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ABB ACS480 Manuals
Manuals and User Guides for ABB ACS480. We have
7
ABB ACS480 manuals available for free PDF download: Hardware Manual, Troubleshooting Manual, Manual, Quick Installation And Start-Up Manual
ABB ACS480 Hardware Manual (240 pages)
Brand:
ABB
| Category:
DC Drives
| Size: 8.27 MB
Table of Contents
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
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ABB ACS480 Hardware Manual (180 pages)
Brand:
ABB
| Category:
DC Drives
| Size: 7.42 MB
Table of Contents
Table of Contents
5
1 Safety Instructions
13
Contents of this Chapter
13
Use of Warnings and Notes
13
General Safety in Installation, Start-Up and Maintenance
14
Electrical Safety in Installation, Start-Up and Maintenance
14
Electrical Safety Precautions
14
Additional Instructions and Notes
15
Printed Circuit Boards
16
Grounding
16
General Safety in Operation
17
Additional Instructions for Permanent Magnet Motor Drives
17
Safety in Installation, Start-Up, Maintenance
17
Safety in Operation
18
2 Introduction to the Manual
19
Contents of this Chapter
19
Applicability
19
Target Audience
19
Purpose of the Manual
19
Categorization by Frame Size
19
Quick Installation and Commissioning Flowchart
20
Terms and Abbreviations
21
Related Manuals
22
3 Operation Principle and Hardware Description
25
Contents of this Chapter
25
Operation Principle
25
Simplified Main Circuit Diagram
26
Product Variants
26
IEC and UL (NEC) Product Types
26
Layout
27
Control Connections
28
Standard Unit
28
Base Unit
29
Option Modules
29
Control Panel Options
30
UL Type 1 Kits
30
Drive Labels
31
Type Designation Key
32
Basic Code
32
Option (Plus) Codes
32
4 Mechanical Installation
35
Contents of this Chapter
35
Installation Alternatives
35
Examining the Installation Site
36
Required Tools
36
Unpacking the Delivery
36
Installing the Drive
37
To Install the Drive with Screws
37
To Install the Drive to a DIN Installation Rail
37
5 Guidelines for Planning the Electrical Installation
39
Contents of this Chapter
39
Limitation of Liability
39
Selecting the Main Supply Disconnecting Device
39
European Union
39
North America
40
Other Regions
40
Selecting the Main Contactor
40
Checking the Compatibility of the Motor and Drive
40
Selecting the Power Cables
40
General Guidelines
40
Typical Power Cable Sizes
41
Power Cable Types
41
Preferred Power Cable Types
41
Alternate Power Cable Types
42
Not Allowed Power Cable Types
42
Additional Guidelines, North America
43
Metal Conduit
43
Power Cable Shield
43
Selecting the Control Cables
44
Shielding
44
Signals in Separate Cables
44
Signals that Can be Run in the same Cable
44
Relay Cable Type
44
Control Panel to Drive Cable
45
Routing the Cables
45
General Guidelines - IEC
45
General Guidelines - North America
45
Continuous Motor Cable Shield/Conduit or Enclosure for Equipment on the Motor Cable
46
Separate Control Cable Ducts
47
Implementing Short-Circuit and Thermal Overload Protection
47
Protecting the Drive and Input Power Cable in Short-Circuits
47
Protecting the Motor and Motor Cable in Short-Circuits
47
Protecting the Drive, and the Input Power and Motor Cables against Thermal Overload
47
Protecting the Motor against Thermal Overload
47
Protecting the Motor against Overload Without Thermal Model or Temperature Sensors
48
Implementing a Motor Temperature Sensor Connection
48
Protecting the Drive against Ground Faults
49
Residual Current Device Compatibility
49
Implementing the Emergency Stop Function
49
Implementing the Safe Torque off Function
49
Using a Safety Switch between the Drive and the Motor
49
Implementing the Control of a Contactor between Drive and Motor
49
Protecting the Contacts of Relay Outputs
