of the drive control unit de-energize, and the drive control board
cuts off the control voltage from the drive IGBTs.
3. The control program generates an indication as defined by parameter 31.22 (refer
to the drive firmware manual).
4. The motor coasts to a stop (if running). The drive does not restart while the
activation switch or safety relay contacts are open.
5. Deactivate the STO by closing the activation switch, or resetting the safety
functionality that is wired to the STO connection.
6. Reset any faults before restarting.
WARNING! The Safe torque off function does not disconnect the voltage of
the main and auxiliary circuits from the drive. Therefore maintenance work
on electrical parts of the drive or the motor can only be carried out after
isolating the drive from the main supply.
Safe torque off function 137
WARNING! (With permanent magnet motors or synchronous reluctance
motors [SynRM] only) In case of a multiple 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 cuts
off the motor supply voltage and the motor will coast to a stop. If this causes
danger or is not otherwise acceptable, stop the drive and machinery using the
appropriate stop mode before you activate the Safe torque off function.
•
•
•
The Safe torque off function overrides all other functions of the drive unit.
The Safe torque off function is ineffective against deliberate sabotage or misuse.
The Safe torque off function has been designed to reduce the recognized
hazardous conditions. In spite of this, it is not always possible to eliminate all
potential hazards. The assembler of the machine must inform the final user about
the residual risks.
•
The Safe torque off diagnostics are not available during power outages, or when
the drive is only powered by the +24 V BAPO-01 auxiliary power extension
module.
138 Safe torque off function
Maintenance
After the operation of the circuit is validated at start-up, the STO function shall be
maintained by periodic proof testing. In high demand mode of operation, the
maximum proof test interval is 20 years. In low demand mode of operation, the
assumed that all dangerous failures of the STO circuit are detected by the proof test.
Note: See also the Recommendation of Use CNB/M/11.050 (published by the
European co-ordination of Notified Bodies) concerning dual-channel safety-related
systems with electromechanical outputs:
•
When the safety integrity requirement for the safety function is SIL 3 or PL e (cat.
3 or 4), the proof test for the function must be performed at least every month.
•
When the safety integrity 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 does not contain any electromechanical components.
In addition to proof testing, it is good practice to check the operation of the function
when other maintenance procedures are carried out on the machinery.
Include the Safe torque off operation test described above in the routine maintenance
program of the machinery that the drive runs.
If any wiring or component change is needed after start up, or the parameters are
Use only ABB approved spare parts.
Record all maintenance and proof test activities in the machine logbook.
Competence
The maintenance and proof test activities of the safety function must be done by a
competent person with expertise and knowledge of the safety function as well as
functional safety, as required by IEC 61508-1 clause 6.
Safe torque off function 139
Fault tracing
The indications given during the normal operation of the Safe torque off function are
selected by drive parameter 31.22. The indications can be read via fieldbus. The
indications are not safety-classified signals.
The diagnostics of the Safe torque off function cross-compare the status of the two
STO channels. If the channels are not in the same state, a fault reaction function is
done 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, triggers
the same reaction.
See the drive firmware manual for the indications generated by the drive, and for
details on directing fault and warning indications to an output on the control unit for
external diagnostics.
Any failures of the Safe torque off function must be reported to ABB.
140 Safe torque off function
Safety data
The safety data for the Safe torque off function is given below.
Note: The safety data is calculated for redundant use, and does not apply if both STO
channels are not used.
Frame
size
PFH
[1/h]
PFD
PFD
MTTF
[a]
DC
[%]
Cat. SC HFT CCF
T
M
[a]
SIL/ PL SFF
SILCL [%]
avg
avg
D
[T =2a] [T =5a]
1
1
3-phase U = 380…480 V
N
R1
R2
R3
R4
3
3
3
3
e
e
e
e
>90 8.00E-9 6.68E-5 1.67E-4
>90 8.00E-9 6.68E-5 1.67E-4
>90 8.00E-9 6.68E-5 1.67E-4
>99 8.00E-9 6.68E-5 1.67E-4
2568
2568
2569
2568
≥90
≥90
≥90
≥90
3
3
3
3
3
3
3
3
1
1
1
1
80
80
80
80
20
20
20
20
3AXD10000320081, Rev. D
•
The following temperature profile is used in safety value calculations:
•
•
•
•
•
•
670 on/off cycles per year with ∆T = 71.66 °C (161 °F)
1340 on/off cycles per year with ∆T = 61.66 °C (143 °F)
30 on/off cycles per year with ∆T = 10.0 °C (50 °F)
32 °C (90 °F) board temperature at 2.0% of time
60 °C (140 °F) board temperature at 1.5% of time
85 °C (185 °F) board temperature at 2.3% of time
•
•
The STO is a type A safety component as defined in IEC 61508-2.
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 ISO 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 reaction time (shortest detectable break): 1 ms
STO response time: 5 ms (typical), 10 ms (maximum)
Fault detection time: Channels in different states for longer than 200 ms
Fault reaction time: Fault detection time +10 ms
STO fault indication (parameter 31.22) delay: <500 ms
STO warning indication (parameter 31.22) delay: <1000 ms
Safe torque off function 141
Abbreviations
Abbr.
Reference
Description
Cat.
EN ISO 13849-1
Classification of the safety-related parts of a control system
in respect of their resistance to faults and their subsequent
behavior in the fault condition, and which is achieved by the
structural arrangement of the parts, fault detection and/or by
their reliability. The categories are: B, 1, 2, 3 and 4.
