ABB ACS280-04LC Series Hardware Manual

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ABB MACHINERY DRIVES

ACS280-04LC

Hardware manual

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Page 1 — ABB MACHINERY DRIVES ACS280-04LC Hardware manual...
Page 3 ACS280-04LC Hardware manual Table of contents 1. Safety instructions 4. Mechanical installation 6. Electrical installation 3AXD50001176129 Rev A EFFECTIVE: 2025-01-10...
Page 5: Table Of Contents
Table of contents 5 Table of contents 1 Safety instructions Contents of this chapter ............... . Use of warnings and notes .
Page 6 6 Table of contents 5 Guidelines for planning the electrical installation Contents of this chapter ............... . Limitation of liability .
Page 7 Table of contents 7 Implementing the control of a contactor between drive and motor ....Protecting the contacts of relay outputs ........... . 6 Electrical installation Contents of this chapter .
Page 8 8 Table of contents Energy efficiency data (ecodesign) ............Degrees of protection .
Page 9: Safety Instructions
Safety instructions 9 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 10 10 Safety instructions WARNING! Obey these instructions. If you ignore them, injury or death, or damage to the equipment can occur. • Keep the drive in its package until you install it. After unpacking, protect the drive from dust, debris and moisture. •...
Page 11: Electrical Safety In Installation, Start-Up And Maintenance
Safety instructions 11 Electrical safety in installation, start-up and maintenance Electrical safety precautions ￭ These electrical safety precautions are for all persons 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 12: Additional Instructions And Notes
12 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 are not a qualified electrical professional, do not do installation or maintenance work. •...
Page 13: General Safety In Operation
Safety instructions 13 • When you use shielded cables, make a 360° grounding of the cable shields at the cable entries to reduce electromagnetic emission and interference. • In a multiple-drive installation, connect each drive separately to the protective earth (PE) busbar of the power supply. General safety in operation These instructions are for all persons that operate the drive.
Page 14: Additional Instructions For Permanent Magnet Motor Drives
14 Safety instructions Additional instructions for permanent magnet motor drives Safety in installation, start-up, maintenance ￭ These are additional warnings for permanent magnet motor drives. The other safety instructions in this chapter are also valid. WARNING! Obey these instructions. If you ignore them, injury or death, or damage to the equipment can occur.
Page 15: Introduction To The Manual
Introduction to the manual 15 Introduction to the manual Contents of this chapter This chapter describes the intended audience and contents of the manual. It contains a flowchart of steps in examining the delivery, installing and commissioning the drive. The flowchart refers to chapters/sections in this manual and other manuals. Applicability This manual is applicable to ACS280-04LC drives.
Page 16 16 Introduction to the manual Task Identify the frame size: R1. Type designation key (page 22) Plan the installation. Electrical installa- tion (page 41) Examine the ambient conditions, ratings and required cooling air flow. Technical data (page 51) Unpack and examine the drive. Unpacking the deliv- ery (page 25) Grounding system compatib-...
Page 17: Terms And Abbreviations
Introduction to the manual 17 Terms and abbreviations Term Description Type of control unit Drive Frequency converter for controlling AC motors Electromagnetic compatibility Electromagnetic interference FEN-01 Optional TTL incremental encoder interface module FEN-11 Optional absolute encoder interface module FEN-21 Optional resolver interface module FEN-31 Optional HTL incremental encoder interface module FIO-11...
Page 18: Manuals On Internet
18 Introduction to the manual Manuals on internet You can find manuals on the Internet. See below for the relevant code/link. For more documentation, go to www.abb.com/drives/documents. ACS280 manuals...
Page 19: Operation Principle And Hardware Description
Operation principle and hardware description 19 Operation principle and hardware description Contents of this chapter This chapter briefly describes the operation principle and construction of the drive. Operation principle The ACS280-04LC is a drive for controlling asynchronous AC induction motors and permanent magnet synchronous motors.
Page 20: Layout
I1 ..31.2A IHd ..24.2A f2 ..0-598 Hz Pn ..7.5kW PHd ...5.5kW 20 Operation principle and hardware description IP20 ICC 65kA IEC(90;100)2.7% Layout SN: W2442A0001 Frame sizes R1 ￭ Front enclosure Input voltage lable Input power connection terminals Grounding hole for input power cables Motor connection terminal Type designation lable Cold configuration connection for CCA-...
