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ABB ACS380 Hardware Manual
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ABB ACS380 Hardware Manual

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ABB MACHINERY DRIVES
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  • 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 E Original instructions EFFECTIVE: 2021-06-30...

  • Page 5: Table Of Contents

    Operation principle ....................Simplified main circuit diagram ..............Product variants ....................Layout ......................... Control connections .................... Standard variant (I/O and Modbus) (ACS380-04xS) ........Configured variant (ACS380-04xC) ............. Base variant (ACS380-04xN) ............... Option modules ....................Control panel options ..................UL Type 1 kits .....................
  • 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 in separate cables ................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 –...
  • Page 8 Connecting the power cables – IEC (shielded cables) ........Connection diagram ..................Connection procedure .................. Connecting the control cables ................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 ................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 .......... PNP configuration for digital inputs ..........
  • Page 10 10 Table of contents Sizing ......................Output derating ....................Surrounding air temperature derating ............Altitude derating ................... Switching frequency derating ............... Fuses ........................IEC fuses ...................... gG fuses ................... gR fuses .................... UL (NEC) fuses .................... Alternative short-circuit protection ..............Miniature circuit breakers (IEC) ..............
  • Page 11 Start-up ....................... 13 The Safe torque off function Contents of this chapter ..................Description ......................Compliance with the European Machinery Directive ........Wiring ........................Connection principle ..................Single ACS380 drive, internal power supply ........Single ACS380 drive, external power supply ........
  • Page 12 12 Table of contents Single-channel connection of activation switch ........ Wiring examples ................... Single ACS380 drive, internal power supply ........Single ACS380 drive, external power supply ........Multiple ACS380 drives, internal power supply ........ Multiple ACS380 drives, external power supply .......
  • Page 13 Table of contents 13 Encoder adapter settings ................Encoder configuration ............... Diagnostics ......................Technical data ..................... Encoder interface ..................Encoder type ..................Encoder interface connectors ............Cable ....................Encoder and BTAC module power supply ........Back-up power supply for the drive .............. Internal connectors ..................
  • Page 14 14 Table of contents Electrical installation ................... Start-up ....................... Technical data ..................... Further information...

  • Page 15: Safety Instructions

    Safety instructions 15 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 16: General Safety In Installation, Start-Up And Maintenance

    16 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 17: Electrical Safety In Installation, Start-Up And Maintenance

    Safety instructions 17 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 18: Additional Instructions And Notes

    18 Safety instructions • Make sure that the voltage between the drive output terminals (T1/U, T2/V, T3/W) and the grounding (PE) busbar is zero. • Make sure that the voltage between the drive DC terminals (UDC+ and UDC-) and the grounding (PE) terminal is zero. Note: If cables are not connected to the drive DC terminals, measuring the voltage from the DC terminal screws can give incorrect results.

  • Page 19: Printed Circuit Boards

    Safety instructions 19 Printed circuit boards WARNING! Use a grounding wristband when you handle printed circuit boards. Do not touch the boards unnecessarily. The boards contain components sensitive to electrostatic discharge. ￭ Grounding These instructions are for all personnel who are responsible for the grounding of the drive.

  • Page 20: General Safety In Operation

    20 Safety instructions • use a second protective earth conductor of the same cross-sectional area as the original protective earth conductor, • use a device that automatically disconnects the supply if the protective earth conductor is damaged. If the protective earth conductor is separate (that is, it does not form part of the input power cable or the input power cable enclosure), the minimum cross-sectional area must be: •...

  • Page 21: Additional Instructions For Permanent Magnet Motor Drives

    Safety instructions 21 Additional instructions for permanent magnet motor drives ￭ Safety in installation, start-up, maintenance These are additional warnings concerning permanent magnet motor drives. The other safety instructions in this chapter are also valid. WARNING! Obey these instructions. If you ignore them, injury or death, or damage to the equipment can occur.

  • Page 23: Introduction To 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. Target audience This manual is intended for people who plan the installation, install, start up and do maintenance work on the drive, or create instructions for the end user of the drive concerning the installation and maintenance of the drive.

  • Page 24: Quick Installation And Commissioning Flowchart

    America (wiring in conduits) (page 96) Connect the control cables. Connecting the control cables (page 74) Examine the installation. Installation checklist (page 115) Commission the drive. Refer to ACS380 Quick installation and start-up guide (3AXD50000018553 [English]) and ACS380 Firmware manual (3AXD50000029275 [English]).

  • Page 25: Terms And Abbreviations

    Introduction to the manual 25 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 adapter module BCBL-01 Optional USB to RJ45 cable...

  • Page 26: Related Manuals

    3AUA0000068940 FENA-21 Ethernet adapter module quick guide 3AXD50000158522 FEPL-02 Ethernet POWERLINK adapter module quick guide 3AXD50000158164 FEPL-02 Ethernet POWERLINK adapter module user's manual 3AUA0000123527 UL Type 1 kit for ACS380, ACH480 and ACS480 installation guide, frames 3AXD50000235254 R0 to R2...
  • Page 27 Introduction to the manual 27 Name Code UL Type 1 kit for ACS380, ACH480 and ACS480 installation guide, frames 3AXD50000242375 R3 to R4 Tool and maintenance manuals Drive composer PC tool user's manual 3AUA0000094606 Converter module capacitor reforming instructions 3BFE64059629 NETA-21 remote monitoring tool user’s manual...