CCF
DC
EN ISO 13849-1
EN ISO 13849-1
IEC 61508
Common cause failure (%)
Diagnostic coverage
FIT
Failure in time: 1E-9 hours
Hardware fault tolerance
HFT
IEC 61508
MTTFD EN ISO 13849-1
Mean time to dangerous failure: (Total number of life units) /
(Number of dangerous, undetected failures) during a
particular measurement interval under stated conditions
PFDavg IEC 61508
Average probability of dangerous failure on demand. The
mean unavailability of a safety-related system to perform the
specified safety function when the demand occurs.
PFH
IEC 61508
Average frequency of dangerous failure per hour. The
average frequency of a dangerous failure of a safety related
system to perform the specified safety function over a given
period of time.
PL
EN ISO 13849-1
IEC 61508
Performance level. Levels a…e correspond to SIL
Systematic capability
SC
SFF
SIL
IEC 61508
Safe failure fraction (%)
IEC 61508
Safety integrity level (1…3)
SILCL
IEC/EN 62061
Maximum SIL (level 1…3) that can be claimed for a safety
function or subsystem
STO
T1
IEC/EN 61800-5-2
IEC 61508-6
Safe torque off
Proof test interval. T1 is a parameter used to define the
probabilistic failure rate (PFH or PFD) for the safety function
or subsystem. Performing a proof test at a maximum interval
of T1 is required to keep the SIL capability valid. The same
interval must be followed to keep the PL capability
TM
EN ISO 13849-1
Mission time. The period of time that covers the intended
use of the safety function or device. After the mission time
elapses, the safety device must be replaced. Any given TM
values cannot be regarded as a guarantee or warranty.
142 Safe torque off function
Declaration of conformity
TÜV certificate
The TÜV certificate is available on the internet. Refer to Document library on the
Internet on the inner back cover.
BAPO-01 power extension module 143
13
BAPO-01 power extension
module
Contents of this chapter
This chapter contains a description and technical data of the optional BAPO-01
auxiliary power extension module. The chapter also contains references to the
relevant other content elsewhere in the manual.
Safety instructions
ignore them, injury or death, or damage to the equipment can occur.
144 BAPO-01 power extension module
Hardware description
Product overview
The BAPO-01 auxiliary power extension module (option +L534) enables the use of
an external auxiliary power supply with the drive. You need an external auxiliary
power supply to keep the drive on during a power outage. Connect the auxiliary
voltage supply to the +24V and DGND terminals on the drive.
If you change the drive parameters when the control board is energized with the
BAPO module, force parameter saving with parameter 96.07 PARAM SAVE by
setting the value to (1) SAVE. Otherwise, changed data is not saved.
Layout
1. BAPO module
2. Locking screw hole
3. Internal X100 connector
4. Internal X102 connector
3
5. Grounding rail
1
2
4
5
BAPO-01 power extension module 145
Mechanical installation
Electrical installation
Connect the auxiliary voltage supply to the +24V and DGND terminals on the drive.
provide back-up power to the control board (I/O, fieldbus).
Start-up
To configure the BAPO module:
1. Power up the drive.
2. Set the parameter 95.04 Control board supply to 1 (External 24V).
146 BAPO-01 power extension module
Technical data
Voltage and current rating for the auxiliary power supply
Power loss
Power losses with maximum load 4 W.
Dimensions
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3AXD50000031166 rev. A
BIO-01 I/O extension module 147
14
BIO-01 I/O extension module
Contents of this chapter
This chapter contains a description and technical data of the optional BIO-01 I/O
extension module. The chapter also contains references to the relevant other content
elsewhere in the manual.
Safety instructions
ignore them, injury or death, or damage to the equipment can occur.
148 BIO-01 I/O extension module
Hardware description
Product overview
The BIO-01 front option module (Option +L515) is an I/O extension module that can
be used with an optional fieldbus module. The optional fieldbus module is installed on
top of the BIO-01 option 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 can use DI4 and DI5 as
frequency inputs and DO1 as a frequency output.
BIO-01 terminal block is removable and uses spring clamps for assembly.
Layout
1. Locking tab
1
2. Fieldbus option
module slot
2
3. Chassis screw
4. I/O connector
3
4
Mechanical installation
Before you install the BIO-01 option module, make sure that the chassis screw slider
is in the top position. After the option module is installed, tighten the chassis screw
and move the slider to the 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.
Note: If you power up the drive before you install the BIO-01 option module or a
fieldbus module, the drive gives a warning.
BIO-01 I/O extension module 149
Electrical installation
wiring accordingly. The BIO-01 module has removable spring clamp terminals. Use
ferrules on the multistranded cables before assembly.
Sample wiring with the ABB standard macro:
Terminals
External sample connection
Description
Base Internal connection
unit
Aux. voltage output and prog. digital input
+24V Aux. output +24 V DC, max. 200 mA
DGND Aux. voltage output common
DCOM Digital input common for all
DI1 Stop (0)/Start (1)
X
X
X
X
X
DI2 Not configured
Digital and analog I/O extension BIO-01
DI3 Constant frequency/speed selection
DI4 Start interlock 1 (1 = allow start)
DI5 Not configured
DO1 Not configured
AI1 Output frequency/speed ref: 0...10 V
+10V Ref. voltage +10 V DC (max. 10 mA)
GND Analog circuit common / DO common
SCR Signal cable shield / DO screen
Safe torque off (STO)
SGND Safe torque off. Factory connection.
X
X
X
X
Both circuits must be closed for the
drive to start.
IN1
IN2
OUT1
Start-up
The BIO-01 module is automatically identified by the drive firmware. To configure the
inputs refer to the ACH480 firmware manual (3AXD50000247134 [English]).
—
Further information
Product and service inquiries
Address any inquiries about the product to your local ABB representative,
quoting the type designation and serial number of the unit in question. A listing
of ABB sales, support and service contacts can be found by navigating to
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© Copyright 2018 ABB. All rights reserved.
Specifications subject to change without notice.
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