Page 21: Drive Labels
Reforming capacitor of power stock age more than 1 year following section modules Type Description ABB provide standard drive startup service package. 400-810-8885 DPMP-01 Control panel mounting platform (flush mounting) and cable. DPMP-02 Control panel mounting platform (surface mounting) and cable.
Page 22: Type Designation Key
22 Operation principle and hardware description 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: ACS280-04LC-032A-2 Code Description ACS280 Product series 04LC Construction. 04=Drive module, IP00 032A Nominal current.
Page 23: Mechanical Installation
Mechanical installation 23 Mechanical installation Contents of this chapter This chapter tells you how to examine the installation site, examine the delivery, and mechanically install the drive. Installation alternatives you can install the drive onto a flat plate with screws. Installation requirements: •...
Page 24: Required Tools
24 Mechanical installation Required tools 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.
Page 25: Unpacking The Delivery
Mechanical installation 25 Unpacking the delivery The figure shows the drive package with its contents. Make sure that all of the items are present and that there are no signs of damage. Package contents: • Drives (Quantity of drives per package varies on different package type)
Page 26: Installing The Drive
26 Mechanical installation Installing the drive ACS280-04LC must be installed onto a suitable flat metallic surface.
Page 27: Guidelines For Planning The Electrical Installation
Limitation of liability The installation must always be designed and made according to applicable local laws and regulations. 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 28: Selecting The Main Contactor
28 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 29: Typical Power Cable Sizes
Guidelines for planning the electrical installation 29 Typical power cable sizes ￭ See the technical data in the appropriate hardware manual. Power cable types ￭ Preferred power cable types This section shows the preferred cable types. Make sure that the selected cable type also complies with local/state/country electrical codes.
Page 30: Not Allowed Power Cable Types
Symmetrical shielded cable with individual shields for each phase conductor 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).
Page 31: Metal Conduit
Guidelines for planning the electrical installation 31 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. Wiring method Notes 1) 2) Conduit - Metallic Electrical metallic tubing: Type EMT Prefer symmetrical shielded VFD cable.
Page 32: Grounding
￭ Only use shielded control cables. 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 33: Signals In Separate Cables
Relay cable ￭ The cable type with braided metallic shield (for example ÖLFLEX by LAPPKABEL, Germany) has been tested and approved by ABB. Control panel to drive cable ￭ Use EIA-485, Cat 5e (or better) cable with male RJ45 connectors. The maximum length of the cable is 100 m (328 ft).
Page 34: Signals In Separate Cables
34 Guidelines for planning the electrical installation Signals in separate cables ￭ Run analog and digital signals in separate, shielded cables. Do not mix 24 V DC and 115/230 V AC signals in the same cable. Signals that can be run in the same cable ￭...
Page 35: General Guidelines - North America
Guidelines for planning the electrical installation 35 The following figure illustrates the cable routing guidelines with an example drive. min. 300 mm (12 in) min. 300 mm (12 in) min. 500 mm (20 in) 90° min. 200 mm (8 in) min.
Page 36: The Motor Cable
36 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 37: Implementing Short-Circuit And Thermal Overload Protection
The drive protects the motor cable and motor in a short-circuit situation when: • the motor cable is sized correctly • the motor cable type complies with the motor cable selection guidelines by ABB • the cable length does not exceed the allowed maximum length specified for the drive •...
Page 38: Protecting The Motor Against Overload Without Thermal Model Or Temperature Sensors
38 Guidelines for planning the electrical installation The most common temperature sensor types are PTC or Pt100. For more information, see the firmware manual. Protecting the motor against overload without thermal model or ￭ temperature sensors Motor overload protection protects the motor against overload without using motor thermal model or temperature sensors.
Page 39: Protecting The Drive Against Ground Faults
69). 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 40: Protecting The Contacts Of Relay Outputs
40 Guidelines for planning the electrical installation Give a stop command to the drive. Wait until the drive decelerates the motor to zero speed. Open the contactor. WARNING! If vector motor control mode is in use, do not open the output contactor while the drive controls the motor.
Page 41: Electrical Installation
Electrical installation 41 Electrical installation Contents of this chapter This chapter describes how to: • Do an grounding system compatibility check • Change the EMC filter connection • Connect the power and control cables Warnings WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur.
