ABB ACS480-04-03A7-1 Manuals

Manuals and User Guides for ABB ACS480-04-03A7-1. We have 1 ABB ACS480-04-03A7-1 manual available for free PDF download: Hardware Manual

ABB ACS480-04-03A7-1 Hardware Manual (240 pages)

Brand: ABB | Category: DC Drives | Size: 8.27 MB

Table of Contents
5
Safety Instructions
15
Contents of this Chapter
15
Use of Warnings and Notes
15
General Safety in Installation, Start-Up and Maintenance
16
General Safety in Operation
17
Electrical Safety in Installation, Start-Up and Maintenance
18
Electrical Safety Precautions
18
Additional Instructions and Notes
19
Printed Circuit Boards
19
Grounding
20
Additional Instructions for Permanent Magnet Motor Drives
20
Safety in Installation, Start-Up, Maintenance
20
Safety in Operation
21
Introduction to the Manual
23
Contents of this Chapter
23
Applicability
23
Target Audience
23
Categorization by Frame Size
23
Quick Installation and Commissioning Flowchart
24
Terms and Abbreviations
25
Related Manuals
26
Operation Principle and Hardware Description
29
Contents of this Chapter
29
Operation Principle
29
Simplified Main Circuit Diagram
30
Product Variants
30
IEC and UL (NEC) Product Types
30
Layout
31
Control Connections
32
Standard Unit (with RIIO-01)
32
Base Unit
33
Option Modules
33
Control Panel Options
34
UL Type 1 Kits
34
Drive Labels
35
Type Designation Label
35
Software Information Label
36
Type Designation Key
36
Basic Code
36
Option Codes
36
Mechanical Installation
39
Contents of this Chapter
39
Installation Alternatives
39
Examining the Installation Site
40
Required Tools
40
Unpacking the Delivery
41
Installing the Drive
41
To Install the Drive with Screws
41
To Install the Drive to a DIN Installation Rail
42
Guidelines for Planning the Electrical Installation
45
Contents of this Chapter
45
Limitation of Liability
45
Selecting the Main Supply Disconnecting Device
45
European Union and United Kingdom
46
North America
46
Other Regions
46
Selecting the Main Contactor
46
Checking the Compatibility of the Motor and Drive
47
Selecting the Power Cables
47
General Guidelines
47
Typical Power Cable Sizes
47
Power Cable Types
48
Preferred Power Cable Types
48
Alternate Power Cable Types
49
Not Allowed Power Cable Types
50
Additional Guidelines, North America
51
Metal Conduit
51
Power Cable Shield
52
Grounding Requirements
52
Additional Grounding Requirements - IEC
53
Additional Grounding Requirements - UL (NEC)
54
Selecting the Control Cables
54
Shielding
54
Signals in Separate Cables
54
Signals that Can be Run in the same Cable
54
Relay Cable
55
Control Panel to Drive Cable
55
PC Tool Cable
55
Routing the Cables
55
General Guidelines - IEC
55
General Guidelines - North America
56
Continuous Motor Cable Shield/Conduit or Enclosure for Equipment on the Motor Cable
57
Separate Control Cable Ducts
58
Implementing Short-Circuit and Thermal Overload Protection
58
Protecting the Drive and Input Power Cable in Short-Circuits
58
Protecting the Motor and Motor Cable in Short-Circuits
58
Protecting the Drive, and the Input Power and Motor Cables against Thermal Overload
58
Protecting the Motor against Thermal Overload
59
Protecting the Motor against Overload Without Thermal Model or Temperature Sensors
59
Implementing a Motor Temperature Sensor Connection
59
Protecting the Drive against Ground Faults
60
Residual Current Device Compatibility
60
Implementing the Emergency Stop Function
60
Implementing the Safe Torque off Function
61
Using a Safety Switch between the Drive and the Motor
61
Implementing the Control of a Contactor between Drive and Motor
61
Protecting the Contacts of Relay Outputs
61
Electrical Installation - IEC
63
Contents of this Chapter
63
Warnings
63
Required Tools
63
Measuring the Insulation Resistance - IEC
64
Measuring the Insulation Resistance of the Drive
64
Measuring the Insulation Resistance of the Input Power Cable
64
Measuring the Insulation Resistance of the Motor and Motor Cable
64
Measuring the Insulation Resistance of the Brake Resistor Circuit
65
Grounding System Compatibility Check - IEC
65
EMC Filter
65
Ground-To-Phase Varistor
