Page 1 — ABB MACHINERY DRIVES ACS380 drives Hardware manual...
Page 3 ACS380 drives Hardware manual Table of contents 1. Safety instructions 4. Mechanical installation 6. Electrical installation – IEC 7. Electrical installation – North America 3AXD50000029274 Rev G Original instructions EFFECTIVE: 2024-04-10...
Page 5: Table Of Contents
Table of contents 5 Table of contents 1 Safety instructions Contents of this chapter ..................Use of warnings and notes ..................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 ....................Basic code ......................Option codes ...................... Control panel ......................Home view ......................Status icons ................... Message view ..................... Options view ...................... Menu ........................4 Mechanical installation Contents of this chapter ..................Installation alternatives ..................
Page 7 Table of contents 7 Signals that can be run in the same cable ............ Relay cable ......................Control panel to drive cable ................PC tool cable ...................... Routing the cables ....................General guidelines – IEC ................... General guidelines – North America .............. Continuous motor cable shield/conduit and metal enclosure for equipment on the motor cable ...............
Page 8 Connecting the power cables – IEC (shielded cables) ........Connection diagram ..................Connection procedure ..................Connecting the control cables - IEC ..............Default I/O connection diagram (ABB standard macro) ......Fieldbus connection diagram ................. Control cable connection procedure ............. Additional information on the control connections ........
Page 9 Table of contents 9 Connecting the control cables - North America ..........Default I/O connection diagram (ABB standard macro) ......Fieldbus connection diagram ................. Control cable connection procedure ............. Additional information on the control connections ........Embedded EIA-485 fieldbus connection ..........
Page 10 10 Table of contents Definitions ......................Sizing ........................Output derating ......................Surrounding air temperature derating ............Altitude derating ....................Switching frequency derating ................ Derating in case of a phase loss ..............Fuses ........................... IEC fuses ......................gG fuses ....................gR fuses ....................UL (NEC) fuses ....................
Page 11 Table of contents 11 Markings ........................Compliance with the harmonic current limits in a public network (IEC/EN 61000 3-2, IEC/EN 61000-3-12) ................3-phase 230 V, 400 V or 480 V drive with the input choke ....... 3-phase 230 V, 400 V or 480 V drive without the input choke ....1-phase 230 V drive with or without the input choke ........
Page 12 12 Table of contents Frame R2, 3-phase 230 V and 400/480 V, UL Type 1, with side option ... Frame R3 ........................Frame R3, 3-phase 230 V and 400/480 V, IP20 ........... Frame R3, 3-phase 230 V and 400/480 V, IP20, with side option ... Frame R3, 3-phase 230 V and 400/480 V, UL Type 1 ........
Page 13 Table of contents 13 Electrical installation ..................Measuring the insulation ..............Connecting power cables ..............Connection the control cables ............Start-up ........................15 The Safe torque off function Contents of this chapter ..................Description ........................ Compliance with the European Machinery Directive and the UK Supply of Machinery (Safety) Regulations ..............
Page 14 14 Table of contents Mechanical installation .................... Electrical installation ....................Wiring – General ....................Terminal designations ................. Wiring – Encoder power supply interface ............ Wiring – Encoder ....................Phasing ....................Encoder output types ................Wiring diagrams – Push-pull type encoder output ......Differential connection ................
Page 15 Table of contents 15 Technical data ......................Resolver interface ..................... Resolver type ..................Resolver interface connectors (X103, X104) ........Resolver cable ..................Power supply connection (X105) ............Back-up power supply for the drive .............. Internal connectors ................... Dimensions ......................18 BREL-01 relay output extension module Contents of this chapter ..................
Page 16 16 Table of contents Further information...
Page 17: Safety Instructions
Safety instructions 17 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 18: General Safety In Installation, Start-Up And Maintenance
18 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 19 Safety instructions 19 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 20: Electrical Safety In Installation, Start-Up And Maintenance
20 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 21: Additional Instructions And Notes
Safety instructions 21 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 22: Grounding
22 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 23: General Safety In Operation
Safety instructions 23 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 24: Safety In Operation
24 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 25: Introduction To The Manual
Introduction to the manual 25 Introduction to the manual Contents of this chapter The chapter describes the applicability, target audience and purpose of the manual. The chapter contains a list of related manuals and a flowchart for installation and commissioning. Applicability This manual is applicable to ACS380 drives.
Page 26: Quick Installation And Commissioning Flowchart
26 Introduction to the manual Quick installation and commissioning flowchart Task Identify the frame size: R0, R1, R2, etc. Type designation key (page 39) Plan the installation. Guidelines for planning the electrical installa- tion (page 53) Check the ambient conditions, ratings and required cooling air flow.
Page 27 Introduction to the manual 27 Task Refer to ACS380 Quick installation and start- Commission the drive. up guide (3AXD50000018553 [English]) ACS380 Firmware manual (3AXD50000029275 [English]).
Page 28: Terms And Abbreviations
28 Introduction to the manual Terms and abbreviations Term Description ACS-AP-I Industrial assistant non-Bluetooth control panel ACS-AP-S Standard assistant control panel ACS-AP-W Industrial assistant control panel with Bluetooth interface ACS-BP-S Basic control panel BAPO Optional auxiliary power extension module BCAN Optional CANopen®...
Page 29: Related Manuals
Safety integrity level (1…3) (IEC 61508, IEC 62061, IEC 61800-5-2) Safe torque off (IEC/EN 61800-5-2) Related manuals You can find manuals on the Internet. See below for the relevant code/link. For more documentation, go to www.abb.com/drives/documents. ACS380 manuals link list...
Page 31: Operation Principle And Hardware Description
This chapter briefly describes the operation principle and construction of the drive. Operation principle The ACS380 is a drive for controlling asynchronous AC induction motors, permanent magnet synchronous motors and ABB synchronous reluctance motors (SynRM motors). The drive is optimized for cabinet installation.
Page 32: Simplified Main Circuit Diagram
32 Operation principle and hardware description ￭ Simplified main circuit diagram T1/U T2/V T3/W UDC+ UDC- Rectifier. Converts alternating current and voltage to direct current and voltage. DC link. DC circuit between rectifier and inverter. Inverter. Converts direct current and voltage to alternating current and voltage. Brake chopper.
Page 33: Layout
Operation principle and hardware description 33 Layout Front option modules PE connection (motor) Input power terminals Control panel, display and status LED Motor and brake resistor terminals Control terminals Cooling fan (on frames R1…R4) Front option slot Panel and PC tool port (RJ45) Cold configuration connection for CCA-01 Model information label...
Page 34: Control Connections
34 Operation principle and hardware description Control connections In addition to the fixed control connections in the base unit, the other control connections depend on the drive variant. ￭ Standard variant (I/O and Modbus) (ACS380-04xS) The standard variant has a type code as follows: ACS380-04xS. It is supplied with the BMIO-01 I/O and Modbus extension module.
Page 35: Configured Variant (Acs380-04Xc)
Operation principle and hardware description 35 ￭ Configured variant (ACS380-04xC) The configured variant has a type code as follows: ACS380-04xC followed by an option code that indicates the extension module. Use the configured variant to order a product with a specific fieldbus extension module. Connections: 1.
Page 36: Base Variant (Acs380-04Xn)
36 Operation principle and hardware description ￭ Base variant (ACS380-04xN) The base variant has a type code as follows: ACS380-04xN. It is supplied without an extension module. Connections: 1. Auxiliary voltage outputs 2. Digital inputs 3. Safe torque off connections 4.
Page 37: Control Panel Options
Operation principle and hardware description 37 You can use I/O option modules to increase the number of inputs and outputs on the drive. The table shows a comparison between the base unit and different option modules. Base unit BMIO-01 BIO-01 BREL-01 (ACS380-04xx) (ACS380-04xS)
Page 38: Ul Type 1 Kits
38 Operation principle and hardware description In addition, you can order a control panel platform for cabinet door installation. These panel platforms are available: Type Description DPMP-01 Control panel mounting platform (flush mounting) and cable DPMP-02 Control panel mounting platform (surface mounting) and cable UL Type 1 kits There are UL Type 1 kit options available for the drive.
Page 39: Type Designation Label
Operation principle and hardware description 39 Drive type Frame size and ratings Serial number QR code to register the drive ￭ Type designation label Type designation Frame (size) Nominal ratings Valid markings Degree of protection Losses according to IEC 61800-9-2 S/N: Serial number of format MYYWWXXXXX, where M: Manufacturer YY: Year of manufacture: 19, 20, 21, …...
Page 40: Option Codes
40 Operation principle and hardware description Code Description ACS380 Product series 042S Construction: • 04 = Module. When there are no options selected: module optimized for cabinet installa- tion, degree of protection IP20 (UL open type), bottom cable entry, Safe torque off, brake chopper, coated boards, quick installation and start-up guide, user interface guide and safety instructions.
