ABB ACS280 Hardware Manual
  1. Manuals
  2. Brands
  3. ABB Manuals
  4. DC Drives
  5. ACS280
  6. Hardware manual
ABB ACS280 Hardware Manual

ABB ACS280 Hardware Manual

Coldplate drives
Hide thumbs Also See for ACS280:
Table of Contents

Advertisement

Quick Links

Download this manual
—
ABB MACHINERY DRIVES
ACS280 coldplate drives
Hardware manual

Advertisement

Table of Contents
loading

Related Manuals for ABB ACS280

Summary of Contents for ABB ACS280

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

  • Page 5: Table Of Contents

    Table of contents 5 Table of contents 1 Safety instructions Contents of this chapter ..................Use of warnings and notes ..................General safety in installation, start-up and maintenance ........ Electrical safety in installation, start-up and maintenance ......Electrical safety precautions ................Additional instructions and notes ..............
  • Page 6 6 Table of contents Type designation label ..................Type designation key ....................Control panel ......................4 Mechanical installation Contents of this chapter ................. Installation alternatives ..................Examining the installation site ................Required tools ......................Unpacking the delivery .................... Planning the cooling of the drive ................Design the external heatsink ................
  • Page 7 Connecting the power cables ................Connection diagram ..................Connection procedure ..................Connecting the control cables ................Default I/O connection diagram (ABB standard macro) ......Control cable connection procedure ............. Additional information on the control connections .......... Connecting EIA-485 fieldbus cable to the drive ..........
  • Page 8 8 Table of contents 7 Installation checklist Contents of this chapter ..................Checklist ........................8 Maintenance Contents of this chapter ..................Maintenance intervals ..................... Description of symbols ..................Recommended maintenance intervals after start-up ....... Replacing the cooling fans ..................Replacing the cooling fan ................Capacitors ........................
  • Page 9 Table of contents 9 Brake resistor connection data ................Energy efficiency data (ecodesign) ..............Degrees of protection ..................... Ambient conditions ....................Materials ........................Disposal ........................Applicable standards ....................Markings ........................Compliance with EN 61800-3 ................. Definitions ......................Category C1 ......................Category C2 ......................
  • Page 10 Compliance with the European Machinery Directive and the UK Supply of Machinery (Safety) Regulations ..............Wiring .......................... Connection principle ..................Single ACS280 drive, internal power supply ........Single ACS280 drive, external power supply ........Wiring examples ....................Single ACS280 drive, internal power supply ........

  • Page 11: Safety Instructions

    Safety instructions 11 Safety instructions Contents of this chapter This chapter contains the safety instructions which you must obey when you install, start-up, operate and do maintenance work on the drive. If you ignore the safety instructions, injury, death or damage can occur. Use of warnings and notes Warnings tell you about conditions which can cause injury or death, or damage to the equipment.

  • Page 12: General Safety In Installation, Start-Up And Maintenance

    12 Safety instructions General safety in installation, start-up and maintenance These instructions are for all personnel who do work on the drive. WARNING! Obey these instructions. If you ignore them, injury or death, or damage to the equipment can occur. •...
  • Page 13 Safety instructions 13 Note: • If you select an external source for the start command and it is on, the drive will start immediately after fault reset unless you configure the drive for pulse start. See the firmware manual. • If the drive is in remote control mode, you cannot stop or start the drive with the control panel.

  • Page 14: Electrical Safety In Installation, Start-Up And Maintenance

    14 Safety instructions Electrical safety in installation, start-up and maintenance ￭ Electrical safety precautions These electrical safety precautions are for all personnel who do work on the drive, motor cable or motor. WARNING! Obey these instructions. If you ignore them, injury or death, or damage to the equipment can occur.

  • Page 15: Additional Instructions And Notes

    Safety instructions 15 Note: If cables are not connected to the drive DC terminals, measuring the voltage from the DC terminal screws can give incorrect results. 6. Install temporary grounding as required by the local regulations. 7. Ask for a permit to work from the person in control of the electrical installation work.

  • Page 16: Grounding

    16 Safety instructions ￭ Grounding These instructions are for all personnel who are responsible for the grounding of the drive. WARNING! Obey these instructions. If you ignore them, injury or death, or equipment malfunction can occur, and electromagnetic interference can increase. If you are not a qualified electrical professional, do not do grounding work.

  • Page 17: General Safety In Operation

    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. • If you have a cardiac pacemaker or other electronic medical device, keep away from the area near motor, drive, and the drive power cabling when the drive is in operation.