Page 42: When To Disconnect The Emc Filter
42 Electrical installation WARNING! Do not install a drive with the internal EMC filter connected to a grounding system that the EMC filter is not compatible with (for example, an IT system). The supply network becomes connected to ground potential through the internal EMC filter capacitors, which can cause danger or damage to the drive.
Page 43: Identifying The Grounding System Of The Electrical Power Network
Electrical installation 43 Note: Not all ACS280-04LC drives have the EMC/VAR screw, check the product layout diagram for details. Identifying the grounding system of the electrical power network ￭ WARNING! Only a qualified electrical professional may do the work instructed in this section.
Page 44: Connecting The Power Cables
PE conductor. Motor cable. Note: ABB recommends to use a symmetrical shielded cable (VFD cable) as the motor cable. Separate PE cable (motor side). Use a separate grounding cable for the motor side, if the conduct- ivity of the shield is not sufficient, or if there is no symmetrically constructed PE conductor in the cable.
Page 45: Connecting The Control Cables
Electrical installation 45 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. Full configuration of the I/O wire harnesses ￭ Signals Descriptions Digital inputs and outputs...
Page 46: Control Cable Connection Procedure
46 Electrical installation Control cable connection procedure ￭ Do the connections according to the macro in use. Keep the signal wire pairs twisted as near to the terminals as possible to prevent inductive coupling. WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur.
Page 47: Installation Checklist
Installation checklist 47 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 48 48 Installation checklist Make sure that … The ambient operating conditions meet the drive ambient conditions specification and enclosure rating (IP code). The supply voltage matches the nominal input voltage of the drive. Refer the type designation label. The insulation resistance of the input power cable, motor cable and motor is measured according to local regulations and the manuals of the drive.
Page 49: 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 50 • Maintenance and component replacement intervals are based on the assumption that the equipment is operated within the specified ratings and ambient conditions. ABB recommends annual drive inspections to ensure the highest reliability and optimum performance. • Long term operation near the specified maximum ratings or ambient conditions may require shorter maintenance intervals for certain components.
Page 51: Technical Data
Technical data 51 Technical data Contents of this chapter This chapter contains the technical specifications of the drive including the ratings, sizes and technical requirements, provisions for fulfilling the requirements for CE, UL and other approval marks. Ratings IEC ratings ￭...
Page 52: Definitions
Typical motor power in heavy-duty use (50% overload) 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 53: Altitude Derating
Technical data 53 Altitude derating ￭ 1000...2000 m(or 4000m for some frame size) above sea level, the derating is 1% for every 100 m (330 ft). To calculate the output current, multiply the current in the rating table with the derating factor k, which for x meters (1000 m <= x <= 2000 m) is: Switching frequency derating ￭...
Page 54: Gg Fuses (Iec)
Make sure that the operating time of the fuse is less than 0.5 seconds. Obey the local regulations. Input Min. short-cir- Voltage current cuit current rating ACS280-04LC... ABB type 3-phase UN = 380...480 V (380, 400, 415, 440, 460, 480 V) -017A-4 2500 OFAFC000GG25 -025A-4 4000 OFAFC000GG32 -032A-4...
Page 55: Dimensions And Weights
Technical data 55 Dimensions and weights Dimensions Weight ACS280-04LC 8.39 12.32 83.5 3.29 117.5 4.63 15.15...
Page 56: Free Space Requirements
Hardware description 17 56 Technical data Free space requirements Frame size Above Below Left side Front 1.57 1.57 0.39 0.39 Losses, cooling data and noise Note: Power losses are given for nominal supply voltage, default switching frequency, and rated output current/power. Changing these factors may result in increased power losses.
Page 57: Terminal Data For The Power Cables
Technical data 57 Terminal data for the power cables The first table shows the terminal data in SI units. The second table shows the terminal data in imperial units. ACS280- U1, V1, W1, U2, V2, W2 terminals PE/ground terminals 04LC... Maximum Min (solid/stran- Max (sol-...
