ABB ACS380 Quick Installation And Start-Up Manual

—
ABB MACHINERY DRIVES
ACS380 drive
Quick installation and start-up guide
Safety instructions
Read the safety instructions in ACS380 Hardware manual (3AXD50000029274 [EN]).
WARNING! Obey these safety instructions to prevent physical injury or
death, or damage to the equipment. If you are not a qualified electrician, do
not do electrical installation or maintenance work.
•
When you install the drive, make sure that dust does not go into the drive.
•
When the drive or connected equipment is energized, do not do work on
the drive, motor cable, motor, control cables or control circuits.
•
After you disconnect the input power, wait for 5 minutes to let the
intermediate circuit capacitors discharge.
•
Make sure that the installation is not energized:
•
Use a multimeter with an impedance of at least 1 Mohm.
•
Make sure that the voltage between the drive output terminals (U, V, W)
and the ground (PE) is 0 V.
•
Make sure that the voltage between the drive input power terminals (L1,
L2, L3) and the ground (PE) is 0 V.
•
Make sure that the voltage between the DC and brake resistor terminals
(UDC+, UDC- and R-) and the ground (PE) is 0 V.
•
If you use a permanent magnet synchronous motor, do not do work on the
drive when the motor rotates. A permanent magnet motor that rotates
energizes the drive and the input power terminals.
WARNING! The installation, start-up and operation of this equipment
requires detailed instructions. Refer to this quick guide and the user interface
guide in the drive package. Retain the guides with this device at all times.
For more information, refer to the hardware manual and firmware manual.
You can download these manuals from the ABB website or order hard
copies of the manuals with the delivery.
1. Examine the installation area
The drive is intended for cabinet installation and has an ingress protection rating of
IP20.
Make sure that in the installation area:
•
There is sufficient cooling and hot air does not recirculate.
•
The ambient conditions are suitable. Refer to Ambient
•
The mounting surface is non-flammable and can hold the weight of the drive.
Refer to Declaration of conformity.
•
Materials near the drive are non-flammable.
•
There is sufficient space above and below the drive for maintenance work. Refer
to Free space requirements.
2. Install the drive
You can install the drive with screws or to a DIN rail.
Installation requirements:
•
Make sure that there is a minimum of 75 mm of free space at the top and bottom
of the drive for cooling air.
•
Install R0 drives upright. R0 drives do not have a fan.
•
You can install R1, R2, R3 and R4 drives tilted by up to 90 degrees, from vertical
to fully horizontal orientation.
•
You can install several drives side by side. Side-mounted options require
approximately 20 mm of space on the right side of the drive.
WARNING! Do not install the drive upside down. Make sure that the cooling
air exhaust (at the top) is always above the cooling air inlet (at the bottom).

To install the drive with screws
1. Make marks onto the surface for the
mounting holes. Refer to
Declaration of conformity. The R3
and R4 drives contain a mounting
template.
2. Make the holes for the mounting
screws and install suitable plugs or
anchors.
3. Start to tighten the screws into the
mounting holes.
4. Install the drive onto the mounting
screws.
5. Tighten the mounting screws.

To install the drive to a DIN 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.
8. To remove the drive, use a flat-head
screwdriver to open the locking part.
3. Measure the insulation resistance
Drive: Do not do voltage tolerance or insulation resistance tests on the drive, because
this can cause damage to the drive.
Input power cable: Before you connect the input power cable, measure the
insulation of the input power cable. Obey the local regulations.
Motor and motor cable:
1. Make sure that the motor cable is connected to the motor and disconnected from
the drive output terminals T1/U, T2/V and T3/W.
2. Use a voltage of 500 V DC to measure the
insulation resistance between each phase
conductor and the protective earth conductor. The
insulation resistance of an ABB motor must be more
than 100 Mohm (at 25 °C/77 °F). For the insulation
resistance of other motors, refer to the
manufacturer's documentation.
Moisture in the motor decreases the insulation resistance. If you think that there
is moisture in the motor, dry the motor and do the measurement again.
4. Select the cables
Input power cable: For the best EMC performance, use a symmetrical shielded
cable and two grounding conductors.
Motor cable: Use a symmetrical shielded cable.
Control cable: Use a double-shielded twisted-pair cable for analog signals. Use a
single-shielded cable for digital, relay and I/O signals. Use separate cables for analog
and relay signals.
5. Connect the power cables

Connection diagram
b
a
a. Two grounding conductors. Use two conductors if the cross-section of grounding
conductor is less than 10 mm
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
conditions.
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.

