Abb ACH480 User Manual
—
ABB DRIVES FOR HVAC
ACH480 drives
Hardware manual
—
ACH480 manuals
List of related manuals
Drive manuals and guides Code (English)
ACH480 drives hardware manual 3AXD50000245949
ACH480 quick installation guide 3AXD50000247141
ACH480 drives firmware manual 3AXD50000247134
Option manuals and guides
ACX-AP-x assistant control panel user’s manual 3AUA0000085685
DPMP-01 mounting platform for control panels 3AUA0000100140
DPMP-02/03 mounting platform for control panels 3AUA0000136205
FBIP-21 BACnet/IP adapter module user's manual 3AXD50000028468
FBIP-21 BACnet/IP adapter module quick guide 3AXD50000158171
FCAN-01 CANopen adapter module user's manual 3AFE68615500
FCNA-01 ControlNet adapter module user's manual 3AUA0000141650
FDNA-01 DeviceNet adapter module quick guide 3AFE68573360
FECA-01 EtherCAT adapter module user's manual 3AUA0000068940
FENA-01/-11/-21 Ethernet adapter module user's manual 3AUA0000093568
FEPL-02 Ethernet POWERLINK adapter module user's manual 3AUA0000123527
FMBT-21 Modbus/TCP adapter module quick guide 3AXD50000158560
FPBA-01 PROFIBUS DP adapter module user's manual 3AFE68573271
FPNO-21 PROFINET adapter module user's manual 3AXD50000158614
FSCA-01 RS-485 adapter module user's manual 3AUA0000109533
UL Type 1 kit QIG for ACS380 and ACS480 - frames R0 to R2 3AXD50000235254
UL Type 1 kit QIG for ACS380 and ACS480 - frames R3 to R4 3AXD50000242375
Tool and maintenance manuals
Drive composer PC tool user's manual 3AUA0000094606
Converter module capacitor reforming instructions
NETA-21 remote monitoring tool user’s manual 3AUA00000969391
NETA-21 remote monitoring tool installation and start-up guide 3AUA0000096881
3BFE64059629
You can find manuals and other product documents in PDF format on the
Internet. See section Document library on the Internet on the inside of the
back cover. For manuals not available in the Document library, contact your
local ABB representative.
Hardware manual
ACH480 drives
Table of contents
1. Safety instructions
4. Mechanical installation
6. Electrical installation
2018 ABB Oy. All Rights Reserved.
3AXD50000245949 Rev A
EN
EFFECTIVE: 2018-11-22
3
4
Table of contents 5
Table of contents
1. Safety instructions
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Additional instructions and notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
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
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Applicability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Target audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Purpose of the manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Contents of this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Related documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Categorization by frame (size) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Quick installation and commissioning flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3. Hardware description
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
General description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Product variants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Hardware overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Control connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Standard unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Base unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Mounted options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
PC connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Drive labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Model information label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Software information label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Type designation label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Type designation key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Operation principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
4. Mechanical installation
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6 Table of contents
Examining the installation site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Required tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Unpacking the delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Installing the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
To install the drive with screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
To install the drive to a DIN installation rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5. Planning the electrical installation
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Selecting the supply disconnecting device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
European Union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Other regions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Checking the compatibility of the motor and drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Selecting the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Typical power cable sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Recommended power cable types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Power cable types for limited use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Not allowed power cable types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Motor cable shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Additional US requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Selecting the control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Shielding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Signals in separate cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Signals that can be run in the same cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Relay cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Control panel to PC connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Control panel to drive connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Modbus RTU cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Routing the cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Separate control cable ducts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Continuous motor cable shield or conduit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Implementing short-circuit protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Protecting the drive and input power cable in short-circuits . . . . . . . . . . . . . . . . . . . . . . . 50
Protecting the motor and motor cable in short-circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Implementing thermal overload protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Protecting the drive, and the input power and motor cables against thermal overload . . 51
Protecting the motor against thermal overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Protecting the drive against ground faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Residual current device compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Implementing the emergency stop function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Implementing the Safe torque off function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Using a safety switch between the drive and motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Using a contactor between the drive and motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Protecting the contacts of relay outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
6. Electrical installation
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Required tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Table of contents 7
Measuring insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Input power cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Motor and motor cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Brake resistor assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Compatibility with IT (ungrounded) and corner-grounded TN systems . . . . . . . . . . . . . . . . . . 57
EMC filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
EMC filter disconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Ground-to-phase varistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Connecting the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Connection procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Connecting the control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
I/O connections (HVAC default) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Connecting EIA-485 embedded fieldbus terminal to the drive . . . . . . . . . . . . . . . . . . . . . 65
Control cable connection procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Auxiliary voltage connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Option modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
To install a front option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
To remove a front option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
To install a side option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
To remove a side option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
7. Installation checklist