Page 41 Operation principle and hardware description 41 Code Description K490 FEIP-21 EtherNet/IP K491 FMBT-21 Modbus/TCP K492 FPNO-21 PROFINET IO K495 BCAN-11 CANopen L511 BREL-01 External relay option (4x relay) (side option) L515 BIO-01 I/O extension module (front option, can be used together with fieldbus) L516 BRES-01 resolver interface module (side option) L534...
Page 42: Control Panel
42 Operation principle and hardware description Code Description R708 Spanish R709 Portuguese (Portugal) R711 Russian R712 Chinese R713 Polish R714 Turkish 1) The option code determines the language variants of the hardware manual and firmware manual delivered as printed with the drive. The product package includes the user interface guide and quick installation and start-up guide in English, French, German, Italian and Spanish, and in the local language (if available).
Page 43: Home View
Operation principle and hardware description 43 Display (Home view): a) Control location: local or remote b) Status icons c) Reference target value d) Actual measured value e) Left and right softkey actions Back key (opens the Options view in the Home view) OK key (opens the Menu in the Home view) Arrow keys (menu navigation and setting values) Stop key (when the drive is locally controlled)
Page 44: Status Icons
44 Operation principle and hardware description Status icons Icon Animation Description None Local Start/Stop enabled None Stopped None Stopped, start inhibited Blinks Stopped, start commanded but inhibited Rotates Running at reference Rotates Running but not at reference Blinks Running at reference, but reference = 0 Blinks Drive fault None...
Page 45: Menu
Operation principle and hardware description 45 • Set the reference • View the active fault • View a list of the active warnings. ￭ Menu To open the Menu, push the OK key in the Home view. To navigate in the Menu, push the up and down arrow keys to move between menu items.
Page 47: Mechanical Installation
Mechanical installation 47 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. Installation alternatives You can install the drive: • with screws on to a wall •...
Page 48: Examining The Installation Site
48 Mechanical installation • You can install frames R1, R2, R3 and R4 tilted to a maximum of 90 degrees, from vertical to fully horizontal orientation. • Do not install the drive upside down. • Make sure that the hot exhaust air from a drive does not flow into the cooling inlet of other drives or equipment.
Page 49: Unpacking The Delivery
Mechanical installation 49 Unpacking 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: • drive • options, if ordered with an option code •...
Page 50: To Install The Drive To A Din Installation Rail
50 Mechanical installation 5. Put the drive onto the mounting screws. 6. Tighten the mounting screws. ￭ To install the drive to a DIN installation rail Use an IEC/EN 60715 top hat type installation rail, width × height = 35 × 7.5 mm (1.4 ×...
Page 51 Mechanical installation 51 6. Move the locking part to the right. 7. Make sure that the drive is correctly installed. To remove the drive, use a flat-head screwdriver to open the locking part.
Page 53: 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 54: Selecting The Main Contactor
Checking the compatibility of the motor and drive Use asynchronous AC induction motor, permanent magnet synchronous motor or ABB synchronous reluctance motor (SynRM motors) with the drive. Multiple induction motors can be connected to the drive at a time when using the scalar motor control mode.
Page 55: Selecting The Power Cables
Guidelines for planning the electrical installation 55 Selecting the power cables ￭ General guidelines Select the input power and motor cables according to local regulations. • Current: Select a cable capable of carrying the maximum load current and suitable for the prospective short-circuit current provided by the supply network.
Page 56: Power Cable Types
56 Guidelines for planning the electrical installation ￭ 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. Cable type Use as input power cabling Use as motor cabling and as brake resistor cabling Symmetrical shielded (or ar-...
Page 57: Alternate Power Cable Types
Guidelines for planning the electrical installation 57 Alternate power cable types Cable type Use as input power cabling Use as motor cabling and as brake resistor cabling Yes with phase conductor Yes with phase conductor smaller than 10 mm 2 (8 AWG) smaller than 10 mm 2 (8 AWG) Cu, or motors up to 30 kW (40 hp).
Page 58: 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 59: Metal Conduit
Guidelines for planning the electrical installation 59 Wiring method Notes Free air Prefer symmetrical shielded VFD cable. Enclosures, air handlers, etc. Allowed internally in enclosures when in ac- cordance with UL. 1) Metallic conduit may be used as an additional ground path, provided this path is a solid path capable of handling ground currents.
Page 60: Grounding Requirements
60 Guidelines for planning the electrical installation Insulation jacket Helix of copper tape or copper wire Copper wire shield Inner insulation Cable core Grounding requirements This section gives general requirements for grounding the drive. When you plan the grounding of the drive, obey all the applicable national and local regulations. The conductivity of the protective earth conductor(s) must be sufficient.
Page 61: Additional Grounding Requirements - Iec
Guidelines for planning the electrical installation 61 earth conductor must be determined in a manner which produces a conductance equivalent to that which results from the application of this table. Cross-sectional area of the phase conduct- Minimum cross-sectional area of the corres- ponding protective earth conductor S (mm 2 ) S p (mm 2 )
Page 62: Additional Grounding Requirements - Ul (Nec)
Shielding 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 63: Relay Cable
￭ 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 RJ-45 connectors. The maximum length of the cable is 100 m (328 ft).
Page 64: General Guidelines - North America
64 Guidelines for planning the electrical installation min. 300 mm (12 in) min. 300 mm (12 in) min. 500 mm (20 in) 90° min. 200 mm (8 in) min. 500 mm (20 in) Motor cable Input power cable Control cable Brake resistor or chopper cable (if any) ￭...
Page 65: Continuous Motor Cable Shield/Conduit And Metal Enclosure For Equipment On The Motor Cable
Guidelines for planning the electrical installation 65 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 66: Separate Control Cable Ducts
66 Guidelines for planning the electrical installation ￭ 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 67: Protecting The Drive, And The Input Power And Motor Cables Against Thermal Overload
Guidelines for planning the electrical installation 67 ￭ 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 68: Implementing A Motor Temperature Sensor Connection
68 Guidelines for planning the electrical installation Implementing a 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 69: Implementing The Safe Torque Off Function
233). 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 70 70 Guidelines for planning the electrical installation inductively to other conductors in the control cable and form a risk of malfunction in other parts of the system. Install the protective component as close to the inductive load as possible. Do not install protective components at the relay outputs.
Page 71: Electrical Installation - Iec
Electrical installation – IEC 71 Electrical installation – IEC Contents of this chapter This chapter describes how to: • measure the insulation • do the grounding system compatibility check • change the EMC filter or ground-to-phase varistor connection • connect the power and control cables •...
Page 72: Measuring The Insulation Resistance - Iec
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 73: Measuring The Insulation Resistance Of The Brake Resistor Circuit
Electrical installation – IEC 73 ￭ Measuring the insulation resistance of the brake resistor circuit 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 74: Ground-To-Phase Varistor
74 Electrical installation – IEC 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 75 Electrical installation – IEC 75 variant. Before you connect the drive to the input power, examine the screws and do the necessary actions shown in the table. Screw Screw material When to remove EMC screw or VAR screw label Symmetrically Corner-grounded IT systems (un- grounded TN-S sys-...
Page 76: Disconnecting The Emc Filter Or Ground-To-Phase Varistor
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 77: Identifying The Grounding System Of The Electrical Power Network
Electrical installation – IEC 77 ￭ Identifying the grounding system of the electrical power network WARNING! Only a qualified electrical professional may do the work instructed in this section. Depending on the installation site, the work may even be categorized as live working.
Page 78: Connecting The Power Cables - Iec (Shielded 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 conductivity of the shield is not sufficient, or if there is no symmetrically con- structed PE conductor in the cable.
Page 79: Connection Procedure
Electrical installation – IEC 79 ￭ 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 80: Connecting The Control Cables - Iec
Connecting the control cables - IEC Before you connect the control cables, make sure that all option modules are installed. ￭ Default I/O connection diagram (ABB standard macro) This connection diagram is valid for drives with the BMIO-01 I/O & Modbus extension module: •...
Page 81 Electrical installation – IEC 81 • Configured variant (ACS380-04xC) with the BMIO-01 I/O & Modbus extension module (option +L538) Connection Term. Description Digital I/O and relay output connections +24V Aux. voltage output +24 V DC, max. 250 mA × +24V DGND Aux.
Page 82: Fieldbus Connection Diagram
82 Electrical installation – IEC Connection Term. Description EIA-485 Modbus RTU Embedded Modbus RTU (EIA-485) BGND BGND Shield Shield Termina- tion & bi- 1) × = base unit, empty = BMIO-01 module Note: This note is applicable to BMIO-01 option module (material code: 3AXD50000021262), revision D or earlier.
Page 83: Control Cable Connection Procedure
Electrical installation – IEC 83 Connection Term. Description Digital I/O and relay output connections +24V Aux. voltage output +24 V DC, max. 250 mA +24V DGND Aux. voltage output common DGND DCOM DCOM Digital input common Fault reset (operates also through the fieldbus inter- face) Not configured Relay output 1...
Page 84: Additional Information On The Control Connections
84 Electrical installation – IEC 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 85 Electrical installation – IEC 85 Connect the cable to the EIA-485 terminal on the BMIO-01 I/O module. Obey these wiring instructions: • Attach the cable shields together at each drive, but do not connect them to the drive. • Connect the cable shields only to the grounding terminal in the automation controller.