50
6 Electrical Installation - IEC
51
Contents of this Chapter
51
Warnings
51
Required Tools
51
Measuring the Insulation
52
Measuring the Insulation of the Drive System
52
Measuring the Insulation of the Input Cable
52
Measuring the Insulation of the Motor and Motor Cable
52
Measuring the Insulation of Brake Resistor and Resistor Cable
52
Earthing System Compatibility Check - IEC
53
EMC Filter Compatibility
53
Ground-To-Phase Varistor Compatibility
53
When to Disconnect EMC Filter or Ground-To-Phase Varistor
53
Disconnecting the EMC Filter or Ground-To-Phase Varistor
54
Identifying the Earthing System of the Electrical Power Network
55
Connecting the Power Cables - IEC (Shielded Cables)
56
Connection Diagram
56
Connection Procedure
57
Connecting the Control Cables
58
Default I/O Connection Diagrams (ABB Standard Macro)
58
Default Fieldbus Connection Diagram
60
Control Cable Connection Procedure
61
Additional Information on the Control Connections
62
Connecting EIA-485 Fieldbus Cable to the Drive
62
Connection Examples of Two-Wire and Three-Wire Sensors
62
AI and AO (or AI, DI and +10 V) as PTC Motor Temperature Sensor Interface
63
AI1 and AI2 as Pt100, Pt1000, Ni1000, KTY83 and KTY84 Sensor Inputs
64
Auxiliary Voltage Connection
65
Connecting a PC
66
Installing Options
66
Installing a Front Option
66
Installing a Side Option
67
7 Electrical Installation - North America
69
Contents of this Chapter
69
Warnings
69
Required Tools
69
Measuring the Insulation
70
Measuring the Insulation of the Drive System
70
Measuring the Insulation of the Input Cable
70
Measuring the Insulation of the Motor and Motor Cable
70
Measuring the Insulation of Brake Resistor and Resistor Cable
70
Earthing System Compatibility Check - North America
71
EMC Filter
71
Ground-To-Phase Varistor
71
When to Disconnect Ground-To-Phase Varistor, or Connect EMC Filter
71
Disconnecting the Ground-To-Phase Varistor, or Connecting the EMC Filter
73
Identifying the Earthing System of the Electrical Power Network
73
Connecting the Power Cables - North America (Wiring in Conduits)
74
Connection Diagram
75
Connection Procedure
75
Connecting the Control Cables
76
Default I/O Connection Diagrams (ABB Standard Macro)
76
Default Fieldbus Connection Diagram
78
Control Cable Connection Procedure
79
Additional Information on the Control Connections
80
Connecting EIA-485 Fieldbus Cable to the Drive
80
Connection Examples of Two-Wire and Three-Wire Sensors
80
AI and AO (or AI, DI and +10 V) as PTC Motor Temperature Sensor Interface
81
AI1 and AI2 as Pt100, Pt1000, Ni1000, KTY83 and KTY84 Sensor Inputs
82
Auxiliary Voltage Connection
83
Connecting a PC
84
Installing Options
84
Installing a Front Option
84
Installing a Side Option
85
8 Installation Checklist of the Drive
87
Contents of this Chapter
87
Checklist
87
9 Maintenance
89
Contents of this Chapter
89
Maintenance Intervals
89
Cleaning the Heatsink
90
Replacing the Cooling Fans
91
To Replace the Cooling Fan for Frame Sizes R1, R2 and R3
91
To Replace the Cooling Fan for Frame R4
92
Capacitors
94
Reforming the Capacitors
94
10 Technical Data
95
Contents of this Chapter
95
Electrical Ratings
96
IEC Ratings
96
UL (NEC) Ratings
97
Notes and Definitions
98
Sizing
98
Output Derating
98
Surrounding Air Temperature Derating
100
Switching Frequency Derating
100
Altitude Derating
101
Fuses
102
Gg Fuses (IEC)
102
Gr Fuses (IEC)
102
T Fuses (UL(NEC))
103
Alternate Short-Circuit Protection
104
Miniature Circuit Breakers (IEC)
104
Manual Self-Protected Combination Motor Controller - Type E USA (UL (NEC))
105
Dimensions and Weights
106
Free Space Requirements
107
Losses, Cooling Data and Noise
107
Terminal Data for the Power Cables
109
Typical Power Cable Sizes
110
