ABB ACS355 Quick Installation And Start-Up Manual

—
ABB MACHINERY DRIVES
ACS355 drives
Quick installation and start-up guide
Safety instructions
WARNING! Obey these instructions. If you ignore them, injury or death,
or damage to the equipment can occur. If you are not a qualified
electrical professional, do not do electrical installation or maintenance
work.
•
Do not do work on the drive, motor cable, motor, or control cables when the
drive is connected to the input power. Before you start the work, isolate the
drive from all dangerous voltage sources and make sure that it is safe to
start the work. Always wait for 5 minutes after disconnecting the input
power to let the intermediate circuit capacitors discharge.
•
Do not do work on the drive when a rotating permanent magnet motor is
connected to it. A rotating permanent magnet motor energizes the drive,
including its input and output terminals.
1. Unpack the delivery
Keep the drive in its package until you are ready to install it. After unpacking,
protect the drive from dust, debris and moisture. Make sure that these items are
included:
•
clamping plates, clamps and screws
•
fieldbus option ground plate
•
panel cover
•
mounting template, integrated into the package
•
quick installation and start-up guide
•
possible options (extension modules, control panels).
Make sure that there are no signs of damage to the items.
2. Reform the capacitors
If the drive has not been powered up for a year or more, you must reform the DC
link capacitors. The manufacturing date is on the type designation label. Refer
Guide for capacitor reforming
to (3AFE68735190
3. Select the cables and fuses
•
Select the power cables. Obey the local regulations.
•
Input power cable: ABB recommends to use symmetrical shielded cable
(VFD cable) for the best EMC performance.
•
Motor cable: Use symmetrical shielded cable (VFD cable) for the best
EMC performance. Symmetrical shielded cable also reduces bearing
currents, wear, and stress on motor insulation.
•
Power cable types: In IEC installations, use copper or aluminum cables (if
permitted). In UL installations, use only copper cables.
•
Current rating: max. load current.
•
Voltage rating: min. 600 V AC.
•
Temperature rating: In IEC installations, select a cable rated for at least
70 °C (158 °F) maximum permissible temperature of conductor in
continuous use. In UL installations, select a cable rated for at least 75 °C
(167 °F).
•
Size: Refer to Fuses and typical power cable sizes
sizes and to Terminal data for the power cables
sizes.
•
Select the control cables. Use double-shielded twisted-pair cable for analog
signals. Use double-shielded or single-shielded cable for the digital, relay and
I/O signals. Do not run 24 V and 115/230 V signals in the same cable.
•
Protect the drive and input power cable with the correct fuses. Refer to
Fuses and typical power cable sizes
.
4. Examine the installation site
The drive is intended for cabinet installation and has a degree of protection of
IP20 / UL open type as standard.
Examine the site where you will install the drive. Make sure that:
•
The installation site is sufficiently ventilated and hot air does not recirculate.
•
There is sufficient free space around the drive for cooling, maintenance, and
operation. For the minimum free space requirements, refer to
requirements
.
•
The ambient conditions meet the requirements. Refer to
conditions .
•
The installation surface is as close to vertical as possible and strong enough
Dimensions and weights
to support the weight of the drive. Refer to
•
The installation surface, floor and materials near the drive are not flammable.
•
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.
5. Install the drive
You can install the drive with screws, or to a DIN rail (top hat type, width × height
= 35 mm × 7.5 mm [1.4 in × 0.3 in]).
Do not install the drive upside down. Make sure that the cooling air exhaust is
above the cooling air inlet.

To install the drive with screws
1. Cut out the mounting
template from the
package and use it to
mark the locations for
the mounting holes.
2. Make the holes for the
mounting screws and
install suitable plugs or
anchors.
3. Install the mounting
screws. Leave a gap
between the screw
head and mounting
surface.
4. Place the drive onto the
mounting screws.
5. Tighten the mounting
screws.

To install the drive to a DIN rail
1. Put the top of the drive
onto the DIN
installation rail at an
angle as shown in the
figure.
2. Put the drive against
the wall.
3. Make sure that the drive
is correctly installed.
4. To remove the drive,
press the release lever on top of the drive.
6. Attach the clamping plates
1. Attach the clamping
plate to the plate at the
bottom of the drive
with the provided
screws.
2. Frame sizes R0...R2:
Attach the I/O clamping
plate to the clamping
plate with the provided
screws.
7. Measure the insulation resistance
Measuring the insulation is typically not required in North America.
Drive: Do not do voltage tolerance or insulation resistance tests on the drive,
because this can cause damage to the drive.
Input power cable: Measure the insulation of the input power cable before you
connect it to the drive. 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 U2, V2 and W2.
2. Use a voltage of 1000 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.
8. Make sure that the drive is compatible with the
grounding system
You can connect all drive types to a symmetrically grounded TN-S system
(center-grounded wye).
Before you connect the drive to a corner-grounded delta system or IT system
(ungrounded or high-resistance grounded), remove the metal EMC filter
grounding screw. If the drive has a plastic EMC screw (drives with type code
ACS355-03U-...), it is not necessary to remove the screw.
9. Connect the power cables

Connection diagram (shielded cables)
[English]).
ACS355
PE
2
1
for the typical cable
for the maximum cable
PE
1. Two protective earth (ground) conductors. Drive safety standard IEC/EN/
UL 61800-5-1 requires two PE conductors, if the cross-sectional area of the
PE conductor is less than 10 mm
the cable shield in addition to the fourth conductor.
2. Use a separate grounding cable or a cable with a separate PE conductor for
the line side, if the conductivity of the fourth conductor or shield does not
meet the requirements for the PE conductor.
3. Use a separate grounding cable for the motor side, if the conductivity of the
shield is not sufficient, or if there is no symmetrically constructed PE
conductor in the cable.
4. 360-degree grounding of the cable shield is required for the motor cable and
Free space
brake resistor cable (if used). It is also recommended for the input power
cable.
Ambient
5. 1-phase drives: Connect phase to U1 and neutral to V1. Keep W1
disconnected.