Page 86: Pnp Configuration For Digital Inputs
86 Electrical installation – IEC PNP configuration for digital inputs Internal and external +24 V power supply connections for PNP (source) configuration are shown in the figures below. WARNING! If you connect DIO1 or DIO2 as shown in the figures below, make sure that they are configured as inputs.
Page 87: Npn Configuration For Digital Inputs
Electrical installation – IEC 87 NPN configuration for digital inputs Internal and external +24 V power supply connections for NPN (sink) configuration are shown in the figures below. WARNING! If you connect DIO1 or DIO2 as shown in the figures below, make sure that they are configured as inputs.
Page 88: Ai And Ao (Or Ai, Di And +10 V) As Ptc Motor Temperature Sensor Interface
88 Electrical installation – IEC OUT (0)4…20 mA AGND +24V DGND Process actual value measurement or reference, 0(4)…20 mA, R in = 137 ohm AGND +24V Auxiliary voltage output, non-isolated, +24 V DC, max. 250 mA DGND AI and AO (or AI, DI and +10 V) as PTC motor temperature sensor interface WARNING! IEC 61800-5-1 requires double or reinforced insulation between live parts and accessible parts when:...
Page 89 Electrical installation – IEC 89 AGND AGND Motor winding Double or reinforced insulation 1…3 PTC sensors Analog input. Set the analog input type to V (volt) in parameter group 12 Standard AI. Define the temperature sensor type, signal source, etc. with parameters 35.11…35.24. For the sensor type, select: PTC analog I/O.
Page 90: Ai1 And Ai2 As Pt100, Pt1000, Ni1000, Kty83 And Kty84 Sensor Inputs
90 Electrical installation – IEC +10 V DGND DCOM 1…3 PTC sensors Double or reinforced insulation Motor winding Digital input and analog input. Set the analog input type to V (volt) in parameter group 12 Standard AI. Define the temperature sensor type, signal source, etc. with parameters 35.11…35.24.
Page 91: Safe Torque Off
Electrical installation – IEC 91 See the firmware manual for information on the related Motor thermal protection function. AGND AGND Motor winding Double or reinforced insulation 1…3 × (Pt100 or Pt1000) or 1 × (Ni1000 or KTY83 or KTY84) Analog input. Set the analog input type to V (volt) in parameter group 12 Standard AI. Define the temperature sensor type, signal source, etc.
Page 92: Connecting A Pc
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 93: Installing A Front Option
Electrical installation – IEC 93 • Side option: Multifunction extension module slot on the side of the drive. Refer also to the applicable fieldbus module manual for the installation instructions. For other option modules, refer to: • BTAC-02 pulse encoder interface module (page 255) •...
Page 94: Installing A Side Option
94 Electrical installation – IEC 5. Torque the screw to 0.5 N·m (4.4 lbf·in). 6. If the option module has a locking tab, push it down until it locks. 7. Connect the control cables. See the control cable connection instructions. Note: If you have the BIO-01 option module, you can add one additional fieldbus module on top of it.
Page 95 Electrical installation – IEC 95 4. Fully push the option module into position. 5. Torque the screw on the option module to 1 N·m (8.8 lbf·in). 6. Attach the grounding bar to the bottom of the side option and to the front ground tab on the drive.
Page 97: Electrical Installation - North America
Electrical installation – North America 97 Electrical installation – North America Contents of this chapter This chapter describes how to: • measure the insulation • do the grounding system compatibility check • change the EMC filter or ground-to-phase varistor connection •...
Page 98: Measuring The Insulation Resistance - North America
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 99: Measuring The Insulation Resistance Of The Brake Resistor Circuit
Electrical installation – North America 99 U1-PE, V1-PE, W1-PE 1000 V DC, > 100 Mohm ￭ Measuring the insulation resistance of the brake resistor circuit 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 100: Ground-To-Phase Varistor
100 Electrical installation – North America If you are concerned with EMC issues, and install the drive to a symmetrically grounded TN-S system (center-grounded wye), you can connect the internal EMC filter. See Disconnecting the ground-to-phase varistor, or connecting the EMC filter (page 102).
Page 101 Electrical installation – North America 101 variant. Before you connect the drive to the input power, examine the screws and do the necessary actions shown in the table. Screw Screw material When to remove EMC screw or VAR screw label Symmetrically Corner-grounded IT systems (un-...
Page 102: Disconnecting The Ground-To-Phase Varistor, Or Connecting The Emc Filter
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 103: Identifying The Grounding System Of The Electrical Power Network
Electrical installation – North America 103 ￭ Identifying the grounding system of the electrical power network WARNING! Only a qualified electrical professional may do the work instructed in this section. Depending on the installation site, the work may even be categorized as live working.
Page 104: Connecting The Power Cables - North America (Wiring In Conduits)
￭ Connection diagram UDC- UDC+ Drive Drive enclosure Supply disconnecting device and fuses Input power wiring Protective earth (ground) conductor(s) Motor wiring Note: ABB recommends to use a symmetrical shielded cable (VFD cable) as the motor cable. Brake resistor (optional)
Page 105: Connection Procedure
Electrical installation – North America 105 ￭ 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 106 106 Electrical installation – North America 8. Connect the phase conductors of the motor wiring to terminals T1/U, T2/V and T3/W. 9. If you use a brake resistor, connect the brake resistor conductors to terminals R- and UDC+. 10. Make sure that the R- and UDC+ terminal screws are tightened. Do this step also if you do not connect cables to the terminals.
Page 107: Connecting The Control Cables - North America
Connecting the control cables - North America Before you connect the control cables, make sure that all option modules are installed. ￭ Default I/O connection diagram (ABB standard macro) This connection diagram is valid for drives with the BMIO-01 I/O & Modbus extension module: •...
Page 108 108 Electrical installation – North America Connection Term. Description Digital I/O and relay output connections +24V Aux. voltage output +24 V DC, max. 250 mA × +24V DGND Aux. voltage output common × DGND DCOM DCOM Digital input common × Stop (0) / Start (1) ×...
Page 109: Fieldbus Connection Diagram
Electrical installation – North America 109 Connection Term. Description EIA-485 Modbus RTU Embedded Modbus RTU (EIA-485) BGND BGND Shield Shield Termina- tion & bi- 1) × = base unit, empty = BMIO-01 module Note: This note is applicable to BMIO-01 option module (material code: 3AXD50000021262), revision D or earlier.
Page 110: Control Cable Connection Procedure
110 Electrical installation – North America Connection Term. Description Digital I/O and relay output connections +24V Aux. voltage output +24 V DC, max. 250 mA +24V DGND Aux. voltage output common DGND DCOM DCOM Digital input common Fault reset (operates also through the fieldbus inter- face) Not configured Relay output 1...
Page 111: Additional Information On The Control Connections
Electrical installation – North America 111 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 112 112 Electrical installation – North America Connect the cable to the EIA-485 terminal on the BMIO-01 I/O module. Obey these wiring instructions: • Attach the cable shields together at each drive, but do not connect them to the drive. • Connect the cable shields only to the grounding terminal in the automation controller.
Page 113: Pnp Configuration For Digital Inputs
Electrical installation – North America 113 PNP configuration for digital inputs Internal and external +24 V power supply connections for PNP (source) configuration are shown in the figures below. WARNING! If you connect DIO1 or DIO2 as shown in the figures below, make sure that they are configured as inputs.
Page 114: Npn Configuration For Digital Inputs
114 Electrical installation – North America NPN configuration for digital inputs Internal and external +24 V power supply connections for NPN (sink) configuration are shown in the figures below. WARNING! If you connect DIO1 or DIO2 as shown in the figures below, make sure that they are configured as inputs.
Page 115: Ai And Ao (Or Ai, Di And +10 V) As Ptc Motor Temperature Sensor Interface
Electrical installation – North America 115 OUT (0)4…20 mA AGND +24V DGND Process actual value measurement or reference, 0(4)…20 mA, R in = 137 ohm AGND +24V Auxiliary voltage output, non-isolated, +24 V DC, max. 250 mA DGND AI and AO (or AI, DI and +10 V) as PTC motor temperature sensor interface WARNING! IEC 61800-5-1 requires double or reinforced insulation between live parts and accessible parts when:...
Page 116 116 Electrical installation – North America AGND AGND Motor winding Double or reinforced insulation 1…3 PTC sensors Analog input. Set the analog input type to V (volt) in parameter group 12 Standard AI. Define the temperature sensor type, signal source, etc. with parameters 35.11…35.24. For the sensor type, select: PTC analog I/O.
Page 117: Ai1 And Ai2 As Pt100, Pt1000, Ni1000, Kty83 And Kty84 Sensor Inputs
Electrical installation – North America 117 +10 V DGND DCOM 1…3 PTC sensors Double or reinforced insulation Motor winding Digital input and analog input. Set the analog input type to V (volt) in parameter group 12 Standard AI. Define the temperature sensor type, signal source, etc. with parameters 35.11…35.24.