  • Page 18: Safety In Operation

    18 Safety instructions • Do not do work on the drive when a rotating permanent magnet motor is connected to it. A rotating permanent magnet motor energizes the drive including its input and output power terminals. Before installation, start-up and maintenance work on the drive: •...

  • Page 19: Introduction To The Manual

    The flowchart refers to chapters/sections in this manual and other manuals. Applicability This manual is applicable to ACS280 drives. Target audience The reader is expected to know the fundamentals of electricity, wiring, electrical components and electrical schematic symbols.

  • Page 20: Quick Installation And Commissioning Flowchart

    Connect the power cables. Connecting the power cables (page 61) Connect the control cables. Connecting the control cables (page 63) Examine the installation. Installation checklist (page 69) Commission the drive. Refer to the ACS280 Firmware manual (3AXD50001017729 [Eng- lish]).

  • Page 21: Terms And Abbreviations

    Introduction to the manual 21 Terms and abbreviations Term Description ACS-AP-… Assistant control panel BCBL-01 Optional USB to RJ45 cable Capacitor bank The capacitors connected to the DC link Control unit The part in which the control program runs. DC link DC circuit between rectifier and inverter DC link capacitors Energy storage which stabilizes the intermediate circuit DC voltage...

  • Page 22: Related Documents

    22 Introduction to the manual Related documents Name Code Drive manuals and guides ACS280 drives hardware manual 3AXD50001017705 ACS280 quick installation and start-up guide 3AXD50001017743 ACS280 firmware manual 3AXD50001017729 ACS280 recycling instructions 3AXD50001107932 Option manuals and guides ACS-AP-I, -S, -W and ACH-AP-H, -W Assistant control panel user’s...

  • Page 23: Operation Principle And Hardware Description

    Operation principle and hardware description 23 Operation principle and hardware description Contents of this chapter This chapter briefly describes the operation principle and construction of the drive.

  • Page 24: Operation Principle

    24 Operation principle and hardware description Operation principle The ACS280 is a drive for controlling asynchronous AC induction motors and permanent magnet synchronous motors. It is optimized for cold-plate mounting. ￭ Simplified main circuit diagram The figure shows the simplified main circuit diagram of the drive.

  • Page 25: Layout

    Motor connection terminal Cold plate Type designation label Mounting holes QR code for product web-page Control connection terminals Grounding screw for main power Grounding screw for control cables cables EMC filter grounding screw (on Power LED ACS280-04S... only) DC connection terminals...

  • Page 26: Frame Sizes R2

    Cold plate Type designation label Mounting holes QR code for product web-page Control terminals Grounding screw for main power Grounding screw for control cables cables Power LED EMC filter grounding screw (on ACS280-04S... only) DC connection and brake chopper terminals...

  • Page 27: Control Connections

    Operation principle and hardware description 27 Control connections 14 Hardware description ￭ Frame size R1 and R2 Relay output connection CAN termination jumper Safe torque-off connections EIA-485 termination jumper EIA-485 Modbus RTU and CANopen User tool connector (external panel or ad- connections.

  • Page 28: Control Panel Options

    Model information label at the top of the drive • Type designation label on the left side of the drive. Example labels are shown in this section. ￭ Model information label ACS280-04S-05A6-4 S/N : W203300008 Code Description Drive type Serial number...

  • Page 29: Type Designation Label

    XXXX: Running item number that starts each week from 0001. Type designation key The type designation shows the specifications and configuration of the drive. The table below presents the type code digits. Sample type code: ACS280-04S-05A6-4 Code Description ACS280 Product series Construction.

  • Page 30: Control Panel

    Nominal current. See the ratings table in the technical data. Voltage rating. 1=1-phase 230 V AC, 2=3-phase 230V AC, 4=3-phase 380…480 V Control panel Control panels (ACS-BP-S, ACS-AP-x, ACS-AP-W) can be used with ACS280. Refer to the relevant panel manuals.

  • Page 31: Mechanical Installation

    Mechanical installation 31 Mechanical installation ￭ Contents of this chapter This chapter tells how to examine the installation site, unpack and examine the delivery and install the drive mechanically. The chapter tells you how to examine the installation site, unpack, check the delivery and install the drive mechanically.

  • Page 32: Examining The Installation Site

    To install the drive mechanically, you need these tools: • a drill and suitable drill bits • a screwdriver or wrench with a set of suitable bits • personal protective equipment. • (optional) the printed installation template (can be downloaded from ABB.com).

  • Page 33: Unpacking The Delivery

    Mechanical installation 33 Unpacking the delivery rights in this document and in the information contained therein. Reproduction, First angle projection. Original drawing made with 3D CAD. Set the correct scale factor when adding dimensions after DWG/DXF conversion. re to third parties without express authority is strictly forbidden. The figure shows the drive package with its contents.