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
8. Maintenance
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Cleaning the heat sink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Replacing the cooling fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
To replace the cooling fan for frame sizes R1, R2 and R3 . . . . . . . . . . . . . . . . . . . . . . . . 78
To replace the cooling fan for frame R4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Servicing the capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Capacitor reforming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
9. Technical data
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
IEC ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
NEMA ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Surrounding air temperature derating, IP20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Switching frequency derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
8 Table of contents
Altitude derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Fuses (IEC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
gG fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
gR fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
UL fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Alternate short-circuit protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Miniature circuit breakers (IEC environment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Self-protected combination manual controller – Type E
USA (UL) environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Dimensions and weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Free space requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Losses, cooling data and noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Terminal data for the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Terminal data for the control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
External EMC filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Electric power network specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Motor cable length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Motor connection data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Control connection data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Brake resistor connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Degrees of protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Applicable standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
CE marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Compliance with the European Low Voltage Directive . . . . . . . . . . . . . . . . . . . . . . . . . 104
Compliance with the European EMC Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Compliance with the European RoHS Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Compliance with the European WEEE Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Compliance with the European Machinery Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Compliance with EN 61800-3:2004 + A1:2012 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Category C1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Category C2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Category C3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
UL marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
UL checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
CSA marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
RCM marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
EAC marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
WEEE marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
China RoHS marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
TÜV marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Disclaimers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Generic disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Cyber security disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
10. Dimension drawings
Frame R1 (400 V) (front & side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Table of contents 9
Frame R1 (400 V) (bottom & rear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Frame R2 (400 V) (front & side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Frame R2 (400 V) (bottom & rear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Frame R3 (front & side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Frame R3 (bottom & rear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Frame R4 (front & side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Frame R4 (bottom & rear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
11. Resistor braking
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Operation principle and hardware description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Selecting the brake resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Reference brake resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Selecting and routing the brake resistor cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Minimizing electromagnetic interference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Maximum cable length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
EMC compliance of the complete installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Brake resistor installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Protecting the system in brake circuit fault situations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Protecting the system in cable and brake resistor short-circuit situations . . . . . . . . . . . . 125
Protecting the system against thermal overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Mechanical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Electrical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Measuring the insulation of the assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Connection procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
12. Safe torque off function
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Compliance with the European Machinery Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Connection principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Connection with internal +24 V DC power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Connection with external +24 V DC power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Wiring examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Activation switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Cable types and lengths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Grounding of protective shields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Operation principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Start-up including acceptance test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Competence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Acceptance test reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Acceptance test procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Competence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Fault tracing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Safety data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
10 Table of contents
Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Declaration of conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
TÜV certificate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
13. BAPO-01 power extension module
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Hardware description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Product overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Mechanical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Electrical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Voltage and current rating for the auxiliary power supply . . . . . . . . . . . . . . . . . . . . . . . 146
Power loss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
14. BIO-01 I/O extension module
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Hardware description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Product overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Mechanical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Electrical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Control connection data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Further information
Safety instructions 11
1
Safety instructions
Contents of this chapter
This chapter contains the safety instructions which you must obey when you install
and operate the drive and do maintenance on the drive. Obey the safety instructions
to prevent injury or death, or damage to the equipment.
Use of warnings and notes in this manual
Warnings tell you about conditions which can cause injury or death, or damage to the
equipment. They also tell you how to prevent the danger. Notes draw attention to a
particular condition or fact, or give information on a subject.
The manual uses these warning symbols:
Electricity warning tells you about hazards from electricity which can
cause injury or death, or damage to the equipment.
