ABB ACS380-040S-06A9-1 Manuals

Manuals and User Guides for ABB ACS380-040S-06A9-1. We have 1 ABB ACS380-040S-06A9-1 manual available for free PDF download: Hardware Manual

ABB ACS380-040S-06A9-1 Hardware Manual (296 pages)

Brand: ABB | Category: DC Drives | Size: 17 MB

Table of Contents
5
Safety Instructions
17
Contents of this Chapter
17
Use of Warnings and Notes
17
General Safety in Installation, Start-Up and Maintenance
18
Electrical Safety in Installation, Start-Up and Maintenance
20
Electrical Safety Precautions
20
Additional Instructions and Notes
21
Printed Circuit Boards
21
Grounding
22
General Safety in Operation
23
Additional Instructions for Permanent Magnet Motor Drives
23
Safety in Installation, Start-Up, Maintenance
23
Safety in Operation
24
Introduction to the Manual
25
Contents of this Chapter
25
Applicability
25
Target Audience
25
Categorization by Frame Size
25
Quick Installation and Commissioning Flowchart
26
Terms and Abbreviations
28
Related Manuals
29
Operation Principle and Hardware Description
31
Contents of this Chapter
31
Operation Principle
31
Simplified Main Circuit Diagram
32
Product Variants
32
Layout
33
Control Connections
34
Standard Variant (I/O and Modbus) (ACS380-04Xs)
34
Configured Variant (ACS380-04Xc)
35
Base Variant (ACS380-04Xn)
36
Option Modules
36
Control Panel Options
37
UL Type 1 Kits
38
Drive Labels
38
Model Information Label
38
Type Designation Label
39
Type Designation Key
39
Basic Code
39
Option Codes
40
Control Panel
42
Home View
43
Status Icons
44
Message View
44
Options View
44
Menu
45
Mechanical Installation
47
Contents of this Chapter
47
Installation Alternatives
47
Examining the Installation Site
48
Required Tools
48
Unpacking the Delivery
49
Installing the Drive
49
To Install the Drive with Screws
49
To Install the Drive to a DIN Installation Rail
50
Guidelines for Planning the Electrical Installation
53
Contents of this Chapter
53
Limitation of Liability
53
North America
53
Selecting the Main Supply Disconnecting Device
53
Selecting the Main Contactor
54
Checking the Compatibility of the Motor and Drive
54
Selecting the Power Cables
55
General Guidelines
55
Typical Power Cable Sizes
55
Power Cable Types
56
Preferred Power Cable Types
56
Alternate Power Cable Types
57
Not Allowed Power Cable Types
58
Additional Guidelines - North America
58
Metal Conduit
59
Power Cable Shield
59
Grounding Requirements
60
Additional Grounding Requirements - IEC
61
Additional Grounding Requirements - UL (NEC)
62
Selecting the Control Cables
62
Shielding
62
Signals in Separate Cables
62
Signals that Can be Run in the same Cable
62
Relay Cable
63
Control Panel to Drive Cable
63
PC Tool Cable
63
Routing the Cables
63
General Guidelines - IEC
63
General Guidelines - North America
64
Continuous Motor Cable Shield/Conduit and Metal Enclosure for Equipment on the Motor Cable
65
Separate Control Cable Ducts
66
Implementing Short-Circuit and Thermal Overload Protection
66
Protecting the Drive and Input Power Cable in Short-Circuits
66
Protecting the Motor and Motor Cable in Short-Circuits
66
Protecting the Drive, and the Input Power and Motor Cables against Thermal Overload
67
Protecting the Motor against Thermal Overload
67
Protecting the Motor against Overload Without Thermal Model or Temperature Sensors
67
Implementing a Motor Temperature Sensor Connection
68
Protecting the Drive against Ground Faults
68
Residual Current Device Compatibility
68
Implementing the Emergency Stop Function
68
Implementing the Safe Torque off Function
69
Using a Safety Switch between the Drive and the Motor
69
Implementing the Control of a Contactor between Drive and Motor
69
Protecting the Contacts of Relay Outputs
69
Electrical Installation - IEC
71
Contents of this Chapter
71
Required Tools
71
Measuring the Insulation Resistance - IEC
72
Measuring the Insulation Resistance of the Drive