  • Page 29: 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 30: Simplified Main Circuit Diagram

    The drive has three primary product variants: • Standard variant (ACS380-04xS) with BMIO-01 I/O & Modbus extension module • Configured variant (ACS380-04xC) for which the extension module, such as the fieldbus adapter, is chosen when ordering • Base variant (ACS380-04xN) without extension modules.

  • Page 31: Layout

    Operation principle and hardware description 31 Layout Front option modules Varistor grounding screw Input power terminals PE connection (motor) Motor and brake resistor terminals Control panel, display and status LED Cooling fan (on frames R1…R4) Control terminals Panel and PC tool port (RJ45) Front option slot Model information label Cold configuration connection for CCA-01...

  • Page 32: Standard Variant (I/O And Modbus) (Acs380-04Xs)

    32 Operation principle and hardware description ￭ 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. Connections on the base unit: 1. Auxiliary voltage outputs 2.

  • Page 33: Configured Variant (Acs380-04Xc)

    Operation principle and hardware description 33 ￭ 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.

  • Page 34: Base Variant (Acs380-04Xn)

    34 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 35: Control Panel Options

    You can use 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) Inputs Digital inputs (DI1, DI2) (DI3, DI4, DIO1,...

  • Page 36: Ul Type 1 Kits

    There are UL Type 1 kit options available for the drive. For the ordering codes and installation instructions, refer to the table that follows. Frame size Option code Installation instructions 3AXD50000187034 UL Type 1 kit for ACS380, ACS480 and 3AXD50000176779 ACH480 installation guide, frames R0 to R2 (3AXD50000235254) 3AXD50000178780 3AXD50000179220...

  • Page 37: Type Designation Label

    WW: Week of manufacture: 01, 02, 03, … for week 1, week 2, week 3, … XXXX: Running item number that starts each week from 0001. QR code to product information page Type designation key The type designation key shows the specifications and the configuration of the drive. ￭ Basic code Type code example: ACS380-042S-02A6-4.

  • Page 38: Option Codes

    38 Operation principle and hardware description Code Description ACS380 Product series 042S Construction: • 04 = Module. When there are no options selected: module optimized for cabinet installation, degree of protection IP20 (UL open type), bottom cable entry, Safe torque off, brake chopper, coated boards, quick installation and start-up guides.

  • Page 39: Control Panel

    Italian and Spanish, and in the local language (if available). Control panel The drive has an integrated control panel with a display and control keys. For quick reference, there is a ACS380 User interface guide (3AXD50000022224 [English]) under the main cover of the drive.
  • Page 40 40 Operation principle and hardware description Refer to the ACS380 Firmware manual (3AXD50000029275 [English]) for information on how to use the interface, start-up the drive and modify settings and parameters. Display (Home view): a) Control location: local or remote b) Status icons...

  • Page 41: Home View

    Operation principle and hardware description 41 • Push the OK key to open the highlighted setting or item. • Use the left and right arrow keys to highlight a value. • Use the up and down keys to set a value. •...

  • Page 42: Message View

    Quick installation and start-up guide (3AXD50000018553 [English]) for a list of the most typical faults and warnings. For more detailed fault and warning information, refer to the ACS380 Firmware manual (3AXD50000029275 [English]). To reset a fault, push the OK key (with the soft-key label Reset?).

  • Page 43: Mechanical Installation

    Mechanical installation 43 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 44: Examining The Installation Site

    44 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 45: Unpacking The Delivery

    Mechanical installation 45 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 46: To Install The Drive To A Din Installation Rail

    46 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 47 Mechanical installation 47 5. Release the locking button. 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 49: 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 50: European Union And United Kingdom

    50 Guidelines for planning the electrical installation ￭ European Union and United Kingdom To meet the European Union Directives and United Kingdom Regulations, according to standard EN 60204-1, Safety of Machinery, the disconnecting device must be one of the following types: •...

  • Page 51: Checking The Compatibility Of The Motor And Drive

    Guidelines for planning the electrical installation 51 Checking the compatibility of the motor and drive Use asynchronous AC induction motor, or permanent magnet synchronous motor with the drive. Multiple induction motors can be connected to the drive at a time when using the scalar motor control mode.

  • Page 52: Typical Power Cable Sizes

    52 Guidelines for planning the electrical installation 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 conductor S (mm 2 ) S p (mm 2 ) S ≤...

  • Page 53: Alternate Power Cable Types

    Guidelines for planning the electrical installation 53 Cable type Use as input power cabling Use as motor cabling Symmetrical shielded (or ar- mored) cable with three phase conductors and symmetrically constructed PE conductor and a shield (or armor) Symmetrical shielded (or ar- mored) cable with three phase conductors and a shield (or ar- mor), and separate PE conduct-...

  • Page 54: Not Allowed Power Cable Types

    54 Guidelines for planning the electrical installation Cable type Use as input power cabling Use as motor cabling Yes with motors up to 100 kW (135 hp). A potential equaliza- tion between the frames of mo- tor and driven equipment is re- quired.

  • Page 55: Additional Guidelines, North America

    ￭ Additional guidelines, North America ABB recommends the use of conduit for power wiring to the drive and between the drive and the motor(s). Due to the variety of application needs, metallic and non-metallic conduit can be used. ABB recommends the use of metallic conduit.