  • Page 34: Planning The Cooling Of The Drive

    The cold-plate drive ACS280 must be installed on a suitable turbulent air flow inside the drive to dissipate the heat inside the drive, and the...

  • Page 35: Design The External Heatsink

    350mA 3. Many factors, such as dirt, installation orientation, and non-uniform heating area, may affect the cooling capacity of the heatsink in a real application. ABB recommends to spare enough margin while you calculate the thermal resistance of the heatsink.

  • Page 36: Installing The Drive

    Do not operate the drive without providing suitable heatsink capacity for the drive and application requirement. ACS280 must be installed onto a suitable flat metallic surface with sufficiently low thermal resistance to allow dissipation of the heat produced. Prepare the suitable mounting surface according to the external heatsink mounting hole dimensions.
  • Page 37 Mechanical installation 37 2. Make sure that the surface of the heat sink and cold plate are free from dust, dirt, oil and particles, and the mounting surface is smooth and made of uncoated metal (steel or aluminum). 3. Apply a thin and uniform film of heat conducting paste on the cold plate (R1 3.5 ml, R2 5 ml) to ensure good conductivity.

  • Page 39: Guidelines For Planning The Electrical Installation

    ABB does not assume any liability whatsoever for any installation which breaches the local laws and/or other regulations. Furthermore, if the recommendations given by ABB are not followed, the drive may experience problems that the warranty does not cover.

  • Page 40: Selecting The Main Contactor

    40 Guidelines for planning the electrical installation To comply with European Union directives and United Kingdom regulations related to standard EN 60204-1, the disconnecting device must be one of these types: • switch-disconnector of utilization category AC-23B (IEC 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)

  • Page 41: Typical Power Cable Sizes

    Guidelines for planning the electrical installation 41 To comply with the EMC requirements of the CE mark, use one of the preferred cable types. See Preferred power cable types (page 41). Symmetrical shielded cable reduces electromagnetic emission of the whole drive system as well as the stress on motor insulation, bearing currents and wear.

  • Page 42: Alternate Power Cable Types

    42 Guidelines for planning the electrical installation Cable type Use as input power cabling Use as motor cabling and as brake resistor cabling Symmetrical shielded (or ar- mored) cable with three phase conductors and a shield (or armor), and separ- ate PE conductor/cable 1) A separate PE conductor is required if the conductivity of the shield (or armor) is not sufficient for the PE use.

  • Page 43: Not Allowed Power Cable Types

    ￭ Additional guidelines – North America ABB recommends the use of metallic conduit for power wiring. ABB also recommends the use of symmetrical shielded VFD cable between drive and motor(s). This table shows examples of methods for wiring the drive. Refer to NFPA 70 (NEC) along with state and local codes for the appropriate methods for your application.

  • Page 44: Metal Conduit

    44 Guidelines for planning the electrical installation Wiring method Notes Wireways Prefer symmetrical shielded VFD cable. Separate motor wiring from input power wiring and other low voltage wiring. Metallic Do not run outputs of multiple drives parallel. Bundle each cable (wiring) together and use separators where possible.

  • Page 45: Grounding

    Guidelines for planning the electrical installation 45 Insulation jacket Helix of copper tape or copper wire Copper wire shield Inner insulation Cable core Grounding These instructions are for all personnel who are responsible for the grounding of the drive. WARNING! Obey these instructions.

  • Page 46: Signals In Separate Cables

    46 Guidelines for planning the electrical installation Use a double-shielded twisted pair cable for analog signals. ABB recommends this type of cable also for the pulse encoder signals. Use one individually shielded pair for each signal. Do not use common return for different analog signals.

  • Page 47: General Guidelines - North America

    Guidelines for planning the electrical installation 47 • Avoid long parallel runs of motor cables with other cables. • Where control cables must cross power cables, make sure that they are arranged at an angle as near to 90 degrees as possible. •...

  • Page 48: Continuous Motor Cable Shield/Conduit And Metal Enclosure For Equipment On The Motor Cable

    48 Guidelines for planning the electrical installation Input power cabling Motor cabling Conduit ￭ Continuous motor cable shield/conduit and metal enclosure for equipment on the motor cable To minimize the emission level when safety switches, contactors, connection boxes or similar equipment are installed on the motor cable between the drive and the motor: •...

  • Page 49: Separate Control Cable Ducts

    Guidelines for planning the electrical installation 49 ￭ Separate control cable ducts Put 24 V DC and 230 V AC (120 V AC) control cables in separate ducts, unless the 24 V DC cable is insulated for 230 V AC (120 V AC) or insulated with an insulation sleeving for 230 V AC (120 V AC).