Page 118: Safe Torque Off
118 Electrical installation – North America See the firmware manual for information on the related Motor thermal protection function. AGND AGND Motor winding Double or reinforced insulation 1…3 × (Pt100 or Pt1000) or 1 × (Ni1000 or KTY83 or KTY84) Analog input.
Page 119: Connecting A Pc
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 120: Installing A Front Option
120 Electrical installation – North America • Side option: Multifunction extension module slot on the side of the drive. Refer also to the applicable fieldbus module manual for the installation instructions. For other option modules, refer to: • BTAC-02 pulse encoder interface module (page 255) •...
Page 121: Installing A Side Option
Electrical installation – North America 121 5. Torque the screw to 0.5 N·m (4.4 lbf·in). 6. If the option module has a locking tab, push it down until it locks. 7. Connect the control cables. See the control cable connection instructions. Note: If you have the BIO-01 option module, you can add one additional fieldbus module on top of it.
Page 122 122 Electrical installation – North America 4. Fully push the option module into position. 5. Torque the screw on the option module to 1 N·m (8.8 lbf·in). 6. Attach the grounding bar to the bottom of the side option and to the front ground tab on the drive.
Page 123: Installation Checklist
Installation checklist 123 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 124 124 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 125 Installation checklist 125 Make sure that … The control cables are connected to the correct terminals, and the terminals are tightened to the correct torque. If a drive bypass connection will be used: The direct-on-line contactor of the motor and the drive output contactor are either mechanically and/or electrically interlocked, that is, they cannot be closed at the same time.
Page 127: Maintenance
Contents of this chapter The chapter contains maintenance intervals and instructions. Maintenance intervals The tables below show the maintenance tasks which can be done by the end user. For ABB Service offering, refer to www.abb.com/drivesservices or consult your local ABB Service representative (www.abb.com/searchchannels).
Page 128: Functional Safety Components
• 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 129: Cleaning The Heatsink
The remaining mission time of the whole circuit is however determined by its oldest component. Contact your local ABB service representative for more information. Cleaning the heatsink The drive module heatsink fins pick up dust from the cooling air. The drive runs into overtemperature warnings and faults if the heatsink is not clean.
Page 130: Replacing The Cooling Fan, Frames R1
130 Maintenance You can get replacement fans from ABB. Use only ABB specified spare parts. ￭ Replacing the cooling fan, frames R1…R3 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 131 Maintenance 131 7. Install the new fan into the fan cover. Make sure that the air flow is in the correct direction. The air flows in from the bottom of the drive and out from the top of the drive. 8.
Page 132: Replacing The Cooling Fan, Frame R4
132 Maintenance ￭ Replacing the cooling fan, frame R4 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 133: Capacitors
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 135: Technical Data
Technical data 135 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. Electrical ratings ￭ IEC ratings Type Input current...
Page 136 136 Technical data Type Input current Output ratings Frame ACS380- size With Max. Nominal use Light-duty Heavy-duty 04xx-… choke choke cur- rent I 1n I 1n I max I Ld P Ld I Hd P Hd 12A2-1 25.6 21.1 17.6 12.2 11.6 3-phase U n = 230 V...
Page 137: Ul (Nec) Ratings
Technical data 137 Type Input current Output ratings Frame ACS380- size With Max. Nominal use Light-duty Heavy-duty 04xx-… choke choke cur- rent I 1n I 1n I max I Ld P Ld I Hd P Hd 032A-4 40.7 32.0 45.0 32.0 15.0 30.5...
Page 138: Ul Listed Multiple Drive Ratings
138 Technical data Type Input current Output ratings Frame ACS380- size With Max. Light-duty use Heavy-duty use 04xx-… choke choke current I 1Ld I 1Ld I max I Ld P Ld I Hd P Hd 17A5-2 21.0 16.7 22.0 16.7 11.6 25A0-2 30.5...
Page 139: Definitions
In these situations, power distribution components are often oversized to comply with NEC requirements. ABB has collaborated with Underwriters Laboratories (UL) to create multiple drive ratings from 50% to 100% in 5% increments for the drive. For more information,...
Page 140: Sizing
140 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 ) (50% for drive type ACS380-04xx-01A8-4).
Page 141 Technical data 141 Example 1, UL (NEC): How to calculate the derated current The drive type is ACS380-04xx-17A0-4, which has light-duty output current ( I ) of 14 A at 480 V. Calculate the derated output current at 4 kHz switching frequency, at 6000 ft altitude and at 131 °F surrounding air temperature.
Page 142: Surrounding Air Temperature Derating
142 Technical data Altitude derating: The derating factor for 5500 ft is Surrounding air temperature derating: Derating is not necessary at 95 °F surrounding air temperature. To see if the derated output current of a drive is sufficient for the application, multiply the drive output current for light-duty use ( I ) by all the applicable derating factors.
Page 143: Switching Frequency Derating
Technical data 143 400/480 V drives: At altitudes 1000 … 4000 m (3281 … 13123 ft) above sea level, the derating is 1% for each added 100 m (328 ft) above 1000 m (3281 ft). In addition: • A maximum altitude of 4000 m (13123 ft) is permitted for these grounding systems: TN-S, TT.
Page 144 144 Technical data Type Derating factor ACS380- < 4 kHz 8 kHz 12 kHz 04xx-… 09A8-1 0.85 0.74 12A2-1 0.82 0.69 3-phase U n = 230 V 02A4-2 0.84 0.73 03A7-2 0.84 0.73 04A8-2 0.84 0.73 06A9-2 0.84 0.73 07A8-2 0.83 0.70 09A8-2...
Page 145: Derating In Case Of A Phase Loss
Type Fuses Min. ACS380- short-cir- 04xx-… Nominal Voltage cuit cur- I 2 t IEC 60269 current rating rent ABB type size A 2 s 1-phase U n = 230 V 02A4-1 OFAF000H10 03A7-1 OFAF000H10 04A8-1 OFAF000H16 06A9-1 1500 OFAF000H20...
Page 146 Type Fuses Min. ACS380- short-cir- 04xx-… Nominal Voltage I 2 t cuit cur- IEC 60269 current rating rent ABB type size A 2 s 07A8-1 2500 OFAF000H25 09A8-1 2500 OFAF000H32 12A2-1 7000 OFAF000H35 3-phase U n = 230 V 02A4-2...
Page 147: Gr Fuses
Technical data 147 Type Fuses Min. ACS380- short-cir- 04xx-… Nominal Voltage I 2 t cuit cur- IEC 60269 current rating rent ABB type size A 2 s 033A-4 20000 OFAF000H63 032A-4 20000 OFAF000H63 038A-4 36000 OFAF000H80 045A-4 65000 OFAF000H100 050A-4...
Page 148: Ul (Nec) Fuses
148 Technical data Type Fuses Min. ACS380- short-cir- 04xx-… Nominal Voltage I 2 t cuit cur- IEC 60269 current rating rent Bussmann type size A 2 s 25A0-2 3600 170M2699 033A-2 6650 170M2700 032A-2 6650 170M2700 048A-2 22500 170M2702 055A-2 22500 170M2702 3-phase U n = 400 V...
Page 149 Technical data 149 Type Fuses ACS380- Max. fuse rat- 04xx-… Nominal cur- Voltage rating ing for group Bussmann/ rent Type installation Edison type 1-phase U n = 230 V 02A4-1 JJN/TJN10 UL class T 03A7-1 JJN/TJN10 UL class T 04A8-1 JJN/TJN15 UL class T 06A9-1...
Page 150 2. Fuses with a higher current rating than specified must not be used. 3. The UL listed fuses recommended by ABB are the required branch circuit protection per NEC. 4. The recommended size or smaller UL listed 248 fast acting, time delay, or high speed fuses must be used to maintain the UL listing of the drive.
Page 151: Alternative Short-Circuit Protection
Obey the manufacturer’s instructions. You can use the circuit breakers specified by ABB. 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 of the circuit breakers not specified by ABB.
Page 152 152 Technical data Frame Miniature circuit breaker Network Type ACS380- 04xx-… ABB type 04A8-2 S 203P-Z 10 NA 06A9-2 S 203P-Z 16 NA 07A8-2 S 203P-Z 16 NA 09A8-2 S 203P-Z 25 NA 12A2-2 S 203P-Z 25 NA 17A5-2 S 203P-Z 32 NA...
Page 153: Miniature Circuit Breakers (Ul)
1) 2) Type Frame Miniature circuit breaker Minimum enclosure volume ACS380- in 3 04xx-… ABB type 1-phase U n = 230 V 02A4-1 SU202M-C10 1850 03A7-1 SU202M-C10 1850 04A8-1 SU202M-C20...
Page 154: Manual Self-Protected Combination Motor Controller - Type E Usa (Ul (Nec))
Manual self-protected combination motor controller – Type E USA (UL (NEC)) You can use the ABB Type E manual motor protectors (MMP) MS132 & S1-M3-25, MS165-xx and MS5100-100 as an alternative to the recommended fuses as a means of branch circuit protection. This is in accordance with the National Electrical Code (NEC).