General warning tells you about conditions, other than those caused by
electricity, which can cause injury or death, or damage to the equipment.
Electrostatic sensitive devices warning tells you about the risk of
electrostatic discharge which can cause damage to the equipment.
12 Safety instructions
General safety in installation, start-up and maintenance
These instructions are for all personnel that install the drive and do maintenance work
on it.
WARNING! Obey these instructions. If you ignore them, injury or death, or
damage to the equipment can occur.
• Handle the drive carefully.
• Use safety shoes with a metal toe cap.
• Keep the drive in its package or protect it otherwise from dust and burr from
drilling and grinding until you install it.
• Vacuum clean the area below the drive before the start-up to prevent the drive
cooling fan from drawing the dust inside the drive.
• Protect also the installed drive against dust and burr. Electrically conductive
debris inside the drive may cause damage or malfunction.
• Do not cover the air inlet and outlet when the drive runs.
• Make sure that there is sufficient cooling.
• Before you connect voltage to the drive, make sure that the drive covers are on.
Keep the covers on during operation.
• Before you adjust the drive operation limits, make sure that the motor and all
driven equipment can operate throughout the set operation limits.
• Before you activate the automatic fault reset or automatic restart functions of the
drive control program, make sure that no dangerous situations can occur. These
functions reset the drive automatically and continue operation after a fault or
supply break. If these functions are activated, the installation must be clearly
marked as defined in IEC/EN 61800-5-1, subclause 6.5.3, for example, “THIS
MACHINE STARTS AUTOMATICALLY”.
• The maximum number of drive power-ups is two per minute. Too frequent powerups can damage the charging circuit of the DC capacitors. The maximum total
number of chargings is 15000.
• If you have connected safety circuits to the drive (for example, emergency stop
and Safe torque off), validate them at the start up.
Note:
• If you select an external source for the start command and it is on, the drive starts
immediately after a fault reset, unless you configure the drive for pulse start.
• When the control location is not set to local, the stop key on the control panel
does not stop the drive.
• Drives can be repaired only by an authorized person.
Safety instructions 13
Electrical safety in installation, start-up and maintenance
Precautions before electrical work
These warnings are for all personnel who do work on the drive, motor cable or motor.
WARNING! Obey these instructions. If you ignore them, injury or death, or
damage to the equipment can occur. If you are not a qualified electrician, do
not do electrical installation or maintenance work. Do these steps before you begin
any installation or maintenance work.
1. Clearly identify the work location.
2. Disconnect all possible voltage sources.
• Open the main disconnector at the power supply of the drive.
• Make sure that reconnection is not possible. Lock the disconnector to open
position and attach a warning notice to it.
• Disconnect any external power sources from the control circuits before you do
work on the control cables.
• After you disconnect the drive, always wait for 5 minutes to let the
intermediate circuit capacitors discharge before you continue.
3. Protect any other energized parts in the work location against contact.
4. Take special precautions when close to bare conductors.
5. Measure that the installation is de-energized.
• Use a multimeter with an impedance of at least 1 Mohm.
• Make sure that the voltage between the drive input power terminals (L1, L2,
L3) and the grounding terminal (PE) is close to 0 V.
• Make sure that the voltage between the drive DC terminals (UDC+ and UDC-)
and the grounding terminal (PE) is close to 0 V.
6. Install temporary grounding as required by the local regulations.
7. Ask for a permit to work from the person in control of the electrical installation
work.
14 Safety instructions
Additional instructions and notes
WARNING! Obey these instructions. If you ignore them, injury or death, or
damage to the equipment can occur.
• If you install the drive on an IT system (an ungrounded power system or a highresistance-grounded [over 30 ohms] power system), disconnect the internal EMC
filter; otherwise the system will be connected to ground potential through the EMC
filter capacitors. This can cause danger or damage the drive.
Note: Disconnecting the internal EMC filter increases the conducted emission
and reduces the drive EMC compatibility considerably.
• If you connect the drive to an IT system (an ungrounded power system or a highresistance-grounded [over 30 ohms] power system), disconnect the varistor from
ground. Failure to do so can cause damage to the varistor circuit.
• If you install the drive on a corner-grounded TN system, disconnect the internal
EMC filter; otherwise the system will be connected to ground potential through the
EMC filter capacitors. This will damage the drive.