  • Page 50: Protecting The Drive, And The Input Power And Motor Cables Against Thermal Overload

    50 Guidelines for planning the electrical installation ￭ 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. No additional thermal protection devices are needed.

  • Page 51: Implementing Motor Temperature Sensor Connection

    Guidelines for planning the electrical installation 51 Implementing motor temperature sensor connection WARNING! IEC 61800-5-1 requires double or reinforced insulation between live parts and accessible parts when: • the accessible parts are not conductive, or • the accessible parts are conductive, but not connected to the protective earth.

  • Page 52: Implementing The Emergency Stop Function

    119). Using a safety switch between the drive and the motor ABB recommends to install a safety switch between the permanent magnet motor and the drive output. The switch is needed to isolate the motor from the drive during maintenance work on the drive.

  • Page 53: Protecting The Contacts Of Relay Outputs

    Guidelines for planning the electrical installation 53 When you select the vector motor control mode and the motor coast stop mode, you can open the contactor immediately after the drive has received the stop command. This is the case also if you use the scalar motor control mode. Protecting the contacts of relay outputs Inductive loads (relays, contactors, motors) cause voltage transients when switched off.

  • Page 55: Electrical Installation

    Electrical installation 55 Electrical installation Contents of this chapter This chapter describes how to: • Measure the insulation • Do an grounding system compatibility check • Change the EMC filter connection • Connect the power and control cables • Connect a PC Warnings WARNING! Obey the safety instructions of the drive.

  • Page 56: Measuring The Insulation

    Use a measuring voltage of 1000 V DC. The insulation resistance of an ABB motor must be more than 100 Mohm (reference value at 25 °C [77 °F]). For the insulation resistance of other motors, refer to the manufacturer’s instructions.

  • Page 57: Grouding System Compatibility Check

    Grouding system compatibility check ￭ EMC filter The drive ACS280-04S has an internal EMC filter as standard. You can install the drive to a symmetrically grounded TN-S system. If you install the drive to another system, you must disconnect the EMC filter.

  • Page 58: Disconnecting The Emc Filter

    Metal Plastic Plastic Metal Metal Plastic Note: Not all ACS280 drives have the EMC/VAR screw, check the product layout diagram for details. ￭ Disconnecting the EMC filter Do the steps in section Electrical safety precautions (page 14) before you start the work.

  • Page 59: Guidelines For Installing The Drive To A Tt System

    Note: • ABB does not guarantee the EMC performance, because the internal EMC filter is disconnected. • ABB does not guarantee the functioning of the ground leakage detector built inside the drive.
  • Page 60 60 Electrical installation The table below shows the line-to-ground voltages in relation to the line-to-line voltage for each grounding system. U L-L U L1-G U L2-G U L3-G Electrical power system type 0.58·X 0.58·X 0.58·X TN-S system (symmetrically grounded) Corner-grounded delta system (nonsym- 1.0·X 1.0·X metrical)

  • Page 61: Connecting The Power Cables

    Motor cable PE conductor for the line side, if the conductivity of the fourth conductor or shield Note: ABB recommends to use a symmetrical shielded cable (VFD cable) as the motor does not meet the requirements for the PE conductor.

  • Page 62: Connection Procedure

    62 Electrical installation ￭ Connection procedure WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. If you are not a qualified electrical professional, do not do installation, commissioning or maintenance work.

  • Page 63: Connecting The Control Cables

    Electrical installation 63 10. Mechanically attach the cables on the outside of the drive. Connecting the control cables Refer to Default I/O connection diagram (ABB standard macro) for the default I/O connections of the ABB standard macro.

  • Page 64: Default I/O Connection Diagram (Abb Standard Macro)

    64 Electrical installation ￭ Default I/O connection diagram (ABB standard macro) Terminals Descriptions Digital I/O connections 24 V Aux. +24 V DC, max 100 mA Aux. voltage output common Stop (0) / Start (1) Forward (0) / Reverse (1) Analog I/O Speed reference (0…10V)
  • Page 65 Electrical installation 65 2. Strip a part of the outer shield of the control cable for 360-degree grounding. 3. Use a 360-degree grounding clamp to connect the cable to the grounding tab. 4. Strip the ends of the control cable conductors. For stranded (multi-wire) conductors, install ferrules at the bare conductor ends.