Page 155 Technical data 155 WARNING! Use fuses for the short-circuit protection of a wall-mounted drive with the UL Type 1 kit (optional). Serious injury, fire, or damage to equipment can result from the use of MMPs instead of fuses. Minimum enclosure volume Type ACS380- 2) 3) 4) Frame...
Page 156 Refer to the technical data. For UL only: The minimum enclosure volume is specified in the UL listing when applied with the ABB Type E MMP shown in the table. Fuses must be used for wall-mounted drives installed with a UL Type 1 kit.
Page 157: Dimensions And Weights
Technical data 157 Dimensions and weights ￭ Dimensions – IP20 / UL open type H2 H1 Frame Dimensions, IP20 / UL open type size 1.97 7.52 1.97 7.52 2.95 7.52 241.3 5.83 7.52 9.45 10.2 9.21 7.52 1) A side option increases the width of the drive. 2) The BIO-01 high cover increases the depth of the drive by 15 mm (0.6 in).
Page 158: Dimensions - Drive With Ul Type 1 Kit
158 Technical data ￭ Dimensions – Drive with UL Type 1 kit Frame Dimensions, drive with UL Type 1 kit size 11.2 1.97 7.52 1.26 11.5 1.97 7.52 1.26 11.5 2.95 7.52 1.26 13.0 10.3 5.83 7.52 1.42 15.3 12.3 10.2 9.21 7.52...
Page 159: Weights
Technical data 159 ￭ Weights Frame Weights size IP20 / UL open type UL Type 1 11.7 14.4 Free space requirements Frame Free space requirement Below Sides Above 1) Drives with the optional UL Type 1 kit: 50 mm (2 in), measured from the top of the hood. Losses, cooling data and noise Drives with frame size R0 have natural convection cooling.
Page 160 160 Technical data Type Air flow Noise Typical power loss Frame ACS380- size m 3 /h 04xx-… BTU/h dB(A) 3-phase U N = 230 V 02A4-2 03A7-2 04A8-2 06A9-2 07A8-2 09A8-2 12A2-2 17A5-2 25A0-2 1358 033A-2 1194 032A-2 1194 048A-2 1914 055A-2 2307...
Page 161: Typical Power Cable Sizes
Technical data 161 Type Air flow Noise Typical power loss Frame ACS380- size m 3 /h 04xx-… BTU/h dB(A) 050A-4 2293 1) Typical drive losses when it operates at 90% of the motor nominal frequency and 100% of the drive nominal output current.
Page 162: Terminal Data For The Power Cables
162 Technical data Cable size, Cu (mm 2 ) Type Conductor size, Cu (AWG) Frame ACS380- size 04xx-… 048A-2 3×25 + 16 055A-2 3×25 + 16 3-phase U N = 400 V or 480 V 01A8-4 3×1.5 + 1.5 02A6-4 3×1.5 + 1.5 03A3-4 3×1.5 + 1.5...
Page 163 Technical data 163 Type L1, L2, L3, T1/U, T2/V, T3/W, R-, R+/ ACS380- UDC+ 04xx-… Minimum Maximum Tightening Minimum Maximum Tightening torque (sol- (sol- torque (sol- (sol- id/stran- id/stran- id/stran- id/stran- ded) ded) ded) ded) mm 2 mm 2 mm 2 mm 2 N·m N·m...
Page 164 164 Technical data Type L1, L2, L3, T1/U, T2/V, T3/W, R-, R+/ ACS380- UDC+ 04xx-… Minimum Maximum Tightening Minimum Maximum Tightening torque (sol- (sol- torque (sol- (sol- id/stran- id/stran- id/stran- id/stran- ded) ded) ded) ded) mm 2 mm 2 mm 2 mm 2 N·m N·m...
Page 165 Technical data 165 Type L1, L2, L3, T1/U, T2/V, T3/W, R-, R+/ ACS380- UDC+ 04xx-… Minimum Maximum Tightening Minimum Maximum Tightening torque torque lbf·in lbf·in 03A7-2 10.6 04A8-2 10.6 06A9-2 10.6 07A8-2 10.6 09A8-2 10.6 12A2-2 10.6 17A5-2 11…13 10.6 25A0-2 11…13 10.6...
Page 166: Terminal Data For The Control Cables
ACS380-04xx-xxxx-4 drives: 3-phase 380 … 480 V AC -15% … +10% Network type Public low voltage networks. Symmetrically grounded TN-S system, IT (ungrounded), corner-grounded delta. Consult ABB before con- necting to other systems (for example, TT, or midpoint grounded delta).
Page 167: Motor Connection Data
(cos phi) Motor connection data Motor type Asynchronous AC induction motors, permanent magnet synchronous motors or ABB synchronous reluctance motors (SynRM motors) Voltage (U2) 0 … U1, 3-phase symmetrical Short-circuit protec- The motor output is short-circuit proof by IEC 61800-5-1 and UL tion (IEC 61800-5-1, 61800-5-1.
Page 168: Emc Compatibility And Motor Cable Length
168 Technical data Frame Maximum motor cable length Standard drive, without external options R0…R4 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 requirements of IEC/EN 61800-3, do not exceed these maximum motor cable lengths.
Page 169: Control Connection Data
Technical data 169 Frame Maximum motor cable length, 4 kHz 3-phase 380 … 480 V (ACS380-040x) 1) Category C1 with conducted emissions only. Radiated emissions are not compatible when measured with the standard emission measurement setup and must be measured on cabinet and machine installations for each case.
Page 170 170 Technical data Digital inputs Voltage 12 … 24 V DC (int. or ext. supply) Max. 30 V (DI1…DI5) Type PNP and NPN R in = 2 kohm Input impedance As inputs Programmable digital I/O (DIO1, DIO2) Voltage 12 … 24 V DC with internal or external supply. Max.
Page 171: Brake Resistor Connection Data
Energy efficiency data (ecodesign) Energy efficiency data according to IEC 61800-9-2 is available from the ecodesign tool (https://ecodesign.drivesmotors.abb.com/). Energy efficiency data is not provided for the 1~230 V drives. The drives with one phase input are not in the scope of the EU ecodesign requirements (Regulation EU/2019/1781) or the UK ecodesign requirements (Regulation SI 2021 No.
Page 172: Ambient Conditions
172 Technical data Ambient conditions Environmental limits for the drive are given below. The drive must be used in a heated indoor controlled environment. Requirement Operation installed Storage in the pro- Transportation in the for stationary use tective package protective package Installation site alti- 230 V drives: tude...
Page 173: Storage Conditions
Technical data 173 Requirement Operation installed Storage in the pro- Transportation in the for stationary use tective package protective package Sinusoidal vibration frequency 10 … 150 Hz; (IEC 60068-2-6, Test Fc 2007-12) amplitude ±0.075 mm (0.003 in), 10 … 57,56 Hz; constant peak acceler- ation 10 m/s 2 (33 ft/s 2 ), 57,56 …...
Page 174: Package Materials For Options, Accessories And Spare Parts
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-life-services.
Page 175: Applicable Standards
Technical data 175 Applicable standards The drive complies with the following standards: EN ISO 13849-1:2015 Safety of machinery – Safety related parts of the control systems – Part 1: general principles for design EN ISO 13849-2:2012 Safety of machinery – Safety-related parts of the control systems – Part 2: Validation EN 60204-1:2006 + Safety of machinery.
Page 176 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 177: Compliance With The Harmonic Current Limits In A Public Network (Iec/En 61000 3-2, Iec/En 61000-3-12)
Technical data 177 Compliance with the harmonic current limits in a public network (IEC/EN 61000 3-2, IEC/EN 61000-3-12) ￭ 3-phase 230 V, 400 V or 480 V drive with the input choke The drive complies with IEC 61000-3-12 provided that the short-circuit ratio R is greater than or equal to value 350 at the interface point between the user's supply and the public system.
Page 178: Emc Compliance (Iec/En 61800-3:2004 + A1:2012)
178 Technical data EMC compliance (IEC/EN 61800-3:2004 + A1:2012) ￭ Definitions EMC stands for Electromagnetic Compatibility. It is the ability of electrical/electronic equipment to operate without problems within an electromagnetic environment. Likewise, the equipment must not disturb or interfere with any other product or system within its locality. First environment includes establishments connected to a low-voltage network which supplies buildings used for domestic purposes.
Page 179: Category C2
Technical data 179 ￭ Category C2 This is applicable to 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. The EMC recommendations are obeyed.
Page 180: Category C4
180 Technical data WARNING! To prevent radio-frequency interference, do not use a category C3 drive on a low-voltage public network that supplies domestic premises. ￭ Category C4 If the provisions in category 1, 2 or 3 are not met, the requirements of the standard can be met as follows: It is ensured that no excessive emission is propagated to neighboring low-voltage networks.
Page 181: Ul Checklist
UL standard. • The drive is suitable for use on a circuit capable of delivering not more than 65000 rms symmetrical amperes, 480Y/277 V maximum (480 V drive types), when protected by a Type E combination motor controller specified by ABB.