Terminal Data for the Control Cables
110
External EMC Filters
111
Electrical Power Network Specification
112
Motor Connection Data
112
Motor Cable Length
112
Operational Functionality and Motor Cable Length
112
EMC Compatibility and Motor Cable Length
113
Brake Resistor Connection Data
113
Control Connection Data
114
Efficiency
114
Protection Classes
115
Ambient Conditions
115
Materials
116
Disposal
116
Applicable Standards
116
Markings
117
EMC Compliance (IEC/EN 61800-3:2004 + A2012)
117
Definitions
117
Category C1
118
Category C2
118
Category C3
119
Category C4
119
UL and CSA Checklist
120
Disclaimers
121
Generic Disclaimer
121
Cybersecurity Disclaimer
121
11 Dimension Drawings
123
Contents of this Chapter
123
Frame R1
124
Frame R1 (Front & Side) - IP20 / UL Type Open
124
Frame R1 (Bottom & Rear) - IP20 / UL Type Open
125
Frame R1 (Front & Side) - UL Type 1 Kit Installed
126
Frame R1 (Bottom & Rear) - UL Type 1 Kit Installed
127
Frame R2
128
Frame R2 (Front & Side) - IP20 / UL Type Open
128
Frame R2 (Bottom & Rear) - IP20 / UL Type Open
129
Frame R2 (Front & Side) - UL Type 1 Kit Installed
130
Frame R2 (Bottom & Rear) - UL Type 1 Kit Installed
131
Frame R3
132
Frame R3 (Front & Side) - IP20 / UL Type Open
132
Frame R3 (Bottom & Rear) - IP20 / UL Type Open
133
Frame R3 (Front & Side) - UL Type 1 Kit Installed
134
Frame R3 (Bottom & Rear) - UL Type 1 Kit Installed
135
Frame R4
136
Frame R4 (Front & Side) - IP20 / UL Type Open
136
Frame R4 (Bottom & Rear) - IP20 / UL Type Open
137
Frame R4 (Front & Side) - UL Type 1 Kit Installed
138
Frame R4 (Bottom & Rear) - UL Type 1 Kit Installed
139
12 Resistor Braking
141
Contents of this Chapter
141
Safety
141
Operating Principle
141
Selecting the Brake Resistor
141
Reference Brake Resistors
143
Definitions
143
Selecting and Routing the Brake Resistor Cables
144
Minimizing Electromagnetic Interference
144
Maximum Cable Length
144
Placing Custom Brake Resistors
144
Protecting the System in Brake Circuit Fault Situations
144
Protecting the System in Cable and Brake Resistor Short-Circuit Situations
144
Protecting the System against Thermal Overload
145
Mechanical and Electrical Installation of Brake Resistor
145
Mechanical Installation
146
Electrical Installation
146
Measuring the Insulation
146
Connecting Power Cables
146
Connection the Control Cables
146
Start-Up
146
13 The Safe Torque off Function
147
Contents of this Chapter
147
Description
147
Compliance with the European Machinery Directive
148
Wiring
149
Connection Principle
149
Single ACS480 Drive, Internal Power Supply
149
Single ACS480 Drive, External Power Supply
150
Wiring Examples
150
Single ACS480 Drive, Internal Power Supply
150
Single ACS480 Drive, External Power Supply
151
Multiple ACS480 Drives, Internal Power Supply
152
Multiple ACS480 Drives, External Power Supply
153
Activation Switch
153
Cable Types and Lengths
153
Grounding of Protective Shields
154
Operation Principle
155
Start-Up Including Acceptance Test
156
Competence
156
Acceptance Test Reports
156
Acceptance Test Procedure
156
Use
158
Maintenance
159
Competence
159
Fault Tracing
160
Safety Data
161
Abbreviations
161
TÜV Certificate
162
Declaration of Conformity
163
14 BAPO-01 Auxiliary Power Extension Module
165
Contents of this Chapter
165
Safety Instructions
165
Hardware Description
165
Layout
166
Mechanical Installation
166
Electrical Installation
166
Start-Up
167
Technical Data
167
ABB ACS480 Hardware Manual (162 pages)
Brand:
ABB
| Category:
DC Drives
| Size: 7.74 MB
Table of Contents
Table of Contents
5
1 Safety Instructions
11
Contents of this Chapter
11
Use of Warnings and Notes in this Manual
11
General Safety in Installation, Start-Up and Maintenance
12
Electrical Safety in Installation, Start-Up and Maintenance