Note: Disconnecting the internal EMC filter increases the conducted emission
and reduces the drive EMC compatibility considerably.
• Use all ELV (extra low voltage) circuits connected to the drive only within a zone
of equipotential bonding, that is, within a zone where all simultaneously
accessible conductive parts are electrically connected to prevent hazardous
voltages appearing between them. You can accomplish this by a proper factory
grounding, that is, make sure that all simultaneously accessible conductive parts
are grounded to the protective earth (PE) bus of the building.
• Do not do insulation or voltage withstand tests on the drive.
Note:
• The motor cable terminals of the drive are at a dangerous voltage when the input
power is on, regardless of whether the motor is running or not.
• The DC and brake resistor terminals (UDC+, UDC-, R+ and R-) are at a
dangerous voltage.
• External wiring can supply dangerous voltages to the terminals of relay outputs.
• The Safe torque off function does not remove the voltage from the main and
auxiliary circuits. The function is not effective against deliberate sabotage or
misuse.
WARNING! Use a grounding wrist band when you handle the printed circuit
boards. Do not touch the boards unnecessarily. The components on the boards
are sensitive to electrostatic discharge.
Safety instructions 15
Grounding
These instructions are for all personnel who are responsible for the electrical
installation, including the grounding of the drive.
WARNING! Obey these instructions. If you ignore them, injury or death, or
equipment malfunction can occur, and electromagnetic interference can
increase.
• If you are not a qualified electrician, do not do grounding work.
• Always ground the drive, the motor and adjoining equipment to the protective
earth (PE) bus of the power supply. This is necessary for the personnel safety.
Proper grounding also reduces electromagnetic emission and interference.
• In a multiple-drive installation, connect each drive separately to the protective
earth (PE) bus of the power supply.
• Make sure that the conductivity of the protective earth (PE) conductors is
sufficient. Refer to Selecting the power cables on page 42. Obey the local
regulations.
• Connect the power cable shields to the protective earth (PE) terminals of the
drive.
• Make a 360° grounding of the power and control cable shields at the cable entries
to suppress electromagnetic disturbances.
Note:
• You can use power cable shields as grounding conductors only when their
conductivity is sufficient.
• Standard IEC/EN 61800-5-1 (section 4.3.5.5.2.) requires that as the normal touch
current of the drive is higher than 3.5 mA AC or 10 mA DC, you must use a fixed
protective earth (PE) connection. In addition,
• install a second protective earth conductor of the same cross-sectional area
as the original protective earthing conductor,
or
• install a protective earth conductor with a cross-section of at least 10 mm
or 16 mm2Al,
or
• install a device which automatically disconnects the supply if the protective
earth conductor breaks.
2
Cu
16 Safety instructions
Additional instructions for permanent magnet motor drives
Safety in installation, start-up and maintenance
These are additional warnings that apply to 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 and
damage to the equipment can occur.
• Do not work on a drive when a rotating permanent magnet motor is connected
to it. A rotating permanent magnet motor energizes the drive including its input
power terminals.
Before installation, start-up and maintenance work on the drive:
• Stop the motor.
• Disconnect the motor from the drive with a safety switch or by other means.
• If you cannot disconnect the motor, make sure that the motor cannot rotate during
work. Make sure that no other system, like hydraulic crawling drives, can rotate
the motor directly or through any mechanical connection like felt, nip, rope, etc.
• Measure that the installation is de-energized.
• Use a multimeter with an impedance of at least 1 Mohm.
• Make sure that the voltage between the drive output terminals (T1/U, T2/V,
T3/W) and the grounding (PE) busbar is close to 0 V.
• Make sure that the voltage between the drive input power terminals (L1, L2,
L3) and the grounding (PE) busbar is close to 0 V.
• Make sure that the voltage between the drive DC terminals (UDC+, UDC-) and
the grounding (PE) terminal is close to 0 V.
• Install temporary grounding to the drive output terminals (T1/U, T2/V, T3/W).
Connect the output terminals together as well as to the PE.
Start-up and operation:
• Make sure that the operator cannot run the motor over the rated speed. Motor
overspeed causes overvoltage that can damage or explode the capacitors in the
intermediate circuit of the drive.