Page 182: Disclaimers
UL-compliant installations. • The input cable must be protected with UL-rated fuses, or the ABB Type E manual motor protectors (MMP) listed in this manual. The fuses or the manual motor protectors provide branch circuit protection in accordance with the National Electrical Code (NEC) and Canadian Electrical Code.
Page 183: Dimension Drawings
Dimension drawings 183 Dimension drawings Contents of this chapter The chapter contains the dimension drawings of the drive. The dimensions are in millimeters and inches. Note: Drives with the BIO-01 I/O extension module (option +L515) are supplied with a high cover part that increases the depth of the drive by 15 mm (0.6 in).
Page 184: Frame R0
184 Dimension drawings Frame R0 ￭ Frame R0, 1-phase 230 V, IP20...
Page 185: Frame R0, 1-Phase 230 V, Ip20, With Side Option
Dimension drawings 185 ￭ Frame R0, 1-phase 230 V, IP20, with side option...
Page 186: Frame R0, 1-Phase 230 V, Ul Type 1
186 Dimension drawings ￭ Frame R0, 1-phase 230 V, UL Type 1...
Page 187: Frame R0, 1-Phase 230 V, Ul Type 1, With Side Option
Dimension drawings 187 ￭ Frame R0, 1-phase 230 V, UL Type 1, with side option...
Page 188: Frame R0, 3-Phase 400/480 V, Ip20
188 Dimension drawings ￭ Frame R0, 3-phase 400/480 V, IP20...
Page 189: Frame R0, 3-Phase 400/480 V, Ip20, With Side Option
Dimension drawings 189 ￭ Frame R0, 3-phase 400/480 V, IP20, with side option...
Page 190: Frame R0, 3-Phase 400/480 V, Ul Type 1
190 Dimension drawings ￭ Frame R0, 3-phase 400/480 V, UL Type 1...
Page 191: Frame R0, 3-Phase 400/480 V, Ul Type 1, With Side Option
Dimension drawings 191 ￭ Frame R0, 3-phase 400/480 V, UL Type 1, with side option...
Page 192: Frame R1
192 Dimension drawings Frame R1 ￭ Frame R1, 1-phase 230 V, IP20...
Page 193: Frame R1, 1-Phase 230 V, Ip20, With Side Option
Dimension drawings 193 ￭ Frame R1, 1-phase 230 V, IP20, with side option...
Page 194: Frame R1, 1-Phase 230 V, Ul Type 1
194 Dimension drawings ￭ Frame R1, 1-phase 230 V, UL Type 1...
Page 195: Frame R1, 1-Phase 230 V, Ul Type 1, With Side Option
Dimension drawings 195 ￭ Frame R1, 1-phase 230 V, UL Type 1, with side option...
Page 196: Frame R1, 3-Phase 230 V And 400/480 V, Ip20
196 Dimension drawings ￭ Frame R1, 3-phase 230 V and 400/480 V, IP20...
Page 197: Frame R1, 3-Phase 230 V And 400/480 V, Ip20, With Side Option
Dimension drawings 197 ￭ Frame R1, 3-phase 230 V and 400/480 V, IP20, with side option...
Page 198: Frame R1, 3-Phase 230 V And 400/480 V, Ul Type 1
198 Dimension drawings ￭ Frame R1, 3-phase 230 V and 400/480 V, UL Type 1...
Page 199: Frame R1, 3-Phase 230 V And 400/480 V, Ul Type 1, With Side Option
Dimension drawings 199 ￭ Frame R1, 3-phase 230 V and 400/480 V, UL Type 1, with side option...
Page 200: Frame R2
200 Dimension drawings Frame R2 ￭ Frame R2, 1-phase 230 V, IP20...
Page 201: Frame R2, 1-Phase 230 V, Ip20, With Side Option
Dimension drawings 201 ￭ Frame R2, 1-phase 230 V, IP20, with side option...
Page 202: Frame R2, 1-Phase 230 V, Ul Type 1
202 Dimension drawings ￭ Frame R2, 1-phase 230 V, UL Type 1...
Page 203: Frame R2, 1-Phase 230 V, Ul Type 1, With Side Option
Dimension drawings 203 ￭ Frame R2, 1-phase 230 V, UL Type 1, with side option...
Page 204 204 Dimension drawings ￭ Frame R2, 3-phase 230 V and 400/480 V, IP20...
Page 205: Frame R2, 3-Phase 230 V And 400/480 V, Ip20, With Side Option
Dimension drawings 205 ￭ Frame R2, 3-phase 230 V and 400/480 V, IP20, with side option...
Page 206: Frame R2, 3-Phase 230 V And 400/480 V, Ul Type
206 Dimension drawings ￭ Frame R2, 3-phase 230 V and 400/480 V, UL Type 1...
Page 207: Frame R2, 3-Phase 230 V And 400/480 V, Ul Type 1, With Side Option
Dimension drawings 207 ￭ Frame R2, 3-phase 230 V and 400/480 V, UL Type 1, with side option...
Page 208: Frame R3
208 Dimension drawings Frame R3 ￭ Frame R3, 3-phase 230 V and 400/480 V, IP20...
Page 209: Frame R3, 3-Phase 230 V And 400/480 V, Ip20, With Side Option
Dimension drawings 209 ￭ Frame R3, 3-phase 230 V and 400/480 V, IP20, with side option...
Page 210: Frame R3, 3-Phase 230 V And 400/480 V, Ul Type 1
210 Dimension drawings ￭ Frame R3, 3-phase 230 V and 400/480 V, UL Type 1...
Page 211: Frame R3, 3-Phase 230 V And 400/480 V, Ul Type 1, With Side Option
Dimension drawings 211 ￭ Frame R3, 3-phase 230 V and 400/480 V, UL Type 1, with side option...
Page 212: Frame R4
212 Dimension drawings Frame R4 ￭ Frame R4, 3-phase 230 V and 400/480 V, IP20...
Page 213: Frame R4, 3-Phase 230 V And 400/480 V, Ip20, With Side Option
Dimension drawings 213 ￭ Frame R4, 3-phase 230 V and 400/480 V, IP20, with side option...
Page 214: Frame R4, 3-Phase 230 V And 400/480 V, Ul Type 1
214 Dimension drawings ￭ Frame R4, 3-phase 230 V and 400/480 V, UL Type 1...
Page 215: Frame R4, 3-Phase 230 V And 400/480 V, Ul Type 1, With Side Option
Dimension drawings 215 ￭ Frame R4, 3-phase 230 V and 400/480 V, UL Type 1, with side option...
Page 217: Input Chokes
Input chokes 217 Input chokes Contents of this chapter This chapter describes how to select and install input chokes for the drive. The chapter also contains the technical data of the input chokes. When is an input choke necessary? Determine the need for an external input choke at the drive power input on a case-by-case basis.
Page 218: Selecting An Input Choke
218 Input chokes • power output (or input) via DC connection to other drives in the common DC setup • network impedance (short circuit capacity) effect on total harmonics content of the input current. Refer to Electrical power network specification (page 166) for more information.
Page 219 Input chokes 219 Type Frame Input choke type ACS380- 04xx-… 1-phase U n = 230 V 02A4-1 03A7-1 04A8-1 06A9-1 07A8-1 09A8-1 12A2-1 3-phase U n = 230 V 02A4-2 03A7-2 04A8-2 06A9-2 07A8-2 09A8-2 12A2-2 17A5-2 25A0-2 033A-2 032A-2 048A-2 055A-2 3-phase U n = 400 V...
Page 220: Guidelines For Installing An Input Choke
220 Input chokes Type Frame Input choke type ACS380- 04xx-… 05A6-4 07A2-4 09A4-4 12A6-4 17A0-4 25A0-4 033A-4 032A-4 038A-4 045A-4 050A-4 The degree of protection of an input choke is IP20. Refer to Dimensions (page 221) for dimensions, wire sizes and tightening torques. Guidelines for installing an input choke Obey these guidelines when you install the input choke: •...
Page 221: Connection Diagram
Input chokes 221 ￭ Connection diagram AC supply Input choke External EMC filter (if present) Drive Dimensions...
Page 222 222 Input chokes Input choke type CHK-01 CHK-02 CHK-03 CHK-04 CHK-05 CHK-06 CHK-07 CHK-08 Dim A mm (in.) (4.72) (5.91) (5.91) (5.91) (8.15) (8.15) (9.80) (9.80) Dim B mm (in.) (5.75) (6.89) (6.89) (6.89) (10.71) (12.83) (12.83) (13.62) Dim C mm (in.) 79 (3.11) (3.39) (3.94)
Page 223: External Emc Filters
If you use an external EMC filter, you must disconnect the internal EMC filter. Refer to the electrical installation instructions. Select the external EMC filter according to the drive type: Type EMC filter type ACS380- ABB order code Schaffner order code 04xx-… 1-phase U N = 230 V 02A4-1 RFI-11 FS 21754-6.1-07...