72
Measuring the Insulation Resistance of the Input Power Cable
72
Measuring the Insulation Resistance of the Motor and Motor Cable
72
Measuring the Insulation Resistance of the Brake Resistor Circuit
73
Grounding System Compatibility Check - IEC
73
EMC Filter
73
Ground-To-Phase Varistor
74
Compatibility of EMC Filter and Ground-To-Phase Varistor with the Grounding System
74
Disconnecting the EMC Filter or Ground-To-Phase Varistor
76
EMC/VAR Screw Location
76
Guidelines for Installing the Drive to a TT System
76
Identifying the Grounding System of the Electrical Power Network
77
Connecting the Power Cables - IEC (Shielded Cables)
78
Connection Diagram
78
Connection Procedure
79
Connecting the Control Cables - IEC
80
Default I/O Connection Diagram (ABB Standard Macro)
80
Fieldbus Connection Diagram
82
Control Cable Connection Procedure
83
Additional Information on the Control Connections
84
Embedded EIA-485 Fieldbus Connection
84
PNP Configuration for Digital Inputs
86
NPN Configuration for Digital Inputs
87
Connection Examples of Two-Wire and Three-Wire Sensors
87
AI and AO (or AI, DI and +10 V) as PTC Motor Temperature Sensor Interface
88
AI1 and AI2 as Pt100, Pt1000, Ni1000, KTY83 and KTY84 Sensor Inputs
90
Safe Torque off
91
Auxiliary Voltage Connection
91
Connecting a PC
92
Installing Options
92
Installing a Front Option
93
Installing a Side Option
94
Electrical Installation - North America
97
Contents of this Chapter
97
Required Tools
97
Measuring the Insulation Resistance - North America
98
Measuring the Insulation Resistance of the Drive
98
Measuring the Insulation Resistance of the Input Power Cable
98
Measuring the Insulation Resistance of the Motor and Motor Cable
98
Measuring the Insulation Resistance of the Brake Resistor Circuit
99
Grounding System Compatibility Check - North America
99
EMC Filter
99
Ground-To-Phase Varistor
100
Compatibility of EMC Filter and Ground-To-Phase Varistor with the Grounding System
100
Disconnecting the Ground-To-Phase Varistor, or Connecting the EMC Filter
102
EMC/VAR Screw Location
102
Guidelines for Installing the Drive to a TT System
102
Identifying the Grounding System of the Electrical Power Network
103
Connecting the Power Cables - North America (Wiring in Conduits)
104
Connection Diagram
104
Connection Procedure
105
Connecting the Control Cables - North America
107
Default I/O Connection Diagram (ABB Standard Macro)
107
Fieldbus Connection Diagram
109
Control Cable Connection Procedure
110
Additional Information on the Control Connections
111
Embedded EIA-485 Fieldbus Connection
111
PNP Configuration for Digital Inputs
113
NPN Configuration for Digital Inputs
114
Connection Examples of Two-Wire and Three-Wire Sensors
114
AI and AO (or AI, DI and +10 V) as PTC Motor Temperature Sensor Interface
115
AI1 and AI2 as Pt100, Pt1000, Ni1000, KTY83 and KTY84 Sensor Inputs
117
Safe Torque off
118
Auxiliary Voltage Connection
118
Connecting a PC
119
Installing Options
119
Installing a Front Option
120
Installing a Side Option
121
Installation Checklist
123
Contents of this Chapter
123
Checklist
123
Maintenance
127
Contents of this Chapter
127
Maintenance Intervals
127
Description of Symbols
127
Recommended Maintenance Intervals after Start-Up
127
Functional Safety Components
128
Cleaning the Heatsink
129
Replacing the Cooling Fans
129
Replacing the Cooling Fan, Frames R1
130
Replacing the Cooling Fan, Frame R4
132
Capacitors
133
Reforming the Capacitors
133
Technical Data
135
Contents of this Chapter
135
Electrical Ratings
135
IEC Ratings
135
UL (NEC) Ratings
137
UL Listed Multiple Drive Ratings
138
Definitions
139
Sizing
140
Output Derating
140
Surrounding Air Temperature Derating
142
Altitude Derating
142
Switching Frequency Derating
143
Derating in Case of a Phase Loss
145
Fuses
145
IEC Fuses
145
Gg Fuses
145
Gr Fuses
147