  • Page 56: Power Cable Shield

    56 Guidelines for planning the electrical installation resistor, and control wiring. Do not run motor wiring from more than one drive in the same conduit. ￭ Power cable shield If the cable shield is used as the sole protective earth (PE) conductor, make sure that its conductivity agrees with the PE conductor requirements.

  • Page 57: Signals In Separate Cables

    ￭ Relay cable The cable type with braided metallic shield (for example ÖLFLEX by LAPPKABEL, Germany) has been tested and approved by ABB. ￭ Control panel to drive cable Use EIA-485 with male RJ-45 connector, cable type Cat 5e or better. The maximum permitted length of the cable is 100 m (328 ft).

  • Page 58: General Guidelines - North America

    58 Guidelines for planning the electrical installation • Where control cables must cross power cables, make sure that they are arranged at an angle as near to 90 degrees as possible. • Do not run extra cables through the drive. •...

  • Page 59: Continuous Motor Cable Shield/Conduit Or Enclosure For Equipment On The Motor Cable

    Guidelines for planning the electrical installation 59 Input power cabling Motor cabling Conduit ￭ Continuous motor cable shield/conduit or 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 60: Separate Control Cable Ducts

    60 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 61: Protecting The Motor Against Thermal Overload

    Guidelines for planning the electrical installation 61 ￭ Protecting the motor against thermal overload According to regulations, the motor must be protected against thermal overload and the current must be switched off when overload is detected. The drive includes a motor thermal protection function that protects the motor and switches off the current when necessary.

  • Page 62: Protecting The Drive Against Ground Faults

    62 Guidelines for planning the electrical installation 1. If there is double or reinforced insulation between the sensor and the live parts of the motor: You can connect the sensor directly to the analog/digital input(s) of the drive. See the control cable connection instructions. Make sure that the voltage does not exceed the maximum allowed voltage over the sensor.

  • Page 63: Implementing The Safe Torque Off Function

    183). 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 64 64 Guidelines for planning the electrical installation 230 V AC 230 V AC + 24 V DC Relay output Varistor RC filter Diode...

  • Page 65: Electrical Installation - Iec

    Electrical installation – IEC 65 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 66: Measuring The Insulation Resistance

    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 67: Measuring The Insulation Resistance Of The Brake Resistor Circuit

    Electrical installation – IEC 67 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 or maintenance work.

  • Page 68: Ground-To-Phase Varistor

    68 Electrical installation – IEC Note: 200 … 240 V drives with low filtering level (type ACS380-040x, EMC category C4) do not have an internal EMC filter. Note: If you disconnect the EMC filter, the electromagnetic compatibility of the drive decreases.
  • Page 69 Electrical installation – IEC 69 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 delta (B1), mid- grounded or high-...

  • Page 70: 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 71 Electrical installation – IEC 71 working. Continue only if you are an electrical professional certified for the work. Obey the local regulations. If you ignore them, injury or death can occur. To identify the grounding system, examine the supply transformer connection. See the applicable electrical diagrams of the building.

  • Page 72: 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 constructed PE conductor in the cable.

  • Page 73: Connection Procedure

    Electrical installation – IEC 73 ￭ 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 or maintenance work. Refer to Terminal data for the power cables (page 147) for the tightening torques.

  • Page 74: Connecting The Control Cables

    Connecting the control cables 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 75 Electrical installation – IEC 75 • 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 76: Fieldbus Connection Diagram

    1) × = base unit, empty = BMIO-01 module ￭ Fieldbus connection diagram This connection diagram is valid for drives with a fieldbus extension module. The type code is ACS380-04xC followed by an option code that designates the extension module. Connection Term. Description...

  • Page 77: Control Cable Connection Procedure

    Electrical installation – IEC 77 Connection Term. Description Fieldbus connection See the applicable fieldbus Terminal +K451 FDNA-01, DeviceNet adapter manual. block DSUB9 +K454 FPBA-01 Profibus DP DSUB9 +K457 FCAN-01 CANopen RJ45×2 +K469 FECA-01 EtherCAT RJ45×2 +K470 FEPL-02, Ethernet Powerlink RJ45×2 +K475 FENA-21 Ethernet/IP, Profinet, Modbus TCP RJ45×2 +K495 BCAN-11 CANopen interface...

  • Page 78: Additional Information On The Control Connections

    78 Electrical installation – IEC ￭ Additional information on the control connections Embedded EIA-485 fieldbus connection The EIA-485 network uses shielded, twisted-pair cable with a characteristic impedance of 100 … 130 ohm for data signaling. The distributed capacitance between conductors is less than 100 pF per meter (30 pF per foot).
  • Page 79 Electrical installation – IEC 79 Connection examples are shown below. With signal ground reference terminal Without signal ground reference terminal 100 ohm Automation controller Drive Termination jumpers. The devices at the ends of the fieldbus must have termination on. All other devices must have termination off.

  • Page 80: Pnp Configuration For Digital Inputs

    80 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 81: Npn Configuration For Digital Inputs

    Electrical installation – IEC 81 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 82: Ai And Ao (Or Ai, Di And +10 V) As Ptc Motor Temperature Sensor Interface

    82 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 83 Electrical installation – IEC 83 AGND AGND 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. Analog output.

  • Page 84: Ai1 And Ai2 As Pt100, Pt1000, Ni1000, Kty83 And Kty84 Sensor Inputs

    84 Electrical installation – IEC AI1 and AI2 as Pt100, Pt1000, Ni1000, KTY83 and KTY84 sensor inputs WARNING! IEC 61800-5-1 requires double or reinforced insulation between live parts and accessible parts when: • the accessible parts are not conductive, or •...