Page 224 224 External EMC filters Type EMC filter type ACS380- ABB order code Schaffner order code 04xx-… 06A9-2 RFI-32 FN 3258-16-44 07A8-2 RFI-32 FN 3258-16-44 09A8-2 RFI-32 FN 3258-16-44 12A2-2 RFI-33 FN 3258-30-33 17A5-2 RFI-33 FN 3258-30-33 25A0-2 RFI-33 FN 3258-30-33...
Page 225: Resistor Braking
Resistor braking 225 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 226 226 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 227: Reference Brake Resistors
Resistor braking 227 WARNING! Do not use a brake resistor with a resistance below the minimum value specified for the particular drive. The drive and the internal chopper are not able to handle the overcurrent caused by the low resistance. ￭...
Page 228: Definitions
228 Resistor braking Type Example resistor R min R max P BRcont P BRmax ACS380- 1) 2) types 04xx-… Danotherm 3-phase U N = 400/480 V 01A8-4 0.37 0.50 0.56 0.74 CBH 360 C T 406 210R 02A6-4 0.55 0.75 0.83 1.10 CAR 200 D T 406 210R...
Page 229: Minimizing Electromagnetic Interference
Resistor braking 229 ￭ 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 230: 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 231: Mechanical And Electrical Installation Of Brake Resistor
Resistor braking 231 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 232 232 Resistor braking With these parameter settings, the drive generates a fault and coasts to a stop on brake resistor overtemperature.
Page 233: The Safe Torque Off Function
The Safe torque off function 233 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 234: Compliance With The European Machinery Directive And The Uk Supply Of Machinery (Safety) Regulations
234 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 235: Wiring
The Safe torque off function 235 Wiring For the electrical specifications of the STO connection, see the technical data of the control unit. ￭ Connection principle Single ACS380 drive, internal power supply + 24 V DC SGND UDC+ UDC- Drive Control unit Control logic To motor...
Page 236: Single Acs380 Drive, External Power Supply
236 The Safe torque off function Single ACS380 drive, external power supply 24 V DC + 24 V DC SGND UDC+ UDC- Drive Control unit Control logic To motor Activation switch...
Page 237: Single-Channel Connection Of Activation Switch
The Safe torque off function 237 Single-channel connection of activation switch + 24 V DC SGND UDC+ UDC- Drive Control unit Control logic To motor Activation switch Note: A single-channel activation switch can limit the SIL/PL capability of the safety function to a lower level than the SIL/PL capability of the STO function of the drive.
Page 238: Wiring Examples
238 The Safe torque off function ￭ Wiring examples Single ACS380 drive, internal power supply SGND Drive Safety PLC Safety relay Single ACS380 drive, external power supply 24 V DC SGND Drive Safety PLC Safety relay...
Page 239: Multiple Acs380 Drives, Internal Power Supply
The Safe torque off function 239 Multiple ACS380 drives, internal power supply +24 V SGND SGND SGND Drive Control unit Activation switch...
Page 240: Multiple Acs380 Drives, External Power Supply
240 The Safe torque off function Multiple ACS380 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 241: 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 242: Operation Principle
242 The Safe torque off function 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 243: Start-Up Including Validation Test
The Safe torque off function 243 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 244 244 The Safe torque off function 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 245: Use
The Safe torque off function 245 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 246 246 The Safe torque off function causes danger or is not otherwise acceptable, stop the drive and machinery using the appropriate stop mode before activating the Safe torque off function. • The Safe torque off function overrides all other functions of the drive. •...
Page 247: 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 243). Use only spare parts approved by ABB. Record all maintenance and proof test activities in the machine logbook. ￭ Competence...
Page 248: 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 249: Safety Data
The Safe torque off function 249 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 250 250 The Safe torque off function...
Page 251: Terms And Abbreviations
The Safe torque off function 251 • The STO is a type A safety component as defined in IEC 61508-2. • Relevant failure modes: • The STO trips spuriously (safe failure) • The STO does not activate when requested • A fault exclusion on the failure mode “short circuit on printed circuit board”...
Page 252: Tüv Certificate
252 The Safe torque off function Term or Reference Description abbreviation IEC 61508 Average frequency of dangerous failures per hour, that is, average frequency of a dangerous failure of a safety related system to perform the specified safety function over a given period of time PFH diag IEC/EN 62061 Average frequency of dangerous failures per hour for the...
Page 253: Declarations Of Conformity
The product(s) referred in this Declaration of conformity fulfil(s) the relevant provisions of other European Union Directives which are notified in Single EU Declaration of conformity 3AXD10000495941. Authorized to compile the technical file: ABB Oy, Hiomotie 13, 00380 Helsinki, Finland. Helsinki, August 31, 2022...
Page 254 The product(s) referred in this declaration of conformity fulfil(s) the relevant provisions of other UK statutory requirements, which are notified in a single declaration of conformity 3AXD10001323213. Authorized to compile the technical file: ABB Limited, Daresbury Park, Cheshire, United Kingdom, WA4 4BT. Helsinki, August 31, 2022...
Page 255: Btac-02 Pulse Encoder Interface Module
BTAC-02 pulse encoder interface module 255 BTAC-02 pulse encoder interface module Contents of this chapter This chapter contains a description and technical data of the optional BTAC-02 pulse encoder interface module and describes how to start up the module. Safety instructions WARNING! Obey the safety instructions of the drive.
Page 256: Layout
256 BTAC-02 pulse encoder interface module ￭ Layout 1. BTAC module 2. Locking screw hole 3. X103 connector 4. X104 connector 5. X105 connector 6. X106 connector 7. Internal X100 connector 8. Internal X102 connector 9. Grounding rail 10. Grounding screw Mechanical installation Refer to Installing options (page 92)
Page 257: Terminal Designations
BTAC-02 pulse encoder interface module 257 Cable Maximum con- Maximum cable nector size length 2.5 mm 2 4 × (2+1) double-shielded twisted pair cable with indi- 12 AWG 328 ft 100 m vidual and overall shields 1) If the encoder supply voltage is less than 10 V, the maximum cable length is 50 m (164 ft). Terminal designations The encoder user interface of the BTAC module consists of four 1×3-pin terminal blocks.
Page 258: Wiring - Encoder Power Supply Interface
258 BTAC-02 pulse encoder interface module Channels Description BTAC Encoder • Maximum signal frequency: 200 kHz • Signal levels: Encoder supply Logic “1” Logic “0” voltage >2.5 V <1.9 V 15 V >7.5 V <5.3 V 24 V >12.1 V <8.3 V •...
Page 259: Wiring - Encoder
BTAC-02 pulse encoder interface module 259 When using a 24 V encoder, it is possible to supply power to the encoder and BTAC module from the 24 V DC auxiliary power output of the drive. If you supply power from the auxiliary power output, make sure that you do not exceed the maximum load capacity.
Page 260: Encoder Output Types
260 BTAC-02 pulse encoder interface module clockwise, in most encoders channel A leads channel B. To determine the leading channel, refer to the encoder documentation or use an oscilloscope. 90° The diagram shows normal phasing: Pulse A leads (rises earlier than) pulse B.
Page 261: Wiring Diagrams - Push-Pull Type Encoder Output
BTAC-02 pulse encoder interface module 261 Wiring diagrams – Push-pull type encoder output Diagram assumes normal pulse order in Forward rotation: Pulse A leads For encoders with pulse B leading, change the diagram: • Wire encoder A and B to BTAC terminals B and A, respectively. •...
Page 262: Single-Ended Connection
262 BTAC-02 pulse encoder interface module Single-ended connection Encoder BTAC module Encoder power supply...
Page 263: Wiring Diagrams - Open Collector (Sinking) Encoder Output
BTAC-02 pulse encoder interface module 263 Wiring diagrams – Open collector (sinking) encoder output Diagram assumes normal pulse order in Forward rotation: Pulse A leads. For encoders with pulse B leading, change the diagram: Wire encoder A and B to BTAC terminals B and A, respectively.
Page 264: Wiring Diagrams - Open Emitter (Sourcing) Encoder Output
264 BTAC-02 pulse encoder interface module Wiring diagrams – Open emitter (sourcing) encoder output Diagram assumes normal pulse order in Forward rotation: Pulse A leads. For encoders with pulse B leading, change the diagram: Wire encoder A and B to BTAC terminals B and A, respectively.
Page 265: Apply Power
BTAC-02 pulse encoder interface module 265 Apply power Turn on the input power to the drive. 2. Continue with Start-up. Start-up To configure the operation of the BTAC module: Power up the drive. 2. Set parameters in groups 90 Feedback selection, 91 Encoder adapter settings and 92 Encoder 1 configuration.
Page 266 266 BTAC-02 pulse encoder interface module Name/Value Description Def/FbEq16/32 90.13 Enc1 revol Displays the revolution counter extension. na/1=1 extension The counter is incremented when encoder position wraps around in the positive direction, and decremented in the negative direction. The parameter is effective only if the position is absolute.The parameter value is updated for both singleturn and multiturn encoders.