UL (NEC) Fuses
148
Alternative Short-Circuit Protection
151
Miniature Circuit Breakers (IEC)
151
Miniature Circuit Breakers (UL)
153
Manual Self-Protected Combination Motor Controller - Type E USA (UL (NEC))
154
Dimensions and Weights
157
Dimensions - IP20 / UL Open Type
157
Dimensions - Drive with UL Type 1 Kit
158
Weights
159
Free Space Requirements
159
Losses, Cooling Data and Noise
159
Typical Power Cable Sizes
161
Terminal Data for the Power Cables
162
Terminal Data for the Control Cables
166
Electrical Power Network Specification
166
Motor Connection Data
167
Motor Cable Length
167
Operational Functionality and Motor Cable Length
167
EMC Compatibility and Motor Cable Length
168
Control Connection Data
169
Brake Resistor Connection Data
171
Energy Efficiency Data (Ecodesign)
171
Protection Classes
171
Ambient Conditions
172
Storage Conditions
173
Color
173
Materials
173
Drive
173
Drive Package
173
Package Materials for Options, Accessories and Spare Parts
174
Materials of Manuals
174
Disposal
174
Applicable Standards
175
Markings
175
Compliance with the Harmonic Current Limits in a Public Network (IEC/EN 61000 3-2, IEC/EN 61000-3-12)
177
3-Phase 230 V, 400 V or 480 V Drive with the Input Choke
177
3-Phase 230 V, 400 V or 480 V Drive Without the Input Choke
177
1-Phase 230 V Drive with or Without the Input Choke
177
EMC Compliance (IEC/EN 61800-3:2004 + A1:2012)
178
Definitions
178
Category C1
178
Category C2
179
Category C3
179
Category C4
180
UL Checklist
181
Disclaimers
182
Generic Disclaimer
182
Cyber Security Disclaimer
182
Dimension Drawings
183
Contents of this Chapter
183
Frame R0
184
Frame R0, 1-Phase 230 V, IP20
184
Frame R0, 1-Phase 230 V, IP20, with Side Option
185
Frame R0, 1-Phase 230 V, UL Type 1
186
Frame R0, 1-Phase 230 V, UL Type 1, with Side Option
187
Frame R0, 3-Phase 400/480 V, IP20
188
Frame R0, 3-Phase 400/480 V, IP20, with Side Option
189
Frame R0, 3-Phase 400/480 V, UL Type 1
190
Frame R0, 3-Phase 400/480 V, UL Type 1, with Side Option
191
Frame R1
192
Frame R1, 1-Phase 230 V, IP20
192
Frame R1, 1-Phase 230 V, IP20, with Side Option
193
Frame R1, 1-Phase 230 V, UL Type 1
194
Frame R1, 1-Phase 230 V, UL Type 1, with Side Option
195
Frame R1, 3-Phase 230 V and 400/480 V, IP20
196
Frame R1, 3-Phase 230 V and 400/480 V, IP20, with Side Option
197
Frame R1, 3-Phase 230 V and 400/480 V, UL Type 1
198
Frame R1, 3-Phase 230 V and 400/480 V, UL Type 1, with Side Option
199
Frame R2
200
Frame R2, 1-Phase 230 V, IP20
200
Frame R2, 1-Phase 230 V, IP20, with Side Option
201
Frame R2, 1-Phase 230 V, UL Type 1
202
Frame R2, 1-Phase 230 V, UL Type 1, with Side Option
203
Frame R2, 3-Phase 230 V and 400/480 V, IP20, with Side Option
205
Frame R2, 3-Phase 230 V and 400/480 V, UL Type
206
Frame R2, 3-Phase 230 V and 400/480 V, UL Type 1, with Side Option
207
Frame R3
208
Frame R3, 3-Phase 230 V and 400/480 V, IP20
208
Frame R3, 3-Phase 230 V and 400/480 V, IP20, with Side Option
209
Frame R3, 3-Phase 230 V and 400/480 V, UL Type 1
210
Frame R3, 3-Phase 230 V and 400/480 V, UL Type 1, with Side Option
211
Frame R4
212
Frame R4, 3-Phase 230 V and 400/480 V, IP20
212
Frame R4, 3-Phase 230 V and 400/480 V, IP20, with Side Option
213
Frame R4, 3-Phase 230 V and 400/480 V, UL Type 1
214
Frame R4, 3-Phase 230 V and 400/480 V, UL Type 1, with Side Option
215
Input Chokes
217
Contents of this Chapter
217
When Is an Input Choke Necessary
217
Maximum Input Current
217
Selecting an Input Choke
218
Guidelines for Installing an Input Choke
220
Connection Diagram
221
Dimensions
221
External EMC Filters
223
Contents of this Chapter
223
Selecting the External EMC Filter
223
Resistor Braking
225
Contents of this Chapter
225
Safety
225
Operation Principle
225
Selecting the Brake Resistor
225
Reference Brake Resistors
227
Definitions
228
Selecting and Routing the Brake Resistor Cables
228