  • Page 85: Auxiliary Voltage Connection

    Electrical installation – IEC 85 Auxiliary voltage connection The drive has 24 V DC (±10%) auxiliary power supply terminals both on the base unit and on the BMIO-01 module. You can use them: • to supply auxiliary power from the drive to external control circuits or option modules •...

  • Page 86: Connecting A Pc

    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 87 Electrical installation – IEC 87 4. Carefully align the option module with the option module slot and push it into position. 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.

  • Page 88: Installing A Side Option

    88 Electrical installation – IEC Note: If you have the BIO-01 option module, you can add one additional fieldbus module on top of it. Replace the drive front cover with the high cover that comes with the BIO-01 module. ￭ Installing a side option WARNING! Obey the safety instructions of the drive.

  • Page 89: Electrical Installation - North America

    Electrical installation – North America 89 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 90: Measuring The Insulation Resistance

    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 91: Measuring The Insulation Resistance Of The Brake Resistor Circuit

    Electrical installation – North America 91 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.

  • Page 92: Emc Filter

    Disconnecting the ground-to-phase varistor, or connecting the EMC filter (page 94). Note: 200 … 240 V drives with low filtering level (type ACS380-040x, EMC category C4) do not have an internal EMC filter. Note: When the internal EMC filter is disconnected, the electromagnetic compatibility of the drive is decreased.
  • Page 93 Electrical installation – North America 93 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 delta (B1), mid-...

  • Page 94: 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 95: Identifying The Grounding System Of The Electrical Power Network

    Electrical installation – North America 95 ￭ 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 96: 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 97: Connection Procedure

    Electrical installation – North America 97 ￭ 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 or maintenance work. Refer to Terminal data for the power cables (page 147) for the tightening torques.
  • Page 98 98 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 99: Connecting The Control Cables

    Default I/O connection diagram (ABB standard macro) This connection diagram is valid for drives with the BMIO-01 I/O & Modbus extension module: • Standard variant (ACS380-04xS) • Configured variant (ACS380-04xC) with the BMIO-01 I/O & Modbus extension module (option +L538)
  • Page 100 100 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 Digital input common × DCOM Stop (0) / Start (1) ×...

  • Page 101: Fieldbus Connection Diagram

    1) × = base unit, empty = BMIO-01 module ￭ Fieldbus connection diagram This connection diagram is valid for drives with a fieldbus extension module. The type code is ACS380-04xC followed by an option code that designates the extension module. Connection Term. Description...

  • Page 102: Control Cable Connection Procedure

    102 Electrical installation – North America Connection Term. Description Fieldbus connection See the applicable fieldbus Terminal +K451 FDNA-01, DeviceNet adapter manual. block DSUB9 +K454 FPBA-01 Profibus DP DSUB9 +K457 FCAN-01 CANopen RJ45×2 +K469 FECA-01 EtherCAT RJ45×2 +K470 FEPL-02, Ethernet Powerlink RJ45×2 +K475 FENA-21 Ethernet/IP, Profinet, Modbus TCP RJ45×2...

  • Page 103: Additional Information On The Control Connections

    Electrical installation – North America 103 ￭ Additional information on the control connections Embedded EIA-485 fieldbus connection The EIA-485 network uses shielded, twisted-pair cable with a characteristic impedance of 100 … 130 ohm for data signaling. The distributed capacitance between conductors is less than 100 pF per meter (30 pF per foot).
  • Page 104 104 Electrical installation – North America Connection examples are shown below. With signal ground reference terminal Without signal ground reference terminal 100 ohm Automation controller Drive Termination jumpers. The devices at the ends of the fieldbus must have termination on. All other devices must have termination off.

  • Page 105: Pnp Configuration For Digital Inputs

    Electrical installation – North America 105 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 106: Npn Configuration For Digital Inputs

    106 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 107: Ai And Ao (Or Ai, Di And +10 V) As Ptc Motor Temperature Sensor Interface

    Electrical installation – North America 107 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 108 108 Electrical installation – North America AGND AGND 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 109: Ai1 And Ai2 As Pt100, Pt1000, Ni1000, Kty83 And Kty84 Sensor Inputs

    Electrical installation – North America 109 AI1 and AI2 as Pt100, Pt1000, Ni1000, KTY83 and KTY84 sensor inputs WARNING! IEC 61800-5-1 requires double or reinforced insulation between live parts and accessible parts when: • the accessible parts are not conductive, or •...

  • Page 110: Auxiliary Voltage Connection

    110 Electrical installation – North America Auxiliary voltage connection The drive has 24 V DC (±10%) auxiliary power supply terminals both on the base unit and on the BMIO-01 module. You can use them: • to supply auxiliary power from the drive to external control circuits or option modules •...

  • Page 111: Connecting A Pc

    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 112 112 Electrical installation – North America 4. Carefully align the option module with the option module slot and push it into position. 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.

  • Page 113: Installing A Side Option

    Electrical installation – North America 113 Note: If you have the BIO-01 option module, you can add one additional fieldbus module on top of it. Replace the drive front cover with the high cover that comes with the BIO-01 module. ￭...