Connection procedure
WARNING! Obey the safety instructions in the ACS380 Hardware manual
(3AXD50000029274 [English]). If you ignore them, injury 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.
1. Strip the motor cable.
2. Ground the motor cable shield under
the grounding clamp.
3. Twist the motor cable shield into a
bundle, mark it accordingly and
connect it to the grounding terminal.
4. Connect the phase conductors of
the motor cable to the T1/U, T2/V
and T3/W motor terminals. Torque
the terminals to 0.8 N·m (7 lbf·in).
5. If it is applicable, connect the brake
resistor cable to the R- and UDC+
terminals. Torque the terminals to
0.8 N·m (7 lbf·in). Use a shielded
cable and ground the shield under
the grounding clamp.
6. Strip the input power cable.
W
7. If the input power cable has a shield,
twist it into a bundle, mark it and
connect it to the grounding terminal.
8. Connect the PE conductor of the
input power cable to the grounding
terminal. If it is necessary, use a
second PE conductor.
9. Connect the phase conductors of the input power cable to the L1, L2 and L3 input
terminals. Torque the terminals to 0.8 N·m (7 lbf·in).
10. Mechanically attach the cables on the outside of the drive.
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.
d
d
c
2 2
Cu or 16 mm Al (IEC/EN 61800-5-1). For example,
6. Connect the control cables

Connection procedure
Do the connections according to the default control connections of the application
macro that you select. For the connections of the factory default macro (ABB standard
macro), refer to Default I/O connections (ABB standard
fieldbus default macro, refer to Fieldbus connections. For the other macros, refer to
the ACS380 Firmware manual (3AXD50000029275 [English]).
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.
3. Use metal cable ties for 360-degree
grounding.
4. Strip the control cable conductors.
5. Connect the conductors to the
correct control terminals. Torque the
terminals to 0.5 N·m (4.4 lbf·in).
6. Connect the shields of the twisted
pairs and grounding wires to the
SCR terminal. Torque the terminals
to 0.5 N·m (4.4 lbf·in).
7. Mechanically attach the control cables on the outside of the drive.

Default I/O connections (ABB standard macro)
For the standard variant (I/O & Modbus) (type ACS380-04xS).
Terminals
Digital I/O connections
Aux. +24 V DC, max. 200 mA
+24V
Aux. voltage output common
DGND
Digital input common
DCOM
Stop (0) / Start (1)
DI1
Forward (0) / Reverse (1)
DI2
Speed selection
DI3
Speed selection
DI4
Ramp 1 (0) / Ramp 2 (1)
DIO1
Ready (0) / Not ready (1)
DIO2
Digital output auxiliary voltage
DIO SRC
Digital input/output common
DIO COM
Analog I/O
1...10 kohm
Freq. ref. / Speed ref. (0...10 V)
AI1
Analog input circuit common
AGND
Not configured
AI2
Analog input circuit common
AGND
Max. 500 ohm
Output frequency (0...20 mA)
AO
Analog output circuit common
AGND
Signal cable shield (screen)
SCR
Reference voltage
+10V
Safe torque off (STO)
Safe torque off function. Connected at factory.
S+
Drive starts only if both circuits are closed.
SGND
S1
S2
Relay output
Relay output 1
RC
No fault [Fault (-1)]
RA
RB
EIA-485 Modbus RTU
Embedded Modbus RTU (EIA-485)
B+
A-
BGND
Shield
Termination

Connecting EIA-485 Modbus RTU terminal to drive
Connect the fieldbus to the EIA-485 Modbus RTU terminal on the BMIO-01 module
which is attached on the control unit of the drive. The connection diagram is shown
below.
Fieldbus controller
Data flow
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
Termination OFF Termination OFF
Drive Drive
1) The device at both ends on the fieldbus must have termination set to ON.

Fieldbus connections
For the configured drives with the preconfigured fieldbus protocol
(type ACS380-04xC).
Terminals
Digital I/O connections
Aux. +24 V DC, 200 mA
+24V
Aux. voltage output common
DGND
Digital input common
DCOM
Fault reset
DI1
Not configured
DI2
Safe torque off (STO)
Safe torque off function. Connected at factory.
S+
Drive starts only if both circuits are closed.
SGND
S1
S2
Relay output
Relay output 1
RC
No fault [Fault (-1)]
RA
RB
Extension module connections
+K457 FCAN-01-M CANopen
DSUB9 CANopen
+K454 FPBA-01-M Profibus DP
DSUB9 Profibus DP
+K469 FECA-01-M EtherCAT
RJ45 X 2 EtherCAT
+K475 FENA-21-M Ethernet/IP, Profinet,
RJ45 X 2 Ethernet IP Modbus TCP
+K495 BCAN-11 CANopen interface
RJ45 X 2 Profinet
+K470 FEPL-02 Ethernet power link (RJ45x2)
RJ45 X 2 Modbus TCP
+K451 FDNA-01, DeviceNet (Terminal Block)
CANopen
Terminal Block
macro), for the connections of
Descriptions
(1
Termination ON
Fieldbus
ON ON
ON
...
1
1 1
(1
Termination ON
Drive
Descriptions