66
Compatibility of EMC Filter and Ground-To-Phase Varistor with the Grounding System
66
Disconnecting the EMC Filter or Ground-To-Phase Varistor
68
EMC/VAR Screw Location
68
Guidelines for Installing the Drive to a TT System
69
Identifying the Grounding System of the Electrical Power Network
69
Connecting the Power Cables - IEC (Shielded Cables)
71
Connection Diagram
71
Connection Procedure
72
Connecting the Control Cables - IEC
74
Default I/O Connection Diagrams (ABB Standard Macro)
74
Default Fieldbus Connection Diagram
76
Control Cable Connection Procedure
77
Additional Information on the Control Connections
78
Embedded EIA-485 Fieldbus Connection
78
PNP Configuration for Digital Inputs
80
NPN Configuration for Digital Inputs
80
Connection for Obtaining 0
81
Connection Examples of Two-Wire and Three-Wire Sensors
81
AI and AO (or AI, DI and +10 V) as PTC Motor Temperature Sensor Interface
82
AI1 and AI2 as Pt100, Pt1000, Ni1000, KTY83 and KTY84 Sensor Inputs
83
Safe Torque off
84
Auxiliary Voltage Connection
84
Connecting a PC
85
Installing Options
85
Installing a Front Option
86
Installing a Side Option
87
Electrical Installation - North America
89
Contents of this Chapter
89
Warnings
89
Required Tools
89
Measuring the Insulation Resistance - North America
90
Measuring the Insulation Resistance of the Drive
90
Measuring the Insulation Resistance of the Input Power Cable
90
Measuring the Insulation Resistance of the Motor and Motor Cable
90
Measuring the Insulation Resistance of the Brake Resistor Circuit
91
Grounding System Compatibility Check - North America
91
EMC Filter
92
Ground-To-Phase Varistor
92
Compatibility of EMC Filter and Ground-To-Phase Varistor with the Grounding System
92
Disconnecting the Ground-To-Phase Varistor, or Connecting the EMC Filter
94
EMC/VAR Screw Location
94
Guidelines for Installing the Drive to a TT System
95
Identifying the Grounding System of the Electrical Power Network
95
Connecting the Power Cables - North America (Wiring in Conduits)
97
Connection Diagram
97
Connection Procedure
98
Connecting the Control Cables - North America
100
Default I/O Connection Diagrams (ABB Standard Macro)
100
Default Fieldbus Connection Diagram
102
Control Cable Connection Procedure
103
Additional Information on the Control Connections
104
Embedded EIA-485 Fieldbus Connection
104
PNP Configuration for Digital Inputs
106
NPN Configuration for Digital Inputs
106
Connection for Obtaining 0
107
Connection Examples of Two-Wire and Three-Wire Sensors
107
AI and AO (or AI, DI and +10 V) as PTC Motor Temperature Sensor Interface
108
AI1 and AI2 as Pt100, Pt1000, Ni1000, KTY83 and KTY84 Sensor Inputs
109
Safe Torque off
110
Auxiliary Voltage Connection
110
Connecting a PC
111
Installing Options
111
Installing a Front Option
112
Installing a Side Option
113
Installation Checklist
115
Contents of this Chapter
115
Checklist
115
Maintenance
119
Contents of this Chapter
119
Maintenance Intervals
119
Description of Symbols
119
Recommended Maintenance Intervals after Start-Up
120
Functional Safety Components
120
Cleaning the Heatsink
121
Replacing the Cooling Fans
121
Replacing the Cooling Fan, Frames R1
122
Replacing the Cooling Fan, Frame R4
124
Capacitors
125
Reforming the Capacitors
125
Technical Data
127
Contents of this Chapter
127
Electrical Ratings
127
IEC Ratings
127
UL (NEC) Ratings
129
Definitions
130
Sizing
130
Output Derating
131
Surrounding Air Temperature Derating
133
Altitude Derating
133
Switching Frequency Derating
134
Fuses
136
IEC Fuses
136
Gg Fuses (IEC)
136
Gr Fuses (IEC)
137
UL (NEC) Fuses
139
UL (NEC) Fuse Alternatives
140
Input Chokes
144
Alternative Short-Circuit Protection
146
Miniature Circuit Breakers (IEC)
146
Manual Self-Protected Combination Motor Controller - Type E USA (UL (NEC))
148
Dimensions and Weights
150
Free Space Requirements
151
Losses, Cooling Data and Noise
151
Typical Power Cable Sizes
153
Terminal Data for the Power Cables
156
Terminal Data for the Control Cables
158
External EMC Filters
158
Electrical Power Network Specification
160