  • Page 115: Installation Checklist

    Installation checklist 115 Installation checklist Contents of this chapter This chapter contains a checklist of 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 116 116 Installation checklist Make sure that … The insulation resistance of the input power cable, motor cable and motor is measured 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 flows freely in and out of the drive.
  • Page 117 Installation checklist 117 Make sure that … The area in front of the drive is clean: the drive cooling fan cannot draw any dust or dirt inside. Drive covers and cover of the motor connection box are in place. The motor and the driven equipment are ready for power-up.

  • Page 119: Maintenance

    Maintenance intervals The tables below show the maintenance tasks which can be done by the end user. The complete maintenance schedule is available on the Internet (www.abb.com/drivesservices). For more information, consult your local ABB Service representative (www.abb.com/searchchannels). ￭ Description of symbols...

  • Page 120: 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 121: Cleaning The Heatsink

    Parameter 05.04 Fan on-time counter shows the running time of the cooling fan. After you replace the fan, reset the fan counter. Refer to the firmware manual. You can get replacement fans from ABB. Use only ABB specified spare parts.

  • Page 122: Replacing The Cooling Fan, Frames R1

    122 Maintenance ￭ 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 or maintenance work. 1.
  • Page 123 Maintenance 123 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 124: Replacing The Cooling Fan, Frame R4

    124 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 or maintenance work. 1.

  • Page 125: 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. ￭...

  • Page 127: Technical Data

    This chapter contains the technical specifications of the drive, for example, 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 Output ratings Frame ACS380- size With Max. Nominal use Light-duty Heavy-duty 04xx-… choke choke...
  • Page 128 128 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 03A7-2 0.55 0.55 0.37 04A8-2 0.75...

  • Page 129: Ul (Nec) Ratings

    Technical data 129 ￭ UL (NEC) ratings 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 1-phase U N = 230 V 02A4-1 0.33...

  • Page 130: Definitions

    130 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 045A-4 49.4 40.0 68.4 40.0 30.0...

  • Page 131: Sizing

    Technical data 131 ￭ 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 132 ) by all the applicable derating factors. For example, drive type ACS380-04xx-12A6-4 has a nominal output current of 12.6 A at 400 V. The switching frequency derating factor for this drive type is 0.68 at 8 kHz. Calculate the derated drive...

  • Page 133: Surrounding Air Temperature Derating

    (1.8 F). 50 … 60 °C Output current decreases by 1% for each additional 1 °C (1.8 F) (122 … 140 °F) • ACS380-04xx-032A-2 • ACS380-04xx-048A-2 • ACS380-04xx-032A-4 • ACS380-04xx-045A-4 Output current decreases by 2% for each additional 1 °C (1.8 F) •...

  • Page 134: Switching Frequency Derating

    40 °C (104 °F), keep parameter 97.02 Minimum switching frequency at its default value (1.5 kHz). Higher switching frequencies decrease the product life time or the performance in the temperature range 40 … 60°C (104 … 140 °F). Type Derating factor ACS380- < 4 kHz 8 kHz 12 kHz 04xx-…...

  • Page 135: Fuses

    Technical data 135 Type Derating factor ACS380- < 4 kHz 8 kHz 12 kHz 04xx-… 05A6-4 0.65 0.48 07A2-4 0.65 0.48 09A4-4 0.65 0.48 12A6-4 0.68 0.51 17A0-4 0.68 0.51 25A0-4 0.67 0.51 032A-4 0.65 0.49 038A-4 0.65 0.49 045A-4 0.66...
  • Page 136 136 Technical data Type Input Fuses Min. ACS380- current short-cir- Nominal Voltage 04xx-… I 2 t cuit cur- current rating ABB type 60269 rent size A 2 s 12A2-1 24.6 7000 OFAF000H35 3-phase U N = 230 V 02A4-2 OFAF000H6...

  • Page 137: Gr Fuses

    Technical data 137 gR fuses Type Input Fuses Min. ACS380- current short-cir- Nominal Voltage 04xx-… I 2 t cuit cur- current rating Bussmann type 60269 rent size A 2 s 1-phase U N = 230 V 02A4-1 170M2695 03A7-1 170M2695...

  • Page 138: Ul (Nec) Fuses

    138 Technical data Type Input Fuses Min. ACS380- current short-cir- Nominal Voltage 04xx-… I 2 t cuit cur- current rating Bussmann type 60269 rent size A 2 s 050A-4 58.9 22500 170M2702 1) Minimum permitted short-circuit current of the electrical power network ￭...
  • Page 139 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 248 listed fast acting, time delay, or high speed fuses must be used to maintain the UL listing of the drive.

  • Page 140: 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 141: Manual Self-Protected Combination Motor Controller - Type E Usa (Ul (Nec))

    This is in accordance with the National Electrical Code (NEC). When the correct ABB Type E manual motor protector is selected from the table and used for branch circuit protection, the drive is suitable for use in a circuit capable of delivering no more than 65 kA rms symmetrical amperes at the maximum rated voltage of the drive.
  • Page 142 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- 1) 2) 3) Frame MMP type 04xx-…...

  • Page 143: Dimensions And Weights

    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 144 144 Technical data Dimensions and weights (drive with UL Type 1 kit) Frame Weight size 11.2 1.97 7.52 11.5 1.97 7.52 11.5 2.95 7.52 13.0 10.3 5.83 7.52 15.3 12.3 10.2 9.21 7.52 1) Additional weight of the UL Type 1 kit. Height back Height Height front...