Page 267: Encoder Adapter Settings
BTAC-02 pulse encoder interface module 267 Name/Value Description Def/FbEq16/32 Does not generate an error if encoder drift is de- tected. Generates fault 7301 Motor speed feedback if en- coder drift is detected. ￭ Encoder adapter settings These parameters display the configuration of the encoder interface modules. Name/Value Description Def/FbEq16/32...
Page 268: Technical Data
268 BTAC-02 pulse encoder interface module Code Fault/Warning Cause (hex) 7301 Motor speed feedback No motor speed feedback is received Drift detected. Check for slippage between encoder and motor. Incorrect motor feedback configuration Incorrect motor speed A7B0 Motor speed feedback No motor speed feedback is received Encoder drift detected.
Page 269: Back-Up Power Supply For The Drive
BTAC-02 pulse encoder interface module 269 ￭ Back-up power supply for the drive Refer to electrical installation instructions. ￭ Internal connectors Connector X102 provides encoder interface signals to the drive control board. Connector X102 data: 1×8 pin header, pitch 2.54 mm, height 33.53 mm. Connector X100 serves as power supply interface between the BTAC module and the drive’s control board.
Page 271: Bres-01 Resolver Interface Module
BRES-01 resolver interface module 271 BRES-01 resolver interface module Contents of this chapter This chapter contains a description and technical data of the optional BRES-01 resolver interface module and describes how to connect and start up the module. Safety instructions WARNING! Obey the safety instructions of the drive.
Page 272: Functional Description
272 BRES-01 resolver interface module ￭ Functional description BRES-01 feeds the excitation signal to the resolver and reads from the resolver analog sine and cosine signals. Based on the sine and cosine signals, the resolver position (angle) and speed can be defined. Position (absolute) of resolver is read at start and then updated based on the speed signal.
Page 273: Layout
BRES-01 resolver interface module 273 ￭ Layout 1. BRES-01 module 2. Locking screw hole 3. X103 connector (D con- nector for resolver feed- back) 4. X104 terminal for resolv- er feedback 5. X105 terminal for extern- al 24 VDC supply 6.
Page 274: Resolver Input (X103, X104)
274 BRES-01 resolver interface module Resolver input (X103, X104) X103 EXCITATION+ PTC/KTY_0V PTC/KTY COS- SIN- EXCITATION- COM_B COS+ SIN+ COM_B COM_B D-con- Signal Description nector (X103) SIN- Inverted SIN signal COS- Inverted COS signal PTC/KTY Not connected PTC/KTY_0V Not connected EXCITATION+ Excitation signal + SIN+...
Page 275: External Power Supply (X105)
BRES-01 resolver interface module 275 X104 Terminal Signal Description block (X104) EXC+ Excitation signal + EXC- Excitation signal - COS+ COS signal COS- Inverted COS signal SIN+ SIN signal SIN- Inverted SIN signal SHLD Ground for shield (SHLD) connection External power supply (X105) Usually, BRES-01 module is powered by the drive internal power supply.
Page 276: Connecting The Resolver Cable
276 BRES-01 resolver interface module Requirements for other user connection(s) to drive 24 V DC auxiliary voltage output Total ￭ Connecting the resolver cable Do not route the resolver cable in parallel to power cables (for example, motor cables). Refer to Routing the cables (page 63) for more information.
Page 277: Resolver Interface Connectors (X103, X104)
Excitation current: 75 mA max. • Transformation ratio: 0,5 • Maximum speed: 10000 rpm. Contact ABB for resolvers that do not match the above ratings. Resolver interface connectors (X103, X104) • D connector: 15-pin high density D-sub, female. • 7-pin screw terminal block:...
Page 278: Dimensions
278 BRES-01 resolver interface module Connector X100 serves as power supply interface between the BRES-01 module and the drive’s control unit. It provides back-up power supply in main power loss situations. Connector X100 data: 2×4 pin header, pitch 2.54 mm, height 15.75 mm. ￭...
Page 279: Brel-01 Relay Output Extension Module
BREL-01 relay output extension module 279 BREL-01 relay output extension module Contents of this chapter This chapter contains a description and technical data of the optional BREL-01 relay output extension module. Safety instructions WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur.
Page 280: Layout
280 BREL-01 relay output extension module ￭ Layout 1. BREL-01 module 2. Locking screw hole 3. X103 connector 4. X104 connector 5. X105 connector 6. X106 connector 7. Internal X100 connector 8. Internal X102 connector 9. Grounding rail 10. Grounding screw Mechanical installation Refer to Installing options (page 92)
Page 281: Start-Up
BREL-01 relay output extension module 281 Identification Description X103 Relay outputs RO4…RO7: Max. switching voltage: 250 V AC / 30 V DC Common Max. switching current: 2 A Normally closed Galvanically isolated. Normally open X104 Common Normally closed Normally open X105 Common Normally closed...
Page 282 282 BREL-01 relay output extension module Name/Value Description Def / FbEq16/32 BREL External relay option BREL-01. 15.02 Detected I/O extension module detected on the drive. None extension module BREL External relay option BREL-01. 15.04 RO status Displays the status of the relay outputs. This 1 = 1 parameter is read-only.
Page 283 BREL-01 relay output extension module 283 Name/Value Description Def / FbEq16/32 Not energized Output is not energized. Energized Output is energized. For the complete parameter list, refer to the drive firmware manual. … 15.08 RO4 ON delay Defines the activation delay for relay output RO4. 0.0 s 0.0 …...
Page 284: Technical Data
284 BREL-01 relay output extension module Name/Value Description Def / FbEq16/32 15.18 RO7 OFF delay Sets the deactivation delay for relay output 7. 0.0 s 0.0…3000.0 s Deactivation delay for relay output 7. 10 = 1 s Technical data External connectors: Four 3-pin (1×3) spring-clamp type terminal blocks, tin plated, 2.5 mm (14 AWG) wire size, pitch 5.0 mm.
Page 285: Bapo-01 Auxiliary Power Extension Module
BAPO-01 auxiliary power extension module 285 BAPO-01 auxiliary power extension module Contents of this chapter This chapter contains a description and technical data of the optional BAPO-01 auxiliary power extension module. Safety instructions WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur.
Page 286: Layout
286 BAPO-01 auxiliary power extension module Note: The BAPO-01 is not a battery. If you change drive parameters when the control board is energized by the BAPO-01 module, force parameter saving by setting the value of parameter 96.07 Parameter save manually to (1) Save. Otherwise, changed data will not be saved. ￭...
Page 287: Mechanical Installation
BAPO-01 auxiliary power extension module 287 Mechanical installation Refer to Installing options (page 92) BAPO, BREL, BRES, and BTAC modules quick installation guide (3AXD50000837946 [English]). Electrical installation Connect the external power supply to the +24 V and DGND terminals on the drive. See the electrical installation instructions of the drive.
Page 288: Start-Up
288 BAPO-01 auxiliary power extension module Start-up To configure the BAPO-01 module: Power up the drive. 2. Set the parameter 95.04 Control board supply to 1 (External 24V). Technical data Voltage and current rating for the auxiliary power supply: +24 V DC ±10%, max. 1000 mA (including internal fan load).
Page 289: Bio-01 I/O Extension Module
BIO-01 I/O extension module 289 BIO-01 I/O extension module Contents of this chapter This chapter contains a description and technical data of the optional BIO-01 I/O extension module. Safety instructions WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur.
Page 290: Layout
290 BIO-01 I/O extension module ￭ Layout 1. Locking tab 2. Option module slot 3. Chassis screw 4. I/O connector 5. Switches for config- uring terminals S1 and Mechanical installation See the electrical installation instructions of the drive. Before you install the BIO-01 option module, make sure that the chassis screw slider is in the top position.
Page 291: Electrical Installation
The BIO-01 module has removable spring clamp terminals. Use ferrules on the multistranded conductor ends. The connection diagram below is applicable to drives with the BIO-01 I/O extension module when the ABB standard macro is selected (parameter 96.04). Terminal Description...
Page 292: Technical Data
292 BIO-01 I/O extension module Technical data Control connection data: Spring type terminal blocks. Conductor size accepted by the terminals: 0.2 … 1.5 mm (24 … 16 AWG). Exception: max. 0.75 mm (18 AWG) for a multistranded conductor with a ferrule and plastic sleeve. Internal connections of GND and SCR terminals +24 V +24 V...
Page 293 BIO-01 I/O extension module 293 Dimensions Note: BIO-01 is supplied with a high cover part (part number 3AXD50000190188) for the ACS380 drives. When used, it increases the drive depth by 15 mm (0.6 in).
Page 295: 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:

Acs380 series Acs380-040n-07a8-1 Acs380-040s-06a9-1 Acs380-040c-07a8-1 Acs380-040n-02a4-1 Acs380-040n-04a8-1 ... Show all

ABB ACS380-040S-12A2-1 Hardware Manual

Quick Links

Need help?

Questions and answers

Related Manuals for ABB ACS380-040S-12A2-1

Summary of Contents for ABB ACS380-040S-12A2-1