Safety instructions 17
General safety in operation
These instructions are for all personnel that operate the drive.
WARNING! Obey these instructions. If you ignore them, injury or death, or
damage to the equipment can occur.
• Do not control the motor with the disconnector at the drive power supply. Use the
control panel start and stop keys or the start/stop commands from an external
control device connected through the I/O or fieldbus interface.
• Give a stop command to the drive before you reset a fault. If you have an external
source for the start command and the start is on, the drive will start immediately
after the fault reset, unless you configure the drive for pulse start. See the
firmware manual.
• Before you activate automatic fault reset functions of the drive control program,
make sure that no dangerous situations can occur. These functions reset the
drive automatically and continue operation after a fault.
Note: When the control location is not set to Local, the stop key on the control panel
will not stop the drive.
18 Safety instructions
Introduction to the manual 19
2
Introduction to the manual
Contents of this chapter
The chapter describes the applicability, target audience and purpose of this manual. It
describes the contents of this manual. The chapter also has a flowchart for the
delivery, installation and commissioning of the drive.
Applicability
The manual applies to ACH480 drives.
Target audience
The reader must know the fundamentals of electricity, wiring, electrical components
and electrical schematic symbols.
Purpose of the manual
This manual has the information needed to plan the installation, and install,
commission and service the drive.
20 Introduction to the manual
Contents of this manual
• Safety instructions (on page 11) gives the safety instructions that you must obey
when you install, commission, operate and service the drive.
• Introduction to the manual (on page 19) describes the applicability, target
audience, purpose and contents of this manual.
• Hardware description (on page 25) describes the operation principle, layout,
power connections and control interfaces, type designation information.
• Mechanical installation (on page 35) describes how to examine the installation
site, unpack, examine the delivery and install the drive mechanically.
• Planning the electrical installation (on page 41) describes how to plan the
electrical installation of the drive.
• Electrical installation (on page 55) describes how to measure the insulation of the
assembly and the compatibility with IT (ungrounded) and corner-grounded TN
systems. It shows how to connect the power and control cables, install optional
modules and connect a PC.
• Installation checklist (on page 73) contains a checklist for the mechanical and
electrical installation of the drive before start-up.
• Maintenance (on page 75) contains the preventive maintenance instructions and
LED indicator descriptions.
• Technical data (on page 83) contains the technical specifications of the drive.
• Dimension drawings (on page 111) shows the dimension drawings of the drive.
• Resistor braking (on page 121) tells you how to select the brake resistor.
• Safe torque off function (on page 129) describes the STO features, installation
and technical data.
• BAPO-01 power extension module (on page 143) describes the optional BAPO01 module.
• BIO-01 I/O extension module (on page 147) decribes the optional I/O extension
module.
Related documents
Refer to List of related manuals on page 2 (the inner front cover).
Categorization by frame (size)
The drive is manufactured in frame sizes, for example, R0, R1, R2 and so on.
Information that is applicable only to certain frames shows the frame size. Some
instructions only apply to specific frame sizes. You can read the frame size from the
type designation label on the drive, refer to Drive labels on page 30.
Introduction to the manual 21
Quick installation and commissioning flowchart
Task Refer to
Identify the frame size: R0, R1, R2, etc. Type designation key on page 32.
Plan the installation.
Check the ambient conditions, ratings and
required cooling air flow.
Unpack and check the drive. Unpacking the delivery on page 37.
If the drive is connected to an IT (ungrounded)
system or corner-grounded TN system, make
sure that the internal EMC filter is not
connected.
Install the drive. Installing the drive on page 38.
Route the cables. Routing the cables on page 49.
Measure the insulation of the input cable,
motor and motor cable.
Connect the power cables. Connecting the power cables on page 59.
Connect the control cables. Connecting the control cables on page 62.
Examine the installation. Installation checklist on page 73.
Planning the electrical installation on page 41.
Technical data on page 83.
Type designation key on page 32.
Compatibility with IT (ungrounded) and
corner-grounded TN systems on page 57.
Measuring insulation on page 56.
Commission the drive. Refer to the ACH480 drives quick installation
guide (3AXD50000247141 [English]) and the
ACH480 drives firmware manual
(3AXD50000247134 [English]).