  • Page 145: Free Space Requirements

    Drives with frame size R0 have natural convection cooling. Drives with frame size R1…R4 have a cooling fan. The air flow direction is from bottom to top. Type Air flow Noise Typical power loss Frame ACS380- size m 3 /h BTU/h dB(A) 04xx-… 1-phase U N = 230 V 02A4-1 <...

  • Page 146: Typical Power Cable Sizes

    146 Technical data Type Air flow Noise Typical power loss Frame ACS380- size m 3 /h BTU/h dB(A) 04xx-… 04A0-4 05A6-4 07A2-4 09A4-4 12A6-4 17A0-4 25A0-4 1331 032A-4 1351 038A-4 1696 045A-4 1986 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 147: Terminal Data For The Power Cables

    Technical data 147 Cable size, Cu (mm 2 ) Type Conductor size, Cu (AWG) Frame ACS380- size 04xx-… 12A2-2 3×2.5 + 2.5 17A5-2 3×6 + 6 25A0-2 3×6 + 6 032A-2 3×10 + 10 048A-2 3×25 + 16 055A-2 3×25 + 16...
  • Page 148 148 Technical data Type L1, L2, L3, T1/U, T2/V, T3/W, R-, R+/ ACS380- UDC+ 04xx-… Minimum Maximum Tightening Minimum Maximum Tightening (solid/stran- (solid/stran- torque (solid/stran- (solid/stran- torque ded) ded) ded) ded) mm 2 mm 2 mm 2 mm 2 N·m N·m...
  • Page 149 Technical data 149 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 1-phase U N = 230 V 02A4-1 10.6 03A7-1 10.6 04A8-1 10.6 06A9-1 10.6 07A8-1 10.6...

  • Page 150: Terminal Data For The Control Cables

    The table shows the external EMC filters. See also EMC compatibility and motor cable length EMC compliance (IEC/EN 61800-3:2004 + A1:2012) (page 159). 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 03A7-1 RFI-12 FS 21754-16.1-07...

  • Page 151: Electrical Power Network Specification

    Electrical power network specification Voltage (U1) Input voltage range: ACS380-04xx-xxxx-1 drives: 1-phase 200 … 240 V AC -15% … +10% ACS380-04xx-xxxx-2 drives: 3-phase 200 … 240 V AC -15% … +10% ACS380-04xx-xxxx-4 drives: 3-phase 380 … 480 V AC -15% … +10% Network type Public low voltage networks.

  • Page 152: 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 61800- tion (IEC 61800-5-1, 5-1.

  • Page 153: Emc Compatibility And Motor Cable Length

    Note: Radiated emissions are according to C2 with ACS380-042x drives. For ACS380-040x drives, use a metal enclosure to fulfill radiated emissions C2 limits with an external EMC filter.

  • Page 154: Control Connection Data

    154 Technical data Control connection data Analog inputs (AI1, Voltage signal, single- 0 … 10 V DC (10% overrange, 11 V DC max.) AI2) ended R in = 221.6 kohm Current signal, single- 0 … 20 mA (10% overrange, 22 mA max.) ended R in = 137 ohm Inaccuracy...

  • Page 155: Brake Resistor Connection Data

    Energy efficiency data (EU ecodesign) Energy efficiency data according to IEC 61800-9-2 is available from the ecodesign tool at https://ecodesign.drivesmotors.abb.com/. Energy efficiency data is not provided for 1-phase 230 V drives. The drives with 1-phase input are not in the scope of the EU ecodesign requirements (Regulation EU 2019/1781).
  • Page 156 156 Technical data Requirement Operation installed Storage in the protect- Transportation in the for stationary use ive package protective package Installation site alti- 230 V drives: tude 0 … 2000 m (0 … 6562 ft) above sea level (with output derating above 1000 m [3281 ft]) 400/480 V drives:...

  • Page 157: Materials

    IEC 62635 guidelines. To aid recycling, plastic parts are marked with an appropriate identification code. Contact your local ABB distributor for further information on environmental aspects and recycling instructions for professional recyclers. End of life treatment must follow...

  • Page 158: Applicable Standards

    158 Technical data 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 159: Emc Compliance (Iec/En 61800-3:2004 + A1:2012)

    Technical data 159 UL Listed mark for USA and Canada Product has been tested and evaluated against the relevant North American standards by the Underwriters Laboratories. Valid with rated voltages up to 600 V. RCM mark Product complies with Australian and New Zealand requirements specific to EMC, telecommunications and electrical safety.

  • Page 160: Category C1

    160 Technical data Drive of category C2: drive of rated voltage less than 1000 V and intended to be installed and started up only by a professional when used in the first environment. Note: A professional is a person or organization having necessary skills in installing and/or starting up power drive systems, including their EMC aspects.

  • Page 161: Category C3

    Technical data 161 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 162 162 Technical data Medium voltage network Neighboring network Point of measurement Low voltage Equipment (victim) Equipment Supply transformer Static screen Drive 2. An EMC plan for preventing disturbances is drawn up for the installation. A template is available in Technical guide No. 3 EMC compliant installation and configuration for a power drive system (3AFE61348280 [English]).

  • Page 163: Ul Checklist

    • The cables located within the motor circuit must be rated for at least 75 °C in 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 164: Disclaimers

    Notwithstanding any other provision to the contrary and regardless whether the contract is terminated or not, ABB and its affiliates are under no circumstances liable for damages and/or losses related to such security breaches, any unauthorized access, interference,...