13
Precautions before Electrical Work
15
Additional Instructions and Notes
16
Additional Instructions for Permanent Magnet Motor Drives
16
Safety in Installation, Start-Up and Maintenance
16
General Safety in Operation
17
2 Introduction to the Manual
19
Contents of this Chapter
19
Applicability
19
Target Audience
19
Purpose of the Manual
19
Contents of this Manual
20
Related Documents
20
Quick Installation and Commissioning Flowchart
21
Categorization by Frame (Size)
22
3 Hardware Description
25
Contents of this Chapter
25
General Description
25
Product Variants
25
Hardware Overview
26
Control Connections
28
Standard Unit
28
Base Unit
29
Mounted Options
30
Control Panel
30
PC Connection
30
Drive Labels
31
Model Information Label
31
Software Information Label
31
Type Designation Label
33
Type Designation Key
33
Operation Principle
35
4 Mechanical Installation
37
Contents of this Chapter
37
Examining the Installation Site
38
Required Tools
38
Unpacking the Delivery
39
Installing the Drive
40
To Install the Drive with Screws
40
To Install the Drive to a DIN Installation Rail
41
5 Planning the Electrical Installation
43
Contents of this Chapter
43
Selecting the Supply Disconnecting Device
43
European Union
43
Other Regions
44
Checking the Compatibility of the Motor and Drive
44
Selecting the Power Cables
44
Typical Power Cable Sizes
45
Recommended Power Cable Types
47
Power Cable Types for Limited Use
47
Not Allowed Power Cable Types
47
Motor Cable Shield
48
Additional US Requirements
48
Selecting the Control Cables
50
Shielding
50
Signals in Separate Cables
50
Signals that Can be Run in the same Cable
50
Relay Cable
50
Drive Composer PC Tool Cable
50
Routing the Cables
51
Separate Control Cable Ducts
52
Continuous Motor Cable Shield or Conduit
52
Implementing Short-Circuit Protection
52
Protecting the Drive and Input Power Cable in Short-Circuits
52
Protecting the Motor and Motor Cable in Short-Circuits
52
Implementing Thermal Overload Protection
53
Protecting the Drive, and the Input Power and Motor Cables against Thermal Overload
53
Protecting the Motor against Thermal Overload
53
Protecting the Drive against Ground Faults
53
Residual Current Device Compatibility
53
Implementing the Emergency Stop Function
53
Implementing the Safe Torque off Function
54
Using a Safety Switch between the Drive and Motor
54
Using a Contactor between the Drive and Motor
54
Protecting the Contacts of Relay Outputs
55
6 Electrical Installation
57
Contents of this Chapter
57
Warnings
57
Required Tools
57
Measuring Insulation
58
Drive
58
Input Power Cable
58
Motor and Motor Cable
58
Brake Resistor Assembly
58
Compatibility with IT (Ungrounded) and Corner-Grounded TN Systems
59
EMC Filter
59
EMC Filter Disconnection
59
Ground-To-Phase Varistor
60
Connecting the Power Cables
61
Connection Diagram
61
Connection Procedure
62
Connecting the Control Cables
64
Default I/O Connection Diagram (ABB Standard Macro)
65
Connecting EIA-485 Modbus RTU Terminal to the Drive
67
Control Cable Connection Procedure
69
Auxiliary Voltage Connection
70
Option Modules
71
To Install a Front Option
71
To Remove a Front Option
73
To Install a Side Option
73
To Remove a Side Option
73
7 Installation Checklist
75
Contents of this Chapter
75
Warnings
75
Checklist
75
8 Maintenance
77
Contents of this Chapter
77
Maintenance Intervals
78
Cleaning the Heat Sink
79
Replacing the Cooling Fans
80
To Replace the Cooling Fan for Frame Sizes R1, R2 and R3
80
To Replace the Cooling Fan for Frame R4
82
Servicing the Capacitors
84
Capacitor Reforming
84
9 Technical Data
85
Contents of this Chapter
85
Ratings
86
IEC Ratings
86
NEMA Ratings
87
Definitions
87
Sizing
87
Derating
88
Surrounding Air Temperature Derating, IP20