Connection procedure (shielded cables)
.
For the tightening torques, refer to
1. Strip the input
power cable. Ground
the cable shield (if
any) under the
grounding clamp.
Twist the cable
shield into a bundle,
mark it accordingly
and connect it to the
grounding terminal.
Connect other
grounding
conductors (PE) to the grounding terminal. Connect the phase conductors to
the U1, V1 and W1 terminals.
R0...R2
ohm
U1-PE, V1-PE, W1-PE
U1 V1 W1
BRK+ BRK- U2
(L) (N)
4 4
5
Optional brake
U1
resistor or
common DC
L1 L2 L3
(L) (N)
2 2
Cu or 16 mm Al. For example, you can use
Terminal data for the power cables
2. Strip the motor cable. Ground the cable shield
under the grounding clamp. Twist the motor
cable shield into a bundle, mark it accordingly
and connect it to the grounding terminal.
Connect the phase conductors to the U2, V2 and
W2 terminals.
3. If used, connect the brake resistor cable to the
BRK+ and BRK- terminals. Use a shielded cable
and ground the shield under the grounding
clamp.
4. Mechanically attach the cables on the outside of
the drive.
10. Connect the control cables
Do the connections according to the default control connections of the
application macro that you select.

Default I/O connections (ABB standard macro)
The diagram shows the I/O connections when parameter
(ABB STANDARD).
X1A
1
2
3
4
1 ... 10 kohm
5
6
7
8
max. 500 ohm
4)
9
10
11
12
13
14
15
16
X1B
17 ROCOM
18
19
20
21 DOOUT
22 DOGND
X1C:STO
1
2
3
4
1) AI1 is used as a speed reference if vector
U1
M mode is selected.
V1
3~ 2) See parameter group 12 CONSTANT
W1 SPEEDS :
PE
DI3 DI4 Operation (par.)
0 0 Set speed through AI1
1 0 Speed 1 ( 1202 )
0 1 Speed 2 ( 1203 )
1 1 Speed 3 ( 1204 )

Connection procedure
To prevent inductive coupling, keep the
signal wire pairs twisted all the way up
to the terminals. The tightening torque
for the terminal connections is 0.4 N·m
(3.5 lbf·in).
1. Remove the terminal cover.
2. Strip the outer insulation of the
cable and ground the bare shield
360 degrees under the clamp.
3. Connect the conductors to the
correct control terminals.
4. For double-shielded cables, twist
V2 W2
also the grounding conductors of
each pair in the cable together and
connect the bundle to terminal SCR
(1).
5. Mechanically attach the control
cables on the outside of the drive.
3
6. If you will use the optional Safe
torque off (STO) function, connect
the STO conductors to the correct
terminals.
7. If necessary, install the optional
V1 fieldbus module.
W1
M 8. Slide the terminal cover back into
PE
place.
3
11. Install the control panel, if included in the delivery
12. Start up the drive
WARNING! Make sure that it is safe to start the motor. Disconnect the
motor from other machinery, if there is a risk of damage or injury.
Before you start up the drive, make sure that the installation is completed and
that you have the motor nameplate data available.

Start up without a control panel
1. Switch on the input power and wait for a moment.
2. Make sure that:
•
the red LED is off
•
the greed LED is on, but not flashing.
The drive is now ready for use.
.  Start up with a control panel (manual start-up)
You can use the basic control panel or the assistant control panel. The displays
shown are the basic control panel displays, unless the instruction is applicable
to the assistant control panel only.
Power-up
Switch on the input power.
The basic control panel powers up into the
Output mode.
The assistant control panel asks if you want to
run the Start-up assistant. If you press
Start-up assistant is not run. If you do not run
the Start-up assistant, continue with manual
start-up as described below for the basic
control panel.
9902 is set to 1
SCR Signal cable shield (screen)
1)
AI1 Output frequency reference: 0 ... 10 V
GND Analog input circuit common
+10V Reference voltage: +10 V DC, max. 10 mA
AI2 Not in use by default. 0 ... 10 V
GND Analog input circuit common
AO Output frequency value: 0 ... 20 mA
GND Analog output circuit common
+24V Auxiliary voltage output: +24 V DC, max. 200 mA
GND Auxiliary voltage output common
DCOM Digital input common
DI1 Stop (0) / Start (1)
DI2 Forward (0) / Reverse (1)
2)
DI3 Constant speed selection
2)
DI4 Constant speed selection
3)
DI5 Acceleration and deceleration selection
Relay output 1
No fault [Fault (-1)]
RONC
RONO
DOSRC Digital output, max. 100 mA
No fault [Fault (-1)]
OUT1 Safe torque off (STO). Both circuits must be closed
for the drive to start. The drawing shows the
OUT2
simplified connection of a safety circuit through
safety contacts. If STO is not used, leave the factory-
IN1
installed jumpers in place. See also section Safe
IN2 torque off (STO) .
3) 0 = ramp times according to parameters
2202 and 2203 . 1 = ramp times according to
parameters 2205 and 2206 .
4) 360 degree grounding under a clamp.
00
.
REM
OUTPUT
REM CHOICE
EXIT
, the
Do you want to
use the start-up
assistant?
Yes
No
EXIT 00:00 OK
Hz
FWD