Motor Connection Data
161
Motor Cable Length
161
Operational Functionality and Motor Cable Length
161
EMC Compatibility and Motor Cable Length
162
Brake Resistor Connection Data
163
Control Connection Data
163
Energy Efficiency Data (Ecodesign)
164
Protection Classes
165
Ambient Conditions
165
Materials
166
Disposal
166
Applicable Standards
167
Markings
167
EMC Compliance (IEC/EN 61800-3:2004 + A1:2012)
168
Definitions
168
Category C1
169
Category C2
169
Category C3
170
Category C4
170
UL Checklist
171
Disclaimers
172
Generic Disclaimer
172
Cybersecurity Disclaimer
172
Dimension Drawings
175
Contents of this Chapter
175
Frame R0
176
Frame R0 (Front & Side) - IP20 / UL Open Type
176
Frame R0 (Bottom & Rear) - IP20 / UL Open Type
177
Frame R1
178
Frame R1 (Front & Side) - IP20 / UL Open Type
178
Frame R1 (Bottom & Rear) - IP20 / UL Open Type
179
Frame R1 (Front & Side) - UL Type 1 Kit Installed
180
Frame R1 (Bottom & Rear) - UL Type 1 Kit Installed
181
Frame R2
182
Frame R2 (Front & Side) - IP20 / UL Open Type
182
Frame R2 (Bottom & Rear) - IP20 / UL Open Type
183
Frame R2 (Front & Side) - UL Type 1 Kit Installed
184
Frame R2 (Bottom & Rear) - UL Type 1 Kit Installed
185
Frame R3
186
Frame R3 (Front & Side) - IP20 / UL Open Type
186
Frame R3 (Bottom & Rear) - IP20 / UL Open Type
187
Frame R3 (Front & Side) - UL Type 1 Kit Installed
188
Frame R3 (Bottom & Rear) - UL Type 1 Kit Installed
189
Frame R4
190
Frame R4 (Front & Side) - IP20 / UL Open Type
190
Frame R4 (Bottom & Rear) - IP20 / UL Open Type
191
Frame R4 (Front & Side) - UL Type 1 Kit Installed
192
Frame R4 (Bottom & Rear) - UL Type 1 Kit Installed
193
Resistor Braking
195
Contents of this Chapter
195
Safety
195
Operation Principle
195
Selecting the Brake Resistor
195
Reference Brake Resistors
197
Definitions
199
Selecting and Routing the Brake Resistor Cables
199
Minimizing Electromagnetic Interference
199
Maximum Cable Length
200
Placing the Brake Resistors
200
Protecting the System in Brake Circuit Fault Situations
200
Protecting the System in Cable and Brake Resistor Short-Circuit Situations
200
Protecting the System against Thermal Overload
201
Mechanical and Electrical Installation of Brake Resistor
202
Mechanical Installation
202
Electrical Installation
202
Measuring the Insulation
202
Connecting Power Cables
202
Connection the Control Cables
202
Start-Up
202
The Safe Torque off Function
203
Contents of this Chapter
203
Description
203
Compliance with the European Machinery Directive and the UK Supply of Machinery (Safety) Regulations
204
Wiring
205
Connection Principle
205
Single ACS480 Drive, Internal Power Supply
205
Single ACS480 Drive, External Power Supply
206
Wiring Examples
207
Single ACS480 Drive, Internal Power Supply
207
Single ACS480 Drive, External Power Supply
207
Multiple ACS480 Drives, Internal Power Supply
208
Multiple ACS480 Drives, External Power Supply
209
Activation Switch
209
Cable Types and Lengths
210
Grounding of Protective Shields
210
Operation Principle
211
Start-Up Including Validation Test
212
Competence
212
Validation Test Reports
212
Validation Test Procedure
212
Use
214
Maintenance
216
Competence
216
Fault Tracing
217
Safety Data
218
Terms and Abbreviations
219
TÜV Certificate
220
Declarations of Conformity
221
BAPO-01 Auxiliary Power Extension Module
223
Contents of this Chapter
223
Safety Instructions
223
Hardware Description
223
Layout
224
Mechanical Installation
225
Electrical Installation
225
Start-Up
225
Technical Data
226
BIO-01 I/O Extension Module
227
Contents of this Chapter
227
Safety Instructions
227
Hardware Description
227
Product Overview
227
Layout
228
Mechanical Installation
228
Terminal Configuration
228
Electrical Installation
229
Start-Up
229
Technical Data
229
BREL-01 Relay Output Extension Module
233
Contents of this Chapter
233
Safety Instructions
233
Hardware Description
233
Product Overview
233
Layout
234
Mechanical Installation
234
Electrical Installation
234
Start-Up
235
Configuration Parameters
235
Technical Data
237
Further Information
239

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