Minimizing Electromagnetic Interference
229
Maximum Cable Length
229
Selecting the Installation Location for the Brake Resistors
229
Protecting the System in Brake Circuit Fault Situations
229
Protecting the System in Cable and Brake Resistor Short-Circuit Situations
229
Protecting the System against Thermal Overload
230
Mechanical and Electrical Installation of Brake Resistor
231
Mechanical Installation
231
Electrical Installation
231
Measuring the Insulation
231
Connecting Power Cables
231
Connection the Control Cables
231
Start-Up
231
The Safe Torque off Function
233
Contents of this Chapter
233
Description
233
Compliance with the European Machinery Directive and the UK Supply of Machinery (Safety) Regulations
234
Wiring
235
Connection Principle
235
Single ACS380 Drive, Internal Power Supply
235
Single ACS380 Drive, External Power Supply
236
Single-Channel Connection of Activation Switch
237
Wiring Examples
238
Single ACS380 Drive, Internal Power Supply
238
Single ACS380 Drive, External Power Supply
238
Multiple ACS380 Drives, Internal Power Supply
239
Multiple ACS380 Drives, External Power Supply
240
Activation Switch
240
Cable Types and Lengths
241
Grounding of Protective Shields
241
Operation Principle
242
Start-Up Including Validation Test
243
Competence
243
Validation Test Reports
243
Validation Test Procedure
243
Use
245
Maintenance
247
Competence
247
Fault Tracing
248
Safety Data
249
Terms and Abbreviations
251
TÜV Certificate
252
Declarations of Conformity
253
BTAC-02 Pulse Encoder Interface Module
255
Contents of this Chapter
255
Safety Instructions
255
Hardware Description
255
Product Overview
255
Layout
256
Mechanical Installation
256
Electrical Installation
256
Wiring - General
256
Terminal Designations
257
Wiring - Encoder Power Supply Interface
258
Wiring - Encoder
259
Phasing
259
Encoder Output Types
260
Wiring Diagrams - Push-Pull Type Encoder Output
261
Differential Connection
261
Single-Ended Connection
262
Wiring Diagrams - Open Collector (Sinking) Encoder Output
263
Wiring Diagrams - Open Emitter (Sourcing) Encoder Output
264
Apply Power
265
Start-Up
265
Feedback Selection
265
Encoder Adapter Settings
267
Encoder Configuration
267
Diagnostics
267
Technical Data
268
Encoder Interface
268
Encoder Type
268
Encoder Interface Connectors
268
Cable
268
Encoder and BTAC Module Power Supply
268
Back-Up Power Supply for the Drive
269
Internal Connectors
269
Dimensions
269
BRES-01 Resolver Interface Module
271
Contents of this Chapter
271
Safety Instructions
271
Hardware Description
271
Product Overview
271
Functional Description
272
Layout
273
Mechanical Installation
273
Electrical Installation
273
Terminal Designations
273
Resolver Input (X103, X104)
274
External Power Supply (X105)
275
Connecting the Resolver Cable
276
Start-Up
276
Technical Data
276
Resolver Interface
276
Resolver Type
276
Resolver Interface Connectors (X103, X104)
277
Resolver Cable
277
Power Supply Connection (X105)
277
Back-Up Power Supply for the Drive
277
Internal Connectors
277
Dimensions
278
BREL-01 Relay Output Extension Module
279
Contents of this Chapter
279
Safety Instructions
279
Hardware Description
279
Product Overview
279
Layout
280
Mechanical Installation
280
Electrical Installation
280
Start-Up
281
Configuration Parameters
281
Technical Data
284
BAPO-01 Auxiliary Power Extension Module
285
Contents of this Chapter
285
Safety Instructions
285
Hardware Description
285
Layout
286
Mechanical Installation
287
Electrical Installation
287
Start-Up
288
Technical Data
288
BIO-01 I/O Extension Module
289
Contents of this Chapter
289
Safety Instructions
289
Hardware Description
289
Product Overview
289
Layout
290
Mechanical Installation
290
Terminal Configuration
290
Electrical Installation
291
Start-Up
291
Technical Data
292
Further Information
295

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