22 Introduction to the manual
Terms and abbreviations
Term/abbreviation Explanation
ACX-AP-X Assistant control panel. An advanced operator keypad for
BACnet™ BACnet™ is a registered trademark of American Society of Heating,
Brake chopper Conducts the surplus energy from the intermediate circuit of the drive to
Brake resistor Dissipates the drive surplus braking energy conducted by the brake
Capacitor bank Refer to DC link capacitors.
CDPI-02 Communication adapter module
Control board Circuit board in which the control program runs.
BAPO-01 Optional side-mounted auxiliary power extension module
BCBL-01 Optional USB to RJ45 cable
BIO-01 Optional I/O extension module underneath the fieldbus option
CCA-01 Optional cold configuration adapter
DC link DC circuit between rectifier and inverter
DC link capacitors Energy storage which stabilizes the intermediate circuit DC voltage
DPMP-01 Mounting platform for ACX-AP control panel (flange mounting)
DPMP-02 Mounting platform for ACX-AP control panel (surface mounting)
Drive Frequency converter for controlling AC motors
EFB Embedded fieldbus
EMC Electromagnetic compatibility
FBA Fieldbus adapter
FBIP-21 Optional BACnet/IP adapter module
FCAN-01 Optional CANopen adapter module
FCNA-01 Optional ControlNet adapter module
FDNA-01 Optional DeviceNet adapter module
FECA-01 Optional EtherCAT adapter module
FENA-21 Optional Ethernet adapter module for EtherNet/IP, Modbus TCP and
FEPL-02 Optional Ethernet POWERLINK adapter module
FLON-01 Optional LONWORKS adapter module
FPBA-01 Optional PROFIBUS DP adapter module
FSCA-01 Optional RS-485 adapter module
communication with the drive.
Refrigerating and Air-Conditioning Engineers (ASHRAE).
the brake resistor when necessary. The chopper operates when the DC
link voltage exceeds a certain maximum limit. The voltage rise is
typically caused by deceleration (braking) of a high inertia motor.
chopper to heat. Essential part of the brake circuit. Refer to Brake
chopper.
PROFINET IO protocols
Introduction to the manual 23
Term/abbreviation Explanation
Frame (size) Refers to drive physical size, for example, R0 and R1. The type
I/O Input/Output
IGBT Insulated gate bipolar transistor
Intermediate circuit Refer to DC link.
Inverter Converts direct current and voltage to alternating current and voltage.
Macro Pre-defined default set of parameters in a drive control program. Each
NETA-21 Optional remote monitoring tool
Network control With fieldbus protocols based on the Common Industrial Protocol
Parameter User-adjustable operation instruction to the drive, or signal measured or
PLC Programmable logic controller
PROFIBUS,
PROFIBUS DP,
PROFINET IO
R0, R1, R2, R3… Frame (size)
RCD Residual current device
Rectifier Converts alternating current and voltage to direct current and voltage.
RFI Radio-frequency interference
SIL Safety integrity level. Refer to Safe torque off function on page 129.
STO Safe torque off. Refer to Safe torque off function on page 129.
designation label attached to the drive shows the frame of the drive,
refer to Type designation key on page 32.
macro is intended for a specific application.
TM
), such as DeviceNet and Ethernet/IP, denotes the control of the
(CIP
drive using the Net Ctrl and Net Ref objects of the ODVA AC/DC Drive
Profile. For more information, refer to
www.odva.org, and to FDNA-01
DeviceNet adapter module user’s manual (3AFE68573360 [English])
and FENA-01/-11/-21 Ethernet adapter module user’s manual
(3AUA0000093568 [English]).
calculated by the drive
Registered trademarks of PI - PROFIBUS & PROFINET International
24 Introduction to the manual
Hardware description 25
3
Hardware description
Contents of this chapter
This chapter describes the operation principle, layout, type designation label and type
designation information. It shows a general diagram of the power connections and
control interfaces.
General description
The ACH480 is a drive for controlling asynchronous AC induction motors, permanent
magnet synchronous motors and ABB synchronous reluctance motors (SynRM
motors). It is optimized for cabinet mounting.
Product variants
The drive has two primary products:
• Standard unit (for example, ACH480-04-02A7) with the Assistant control panel
ACH-AP-H and an I/O module with integrated EIA-485 RIIO-01.