  • Page 66: Additional Information On The Control Connections

    66 Electrical installation Additional information on the control connections ￭ Connecting EIA-485 fieldbus cable to the drive Connect the fieldbus to the EIA-485 Modbus RTU terminal on the front of the drive. The EIA-485 network uses shielded, twisted-pair cable for data signaling with characteristic impedance between 100 and 130 ohm.

  • Page 67: Pnp Configuration For Digital Inputs

    Electrical installation 67 ￭ PNP configuration for digital inputs Internal and external +24 V power supply connections for PNP (source) configuration are shown in the figure below. Internal +24 V power supply External +24 V power supply +24 V DC +24V +24V 0 V DC...

  • Page 68: Safe Torque Off

    A – type Mini-B cable. The maximum permitted length of the cable is 3 m (9.8 ft). • Use a USB to RJ45 converter. You can order it from ABB (BCBL-01, 3AXD50000032449). Connect the cable to the Panel and PC tool port (RJ45).

  • Page 69: Installation Checklist

    Installation checklist 69 Installation checklist Contents of this chapter This chapter contains a checklist for the mechanical and electrical installation of the drive. Checklist Examine the mechanical and electrical installation of the drive before start-up. Go through the checklist together with another person. WARNING! Obey the safety instructions of the drive.
  • Page 70 70 Installation checklist Make sure that … The insulation resistance of the input power cable, motor cable and motor is meas- ured according to local regulations and the manuals of the drive. The drive is attached securely on an even, vertical and non-flammable wall. The cooling air can flow freely in and out of the drive.
  • Page 71 Installation checklist 71 Make sure that … The motor and the driven equipment are ready for power-up.

  • Page 73: Maintenance

    Maintenance intervals The tables below show the maintenance tasks which can be done by the end user. The complete maintenance schedule is available on the Internet (https://new.abb.com/drives/services/maintenance/preventive-maintenance). For more information, consult your local ABB Service representative (www.abb.com/searchchannels). ￭ Description of symbols...

  • Page 74: Recommended Maintenance Intervals After Start-Up

    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 firmware manual. You can get replacement fans from ABB. Use only ABB specified spare parts.

  • Page 75: Replacing The Cooling Fan

    First angle projection. Original drawing made with 3D CAD. Set the correct scale factor when adding dimensions after DWG/DXF conversion. use or disclosure to third parties without express authority is strictly forbidden. © ABB Oy. PROPRIETARY AND SECRET INFORMATION. CONFIDENTIAL Maintenance 75 ￭...

  • Page 76: Capacitors

    7. Connect the fan power cable. 8. Carefully put the fan cover into position in the drive. Make sure that the fan power cable is routed correctly. Push the cover to lock into position. ACS280 R1S2 Module Dimension Title Doc. des.

  • Page 77: Reforming The Capacitors

    Maintenance 77 Capacitor failure is usually followed by damage to the unit and an input cable fuse failure, or a fault trip. If you think that any capacitors in the drive have failed, contact ABB. ￭ Reforming the capacitors The capacitors must be reformed if the drive has not been powered (either in storage or unused) for a year or more.

  • Page 79: Technical Data

    IEC ratings Output ratings Input Input with Max. Light-duty Heavy-duty Nominal use choke ACS280- current Frame 04... I max I Ld P Ld I Hd P Hd size 1-phase U n = 200...240 V (200, 208, 220, 230, 240 V) -03A7-1 0.55...

  • Page 80: Ul (Nec) Ratings

    80 Technical data Output ratings Input Input with Max. Light-duty Heavy-duty Nominal use choke ACS280- current Frame 04... I max I Ld P Ld I Hd P Hd size -06A9-2 0.75 -09A8-2 12.9 13.3 -12A2-2 16.2 12.2 17.6 12.2 11.6 -17A5-2 21.2...

  • Page 81: Definitions

    Technical data 81 ACS280-04... Input Input Output ratings with Max. Light-duty use Heavy-duty use Frame choke current size I max I Ld P Ld I Hd P Hd 3-phase U n = 440...480 V (440, 460, 480 V) -03A3-4 -05A6-4 -07A2-4 10.1...

  • Page 82: Sizing

    82 Technical data ￭ Sizing ABB recommends the DriveSize tool for selecting the drive, motor and gear combination (https://new.abb.com/drives/software-tools/drivesize). You can also use the ratings tables. The minimum recommended nominal current of the motor is 40% of the drive nominal output current ( I ) .
  • Page 83 For example, if set the 97.01=4kHz, and activate the LS mode, then the equivalent switching frequency in IGBT will be 6kHz. Type Derating factor (k) with different switching frequencies (at 50 °C) ACS280-04... 2 kHz 4 kHz 6 kHz 8 kHz...