  • Page 165: Dimension Drawings

    Dimension drawings 165 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 166: Frame R0 (1-Phase 230 V)

    166 Dimension drawings Frame R0 (1-phase 230 V)

  • Page 167: Frame R0 (400/480 V)

    Dimension drawings 167 Frame R0 (400/480 V)

  • Page 168: Frame R1 (230 V)

    168 Dimension drawings Frame R1 (230 V)

  • Page 169: Frame R1 (3-Phase 230 V And 3-Phase 400/480 V)

    Dimension drawings 169 Frame R1 (3-phase 230 V and 3-phase 400/480 V)

  • Page 170: Frame R2 (230 V)

    170 Dimension drawings Frame R2 (230 V)

  • Page 171: Frame R2 (400/480 V)

    Dimension drawings 171 Frame R2 (400/480 V)

  • Page 172: Frame R3 (400/480 V)

    172 Dimension drawings Frame R3 (400/480 V)

  • Page 173: Frame R4 (400/480 V)

    Dimension drawings 173 Frame R4 (400/480 V)

  • Page 175: Resistor Braking

    Resistor braking 175 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 176 176 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 •...

  • Page 177: Reference Brake Resistors

    The drive and the internal chopper are not able to handle the overcurrent caused by the low resistance. ￭ Reference brake resistors Type Example resistor R min R max P BRcont P BRmax ACS380- types 04xx-… Danotherm 1-phase U N = 230 V 02A4-1 32.5 0.25 0.33 0.38 0.50...

  • Page 178: Definitions

    178 Resistor braking Type Example resistor R min R max P BRcont P BRmax ACS380- types 04xx-… Danotherm 07A2-4 2.20 2.00 3.30 4.40 CBR-V 330 D T 406 78R UL 09A4-4 3.00 3.00 4.50 6.00 12A6-4 4.00 5.00 6.00 8.00 17A0-4 5.50...

  • Page 179: Maximum Cable Length

    ABB recommends to enable the thermal model at start up. ABB recommends to equip the drive with a main contactor for safety reasons even when you have enabled the resistor thermal model. Wire the contactor so that it opens in case the resistor overheats.

  • Page 180: Mechanical And Electrical Installation Of Brake Resistor

    (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 181: Mechanical Installation

    Resistor braking 181 ￭ Mechanical installation Refer to the resistor manufacturer’s instructions. ￭ Electrical installation Measuring the insulation See the electrical installation instructions of the drive. Connecting power cables See the electrical installation instructions of the drive. Connection the control cables Connect the thermal switch of the brake resistor as described in Protecting the system against thermal overload (page...

  • Page 183: The Safe Torque Off Function

    The Safe torque off function 183 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 that stop the drive in case of danger (such as an emergency stop circuit).

  • Page 184: Compliance With The European Machinery Directive

    184 The Safe torque off function Standard Name IEC 61000-6-7:2014 Electromagnetic compatibility (EMC) – Part 6-7: Generic stand- ards – Immunity requirements for equipment intended to perform functions in a safety-related system (functional safety) in indus- trial locations IEC 61326-3-1:2017 Electrical equipment for measurement, control and laboratory use –...

  • Page 185: Wiring

    The Safe torque off function 185 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...

  • Page 186: Single Acs380 Drive, External Power Supply

    186 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 187: Single-Channel Connection Of Activation Switch

    The Safe torque off function 187 Single-channel connection of activation switch + 24 V DC SGND UDC+ UDC- Drive Control unit Control logic To motor Activation switch Note: • Both STO inputs (S1, S2) must be connected to the activation switch. Otherwise, no SIL/PL classification is given.

  • Page 188: Wiring Examples

    188 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 189: Multiple Acs380 Drives, Internal Power Supply

    The Safe torque off function 189 Multiple ACS380 drives, internal power supply +24 V SGND SGND SGND Drive Control unit Activation switch...

  • Page 190: Multiple Acs380 Drives, External Power Supply

    190 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 191: Cable Types And Lengths

    The Safe torque off function 191 • In case a manually operated activation switch is used, the switch must be of a type that can be locked out to the open position. • The contacts of the switch or relay must open/close within 200 ms of each other. ￭...

  • Page 192: Operation Principle

    192 The Safe torque off function Operation principle 1. 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 193: Start-Up Including Validation Test

    The Safe torque off function 193 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 •...
  • Page 194 194 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 195: Use

    The Safe torque off function 195 1. 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 196 196 The Safe torque off function 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 197: 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 193). Use only spare parts approved by ABB. Record all maintenance and proof test activities in the machine logbook. ￭ Competence...

  • Page 198: 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 199: Safety Data

    The Safe torque off function 199 Safety data The safety data for the Safe torque off function is given below. Note: The safety data is calculated for redundant use, and does not apply if both STO channels are not used. PFD avg PFD avg Frame...

  • Page 200: Terms And Abbreviations

    200 The Safe torque off function • 60 °C board temperature at 1.5% of time • 85 °C board temperature at 2.3% of time. • The STO is a type A safety component as defined in IEC 61508-2. • Relevant failure modes: •...

  • Page 201: Tüv Certificate

    After the mission time elapses, the safety device must be replaced. Note that any T M values given cannot be regarded as a guarantee or warranty. ￭ TÜV certificate The TÜV certificate is available on the Internet at www.abb.com/drives/documents.

  • Page 202: Declarations Of Conformity

    202 The Safe torque off function ￭ Declarations of conformity...
  • Page 203 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, May 7, 2021...