• Base unit (for example, ACH480-04-02A7+0J400+0L540) without a control panel
and without an I/O module RIIO-01 with EIA-485.
Refer to Type designation key on page 32.
26 Hardware description
1
2
4
5
6
7
9
12
14
16
10
8
15
11
13
3
17
Hardware overview
No. Description No. Description
1 Type designation label 10 Motor and braking resistor terminals
2 Model information label 11 Cooling fan (not on R0)
3 Software information label 12 Front cover
4 Control panel connection 13 Fixed control terminals
5 Control panel 14 Cold configuration connection (CCA-01)
6 EMC filter grounding screw 15 Slot for front option modules
7 Varistor grounding screw
8 PE connection (motor) 16 I/O or fieldbus module
9 Input power terminal 17 Side option slot for side-mounted options
(I/O module or fieldbus module)
Hardware description 27
RELAYS MAX
250V AC 30 DC 2A
24V
DGND
DCOM
D 3
D 4
D 5
D 6
AI2
AGND
A01
A02
AGND
B +
A -
DGND
SCR
AI1
AGND
+10V
RO2C
R02A
RO2B
RO3C
R 3A
RO3B
D 1
DI2
IN1
IN2
ON
RO C
RO1A
RO1B
+24V
DGND
DCOM
SGND
OUT1
1
1
2
3
4
5
8
10
7
9
6
11
Control connections
There are fixed control connections on the base unit and optional control connections
based on the installed option module.
Standard unit
Connections of the base unit:
1. Auxiliary voltage outputs
2. Digital inputs
3. Safe torque-off connections
4. Relay output connection
5. Cold configuration connection for CCA-01
Connections of the standard I/O module
RIIO-01:
6. Digital inputs
7. Analog inputs and outputs
8. Relay output connections
9. Embedded fieldbus EIA-485 (BACnet
MS/TP, Modbus RTU, N2)
10. Auxiliary voltage output
11.Termination switch and bias resistor switch
28 Hardware description
D 1
DI2
IN1
IN2
+24V
DGND
DCOM
SGND
OUT1
RO C
RO1A
RO1B
1
2
3
4
5
6
Base unit
Connections of the base unit:
1. Auxiliary voltage outputs
2. Digital inputs
3. Safe torque-off connections
4. Relay output connection
5. Cold configuration connection for CCA-01
6. Front option module slot 1
Hardware description 29
Mounted options
For information on mounted optional modules, refer to:
• BAPO-01 power extension module on page 143.
• BIO-01 I/O extension module on page 147.
Control panel
The drive supports these assistant control panels:
• ACH-AP-H (included in the standard delivery)
•ACH-AP-W
• CDPI-02 communication adapter module
For information on the assistant control panels, refer to the ACX-AP-x Assistant
control panels user’s manual (3AUA0000085685 [EN]).
For information on how to start up the drive, and modify the settings and parameters,
refer to the ACH480 drives firmware manual (3AXD50000247134 [English]).
PC connection
To connect a PC to the drive, there are two alternatives:
1. Use an ACH-AP-H/ACH-AP-W assistant control panel as a converter with a USB
Mini-B type cable.
2. Use a USB to RJ45 converter BCBL-01 (3AXD50000032449) with CDPI-02
(3AXD50000009929).
For information on the Drive composer PC tool, refer to Drive composer PC tool
user's manual (3AUA0000094606 [English]).
30 Hardware description
AC,480-04-04A1-4
S/N: 1170301940
1
2
3
AC,480-04-04A1-4
3~400V/480 V (frame R1)
Pld: 1.5 kW (2 hp)
Phd: 1.1 kW (1.5 hp)
SW v2.02.0.8
1
2
3
5
4
Drive labels
The drive has these labels:
• Model information label on the top of the drive
• Software information label on the front cover
• Type designation label on the left side of the drive
For label positions, refer to Hardware overview on page 26.
Model information label
No. Description
1 Drive type
2 Bar code
3 Serial number
Software information label
No. Description
1 Drive type
2 Input voltage rating and frame size
3 Typical motor power in light-duty use (10% overload)
4 Typical motor power in heavy-duty use (50% overload)
5 Drive software version
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