  • Page 84: Fuses

    Min. short- Input Nominal Voltage I 2 t circuit cur- current current rating ACS280-04... ABB type rent A 2 s 1-phase U n = 200...240 V (200, 208, 220, 230, 240 V) -03A7-1 C10G16 -06A9-1 12.6 1200 C10G20 -09A8-1 21.8...

  • Page 85: Gr Or Ar -Type Fuses (Iec)

    -type fuses (IEC) Min. short- Input Nominal Voltage I 2 t circuit cur- current current rating ACS280-04... Bussmann type rent A 2 s 1-phase U n = 200...240 V (200, 208, 220, 230, 240 V) -03A7-1 FWP-32G14F -06A9-1 12.6 2200...

  • Page 86: Alternate Short-Circuit Protection

    You can use the circuit breakers listed below. You can also use other circuit breakers with the drive if they provide the same electrical characteristics. ABB does not assume any liability whatsoever for the correct function and protection with circuit breakers not listed below.

  • Page 87: Miniature Circuit Breakers (Ul)

    ￭ Miniature circuit breakers (UL) ACS280-04 drives are suitable for use on a circuit capable of delivering not more than 5 kA symmetrical amperes (RMS) at 240 or 480Y/277 V maximum, when protected by appropriate circuit breakers in the tables below. Additional fuse protection is not required by UL when using circuit breakers herein.
  • Page 88 88 Technical data Minimum enclosure volume Type ACS280- 2) 3) Frame Breaker type(UL) 04... dm 3 in 3 3-phase U n = 200...240 V -03A7-2 SU203M-C10 -06A9-2 SU203M-C16 -09A8-2 SU203M-C25 -12A2-2 SU203M-C32 -17A5-2 SU203M-C32 3-phase U n = 440...480 V...

  • Page 89: Dimensions And Weights

    Technical data 89 36 Mechanical installation Dimensions and weights Dimensions ACS280 0.24 5.06 11.5 0.45 0.24 0.28 5.26 11.5 0.45 0.28 Weights ACS280 75.5 2.97 5.24 0.45 0.95 2.09 3.54 7.17 0.45 1.33 2.94...

  • Page 90: Free Space Requirements

    Front Losses, cooling data and noise Power loss of ACS280 main part is produced by IGBT and rectifier, and the heat generated by them dissipates through the coldplate. Power loss of ACS280 control part is produced by DC capacitor, SMPS and control components of the drive, and the heat generated by them dissipates in the surrounding air through the internal fan.

  • Page 91: Terminal Data For The Power Cables

    Technical data 91 Noise Typical power loss ACS280-04... Frame size Main loss Control parts dB(A) 1-phase U n = 200...240 V (200, 208, 220, 230, 240 V) -03A7-1 -06A9-1 -09A8-1 -12A2-1 3-phase U n = 200...240 V (200, 208, 220, 230, 240 V)
  • Page 92 92 Technical data ACS280- L1, L2, L3, T1/U, T2/V, T3/W, R-, R+/ 04... UDC+ Minimum Maximum Tightening Minimum Maximum Tightening torque (solid/stran- (solid/stran- torque (solid/stran- (solid/stran- ded) ded) ded) ded) mm 2 mm 2 mm 2 mm 2 N·m N·m 1-phase U n = 200...240 V (200, 208, 220, 230, 240 V)

  • Page 93: Typical Power Cable Sizes

    Technical data 93 ACS280- L1, L2, L3, T1/U, T2/V, T3/W, R-, R+/ 04... UDC+ Minimum Maximum Tightening Minimum Maximum Tightening torque torque lbf·in lbf·in 3-phase U n = 200…240 V (200, 208, 220, 230, 240 V) -03A7-2 10.6 -06A9-2 10.6 -09A8-2 10.6...

  • Page 94: Terminal Data For The Control Cables

    22 - 16 Electrical power network specification Voltage (U1) ACS280-04xx-xxxx-1 drives: 1-phase 200 ... 240 V AC -15% ... +10% ACS280-04xx-xxxx-2 drives: 3-phase 200 ... 240 V AC -15% ... +10% ACS280-04xx-xxxx-4 drives: 3-phase 380 ... 480 V AC -15% ... +10% Network type Public low-voltage networks.

  • Page 95: Motor Connection Data

    Mains choke Use a mains choke if the network's line impedance is low (less than 0.3% total system impedance of all the ACS280 drives in the install- ation), or has voltage imbalance, or harmonic distortion that make the input current bigger than the nominal input current ratings. You can use one choke for several drives as long as the choke current rating is not exceeded.