  • Page 205: Btac-02 Pulse Encoder Interface Module

    BTAC-02 pulse encoder interface module 205 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 206: Layout

    206 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 See the electrical installation instructions of the drive.

  • Page 207: Terminal Designations

    BTAC-02 pulse encoder interface module 207 Cable Maximum con- Maximum cable nector size length 2.5 mm 2 4 × (2+1) double-shielded twisted pair cable with individual 12 AWG 328 ft 100 m 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 208: Wiring - Encoder Power Supply Interface

    208 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 209: Wiring - Encoder

    BTAC-02 pulse encoder interface module 209 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 210: Encoder Output Types

    210 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 A or 1 A or 1 B or 2...

  • Page 211: Wiring Diagrams - Push-Pull Type Encoder Output

    BTAC-02 pulse encoder interface module 211 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 212: Single-Ended Connection

    212 BTAC-02 pulse encoder interface module Single-ended connection Encoder BTAC module Encoder power supply...

  • Page 213: Wiring Diagrams - Open Collector (Sinking) Encoder Output

    BTAC-02 pulse encoder interface module 213 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 214: Wiring Diagrams - Open Emitter (Sourcing) Encoder Output

    214 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 215: Apply Power

    BTAC-02 pulse encoder interface module 215 Apply power 1. Turn on the input power to the drive. 2. Continue with Start-up. Start-up To configure the operation of the BTAC module: 1. Power up the drive. 2. Set parameters in groups 90 Feedback selection, 91 Encoder adapter settings and 92 Encoder 1 configuration.

  • Page 216: Encoder Adapter Settings

    216 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 decremen- ted in the negative direction. The parameter is effective only if the position is abso- lute.The parameter value is updated for both single- turn and multiturn encoders.

  • Page 217: Encoder Configuration

    BTAC-02 pulse encoder interface module 217 Name/Value Description Def/FbEq16/32 91 Enc adapter settings 91.10 Enc par re- Validates any changed encoder interface module Done fresh parameters. This is needed for any parameter changes in groups 90…92 to take effect. After refresh- ing, the value reverts automatically to Done.

  • Page 218: Technical Data

    218 BTAC-02 pulse encoder interface module Technical data ￭ Encoder interface The encoder user interface is isolated with reinforced insulation from the DC potential. Encoder type • Incremental, TTL/HTL encoders • Differential, single-ended, open collector, and open emitter encoder outputs (refer Encoder output types (page 210)) •...

  • Page 219: Dimensions

    BTAC-02 pulse encoder interface module 219 ￭ Dimensions 3AXD50000031154 rev. A...

  • Page 221: Brel-01 Relay Output Extension Module

    BREL-01 relay output extension module 221 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 222: Layout

     Product overview BREL-01 relay output extension module (option +L511) adds four relay outputs to the 222 BREL-01 relay output extension module drive.  Layout ￭ Layout 1. BREL module 1. BREL-01 module 2. Locking screw hole 2. Locking screw hole 3.

  • Page 223: Start-Up

    2. Set the parameter 15.01 Extension module type to 5 (BREL). 3. Use the control panel on the drive and set the parameters for relay outputs RO4…RO7 in 15 I/O extension module. Refer to the ACS380 Firmware manual (3AXD50000029275 [English]) for parameter descriptions.
  • Page 224 224 BREL-01 relay output extension module Name/Value Description Def / FbEq16/32 15.04 RO status Displays the status of the relay outputs. This parameter 1 = 1 is read-only. Bit 0 RO4 1 = Relay output 4 is ON. Bit 1 RO5 1 = Relay output 5 is ON.

  • Page 225: Technical Data

    BREL-01 relay output extension module 225 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. … 15.11 RO5 ON delay Defines the activation delay for relay output RO5. 0.0 s 0.0 …...
  • Page 226 226 BREL-01 relay output extension module Dimensions: 3AXD50000031148 rev. A...

  • Page 227: Bapo-01 Auxiliary Power Extension Module

    BAPO-01 auxiliary power extension module 227 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 228: Layout

    228 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 PARAM SAVE to (1) SAVE.

  • Page 229: Mechanical Installation

    BAPO-01 auxiliary power extension module 229 Mechanical installation See the electrical installation instructions of the drive. 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. Do not chain an external 24 V DC power supply to several drives.

  • Page 230: Technical Data

    230 BAPO-01 auxiliary power extension module Technical data Voltage and current rating for the auxiliary power supply: +24 V DC ±10%, max. 1000 mA (including internal fan load). Power loss: Power losses with maximum load 4 W. Dimensions: 26 [1.024] 11.3 [0.444] 86.1 [3.391] 16 [0.63]...

  • Page 231: Bio-01 I/O Extension Module

    BIO-01 I/O extension module 231 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 232: Layout

    232 BIO-01 I/O extension module ￭ Layout 1. Locking tab 2. Option module slot 3. Chassis screw 4. I/O connector 5. Switches for configur- ing terminals S1 and S2 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 233 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 234 234 BIO-01 I/O extension module Internal connections of GND and SCR terminals +24 V +24 V DGND DGND DCOM DCOM DIO1 +10V SGND...
  • Page 235 BIO-01 I/O extension module 235 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 237 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/searchchannels.
  • Page 238 3AXD50000029274E © Copyright 2021 ABB. All rights reserved. Specifications subject to change without notice.

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