88
Switching Frequency Derating
89
Altitude Derating
90
Fuses (IEC)
91
Gg Fuses
91
Gr Fuses
92
UL Fuses
94
Alternate Short-Circuit Protection
95
Miniature Circuit Breakers (IEC Environment)
95
Self-Protected Combination Manual Controller - Type EUSA (UL) Environment
96
Dimensions and Weights
98
Free Space Requirements
99
Losses, Cooling Data and Noise
99
Terminal Data for the Power Cables
101
Terminal Data for the Control Cables
102
External EMC Filters
103
Electric Power Network Specification
104
Motor Cable Length
105
Motor Connection Data
105
Control Connection Data
107
Brake Resistor Connection
108
Efficiency
108
Degrees of Protection
108
Ambient Conditions
109
Materials
110
Applicable Standards
111
CE Marking
112
Compliance with the European Low Voltage Directive
112
Compliance with the European EMC Directive
112
Compliance with the European Rohs Directive
112
Compliance with the European WEEE Directive
112
Compliance with the European Machinery Directive
113
Compliance with en 61800-3:2004 + A1:2012
114
Definitions
114
Category C1
114
Category C2
114
Category C4
116
UL Marking
117
UL Checklist
117
CSA Marking
117
RCM Marking
117
EAC Marking
118
China Rohs Marking
118
Disclaimers
118
Generic Disclaimer
118
Cyber Security Disclaimer
118
10 Dimension Drawings
119
Frame R0 (230 V) (Front & Side)
120
Frame R0 (230 V) (Bottom & Rear)
121
Frame R1 (400 V) (Front & Side)
122
Frame R1 (400 V) (Bottom & Rear)
123
Frame R2 (400 V) (Front & Side)
124
Frame R2 (400 V) (Bottom & Rear)
125
Frame R3 (Front & Side)
126
Frame R3 (Bottom & Rear)
127
Frame R4 (Front & Side)
128
Frame R4 ()
129
11 Resistor Braking
131
Contents of this Chapter
131
Operation Principle and Hardware Description
131
Selecting the Brake Resistor
131
Reference Brake Resistors
133
Selecting and Routing the Brake Resistor Cables
134
Minimizing Electromagnetic Interference
134
Maximum Cable Length
134
EMC Compliance of the Complete Installation
134
Placing the Brake Resistor
134
Protecting the System in Brake Circuit Fault Situations
135
Protecting the System in Cable and Brake Resistor Short-Circuit Situations
135
Protecting the System against Thermal Overload
135
Mechanical Installation
135
Electrical Installation
136
Checking the Insulation of the Assembly
136
Connection Diagram
136
Connection Procedure
136
Start-Up
137
12 Safe Torque off Function
139
Contents of this Chapter
139
Description
139
Compliance with the European Machinery Directive
140
Connection Principle
141
Connection with Internal +24 V DC Power Supply
141
Connection with External +24 V DC Power Supply
141
Wiring Examples
142
Activation Switch
142
Cable Types and Lengths
143
Grounding of Protective Shields
143
Operation Principle
143
Start-Up Including Acceptance Test
144
Competence
144
Acceptance Test Reports
144
Acceptance Test Procedure
145
Use
146
Maintenance
148
Competence
148
Fault Tracing
148
Safety Data
150
Abbreviations
152
Declaration of Conformity
152
13 BAPO-01 Power Extension Module
153
Contents of this Chapter
153
Safety Instructions
153
Hardware Description
154
Product Overview
154
Layout
154
Mechanical Installation
155
Electrical Installation
155
Start-Up
155
Technical Data
156
Voltage and Current Rating for the Auxiliary Power Supply
156
Power Loss
156
Dimensions
156
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Contents of this Chapter
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Overview of the Reforming
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Reforming Time
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Checking the Converter Age
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Reforming with Power on for 30 Minutes
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