  • Page 96: Emc Compatibility And Motor Cable Length

    96 Technical data Note: In multimotor systems, the calculated sum of all motor cable lengths must not exceed the maximum motor cable length given in the table. 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.

  • Page 97: Brake Resistor Connection Data

    Technical data 97 Analog output (AO) Current output mode 0 … 20 mA (10% overrange, 22 mA max.) into maximum 500 ohm load Voltage output mode 0 … 10 V DC (10% overrange, 11 V DC max.) into 200 kohm minimum load (resistive) Inaccuracy ≤...

  • Page 98: Energy Efficiency Data (Ecodesign)

    Transportation in tionary use protective pack- the protective package Installation site alti- 0 … 1000 m above sea level tude without derating. 1000 … 2000 m above sea level with derating. ACS280-...-4, R2 frame: 1000...4000m above sea level with derating.

  • Page 99: Materials

    Technical data 99 Requirement Operation installed for sta- Storage in the Transportation in tionary use protective pack- the protective package Surrounding air tem- -10... +50 °C (14 … 122 °F) -40...+70 °C -40...+70 °C perature at heavy without derating. (-40...158 °F) (-40...158 °F) duty rating No frost allowed.

  • Page 100: Applicable Standards

    Contact your local ABB distributor for further information on environmental aspects. End of life treatment must follow international and national regulations. For more information on ABB end of life services, refer to new.abb.com/service/end-of-lifeservices. Applicable standards...

  • Page 101: Compliance With En 61800-3

    Product is compliant with the People’s Republic of China Electronic Industry Standard (SJ/T 11364-2014) about hazardous substances. The EFUP is 20 years. China RoHS II Declaration of Conformity is available from https://library.abb.com. WEEE mark At the end of life the product should enter the recycling system at an appropriate collection point and not placed in the normal waste stream.

  • Page 102: Category C1

    400 A, or intended for use in complex systems in the second environment. ￭ Category C1 If without extra measures, the ACS280-04 drive do not compliance with EMC category C1. Contact ABB for more information. ￭ Category C2 This is applicable to ACS280-04S-...-1 drives with an internal EMC C2 filter.

  • Page 103: Category C4

    Drive 2. An EMC plan for preventing disturbances is drawn up for the installation. A template is available from the local ABB representative. 3. The motor and control cables are selected as specified in this manual. 4. The drive is installed according to the instructions given in this manual.

  • Page 104: Ul Checklist

    104 Technical data WARNING! To prevent radio-frequency interference, do not use a category C4 drive on a low-voltage public network which supplies domestic premises. WARNING! You can install a drive with the internal EMC filter connected only on a symmetrically grounded TN-S system. UL checklist WARNING! Operation of this drive requires detailed installation and operation...

  • Page 105: Compliance With The European Machinery Directive

    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...

  • Page 107: Dimension Drawings

    Dimension drawings 107 Dimension drawings Contents of this chapter The chapter contains the dimension drawings of the drive. The dimensions are in millimeters and inches.

  • Page 108: Frame R1

    108 Dimension drawings Frame R1 [.79] [3.35] [.26] [.52] [.53] [3.35] [1.85] [5.71] [2.21] [3.54] [2.96] 23,9 [.54] [.939] [.83] [2.97] [5.24] [.24]...

  • Page 109: Frame R2

    Dimension drawings 109 Frame R2 [1.15] [6.64] [.92] [.32] [1.72] [3.14] [7.717] [3.35] [3.54] [3.54] [.28] [7.17]...

  • Page 111: Resistor Braking

    Resistor braking 111 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. Safety WARNING! Do not do work on the brake resistor or the resistor cable when the drive is energized.
  • Page 112 112 Resistor braking 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...

  • Page 113: Reference Brake Resistors

    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. ￭ Reference brake resistors ACS280-04... 1) 2) R min R max P BRcont...

  • Page 114: Minimizing Electromagnetic Interference

    114 Resistor braking ￭ Minimizing electromagnetic interference Make sure that the installation is compliant with the EMC requirements. Obey these rules in order to minimize electromagnetic interference caused by the rapid voltage and current changes in the resistor cables: • Shield the brake resistor cable.

  • Page 115: Protecting The System Against Thermal Overload

    (1) inside the resistor assembly. The switch indicates overtemperature. ABB recommends that you also wire the thermal switch to a digital input of the drive, and configure the input to cause a fault trip at resistor overtemperature indication.

  • Page 116: Mechanical And Electrical Installation Of Brake Resistor

    116 Resistor braking Mechanical and electrical installation of brake resistor WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. If you are not a qualified electrical professional, do not do installation, commissioning or maintenance work.
  • Page 117 Resistor braking 117 With these parameter settings, the drive generates a fault and coasts to a stop on brake resistor overtemperature.