Page 58: Terminal Data For The Control Cables
ACS280-04LC-xxxx-4 drives: 3-phase 380 ... 480 V AC -15% ... +10% Network type Public low-voltage networks. Symmetrically grounded TN-S system, IT (un- grounded), corner-grounded delta. Consult ABB before connecting to other systems (for example, TT, or midpoint grounded delta). Rated conditional short- 65 kA when protected by fuses given in the fuse tables.
Page 59: Emc Compatibility And Motor Cable Length
Technical data 59 Frame Maximum motor cable length Standard drive, without external options With external output chokes 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 60: Energy Efficiency Data (Ecodesign)
The Safe torque off function (page 69) (SGND, S+, S1, S2) Energy efficiency data (ecodesign) Energy efficiency data according to IEC 61800-9-2 is available from the ecodesign tool (https://ecodesign.drivesmotors.abb.com/). Degrees of protection Degree of protection IP20 (cabinet installation): Standard enclosure. The drive must be installed in (IEC/EN 60529) a cabinet to fulfill the requirements for shielding from contact.
Page 61: Materials
Substances of Concern In articles as such or in complex objects (Products) established under the Waste Framework Directive (2008/98/EC). For further information, contact your local ABB distributor or consult European Chemicals Agency's SCIP database to find out which SVHCs are used in the drive, and to find out where those components are located.
Page 62: Applicable Standards
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...
Page 63: Compliance With En 61800-3
Category C1 ￭ If without extra measures, the ACS280-04LC drive do not compliance with EMC category C1. Contact ABB for more information. Category C2 ￭ This is applicable to ACS280-04LC-...-1 drives with an internal EMC C2 filter. The drive complies with the standard with the following provisions: The motor and control cables are selected as specified in this manual.
Page 64: Category C4
Medium voltage network Neighboring network Point of measurement Low voltage Equipment (victim) Equipment Supply transformer Static screen Drive An EMC plan for preventing disturbances is drawn up for the installation. A template is available from the local ABB representative.
Page 65: 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 theft of...
Page 67: Dimension Drawings
Dimension drawings 67 Dimension drawings Contents of this chapter The chapter contains the dimension drawings of the drive. The dimensions are in millimeters and inches.
Page 68: Frame R1
68 Dimension drawings Frame R1...
Page 69: The Safe Torque Off Function
The Safe torque off function 69 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 70: Chinery (Safety) Regulations
70 The Safe torque off function Standard Name IEC 61326-3-1:2017 Electrical equipment for measurement, control and laboratory use – EMC requirements – Part 3-1: Immunity requirements for safety-re- lated 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 –...
Page 71: Wiring
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 72: Operation Principle
72 The Safe torque off function Operation principle The Safe torque off activates (the activation switch is opened, or safety relay contacts open). The STO inputs of the drive control unit de-energize. The control unit cuts off the control voltage from the output IGBTs. The control program generates an indication as defined by parameter 31.22 (refer the firmware manual of the drive).
Page 73: Start-Up Including Validation Test
The Safe torque off function 73 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 after any changes related to the safety function (circuit boards, wiring, components, settings, replacement of inverter module, etc.)
Page 74 74 The Safe torque off function Action Test the operation of the STO function when the motor is running. • Start the drive and make sure 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 (see the firmware manual).
Page 75: Use
The Safe torque off function 75 Open the activation switch, or activate the safety functionality that is wired to the STO connection. The STO inputs on the drive control unit de-energize, and the control unit cuts off the control voltage from the output IGBTs. The control program generates an indication as defined by parameter 31.22 (refer the firmware manual of the drive).
Page 76: 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 73). Use only spare parts approved by ABB. Record all maintenance and proof test activities in the machine logbook. Competence ￭...
Page 77: Fault Tracing
Refer 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 78: Safety Data
78 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 79 The Safe torque off function 79...
Page 80: Terms And Abbreviations
80 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 81: Tüv Certificate
The Safe torque off function 81 Term or Reference Description abbreviation EN ISO 13849-1 Mission time: the period of time covering the intended use of the safety function/device. After the mission time elapses, the safety device must be replaced. Note that any T values given cannot be regarded as a guarantee or warranty.
Page 83: 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/contact-centers.

This manual is also suitable for:

Acs280-04lc-017a-4 Acs280-04lc-025a-4 Acs280-04lc-032a-4 Acs280-04lc-032a-2 Acs280-04lc-048a-2 Acs280-04lc-055a-2