  • Page 119: The Safe Torque Off Function

    The Safe torque off function 119 The 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 (such as an emergency stop circuit) that stop the drive in case of danger.

  • Page 120: Compliance With The European Machinery Directive And The Uk Supply Of Machinery (Safety) Regulations

    120 The Safe torque off function The Safe torque off function complies with these standards: Standard Name IEC 60204-1:2021 Safety of machinery – Electrical equipment of machines – Part 1: General requirements EN 60204-1:2018 IEC 61000-6-7:2014 Electromagnetic compatibility (EMC) – Part 6-7: Generic standards –...

  • Page 121: Wiring

    The Safe torque off function 121 Wiring For the electrical specifications of the STO connection, see the technical data of the control unit. ￭ Connection principle Single ACS280 drive, internal power supply + 24 V DC SGND UDC+ UDC- Drive...

  • Page 122: Single Acs280 Drive, External Power Supply

    122 The Safe torque off function Single ACS280 drive, external power supply 24 V DC + 24 V DC SGND UDC+ UDC- Drive Control unit Control logic To motor Activation switch...

  • Page 123: Wiring Examples

    The Safe torque off function 123 ￭ Wiring examples Single ACS280 drive, internal power supply SGND Drive Safety PLC Safety relay Single ACS280 drive, external power supply 24 V DC SGND Drive Safety PLC Safety relay...

  • Page 124: Multiple Acs280 Drives, Internal Power Supply

    124 The Safe torque off function Multiple ACS280 drives, internal power supply +24 V SGND SGND SGND Drive Control unit Activation switch...

  • Page 125: Multiple Acs280 Drives, External Power Supply

    The Safe torque off function 125 Multiple ACS280 drives, external power supply 24 V DC – +24 V SGND SGND SGND Drive Control unit Activation switch ￭ Activation switch In the wiring diagrams, the activation switch has the designation [K]. 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.

  • Page 126: Cable Types And Lengths

    The contacts of the switch or relay must open/close within 200 ms of each other. ￭ Cable types and lengths • ABB recommends double-shielded twisted-pair cable. • Maximum cable lengths: • 300 m (1000 ft) between activation switch [K] and drive control unit •...

  • Page 127: Operation Principle

    The Safe torque off function 127 Operation principle The Safe torque off activates (the activation switch is opened, or safety relay contacts open). 2. The STO inputs of the drive control unit de-energize. 3. The control unit cuts off the control voltage from the output IGBTs. 4.

  • Page 128: Start-Up Including Validation Test

    128 The Safe torque off function Start-up including validation 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 a validation test. The test must be performed at initial start-up of the safety function 2.
  • Page 129 The Safe torque off function 129 Action 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. Make sure that the drive operates as follows: •...

  • Page 130: Use

    130 The Safe torque off function Open the activation switch, or activate the safety functionality that is wired to the STO connection. 2. The STO inputs on the drive control unit de-energize, and the control unit cuts off the control voltage from the output IGBTs. 3.
  • Page 131 The Safe torque off function 131 • 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.

  • Page 132: Maintenance

    If any wiring or component change is needed after start-up, or the parameters are restored, do the test given in section Validation test procedure (page 128). Use only spare parts approved by ABB. Record all maintenance and proof test activities in the machine logbook. ￭ Competence...

  • Page 133: Fault Tracing

    See the firmware manual of the drive control program 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.

  • Page 134: Safety Data

    134 The 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 applies only if both STO channels are used.
  • Page 135 The Safe torque off function 135...

  • Page 136: Terms And Abbreviations

    136 The Safe torque off function • 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 13849-2, table D.5). The analysis is based on an assumption that one failure occurs at one time.

  • Page 137: Tüv Certificate

    IEC 61508-6 Dangerous failure rate (per hour) of the diagnostics function of STO λ Diag_s IEC 61508-6 Safe failure rate (per hour) of the diagnostics function of STO ￭ TÜV certificate The TÜV certificate is available on the Internet at www.abb.com/drives/documents.

  • Page 138: Declarations Of Conformity

    138 The Safe torque off function ￭ Declarations of conformity...
  • Page 139 The Safe torque off function 139...
  • Page 140 140 The Safe torque off function...
  • Page 141 The Safe torque off function 141...

  • Page 143: 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 www.abb.com/searchchannels.
  • Page 144 3AXD50001017705 A © Copyright 2023 ABB. All rights reserved. Specifications subject to change without notice.

Table of Contents