Abb ACH480 User Manual

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ABB DRIVES FOR HVAC

ACH480 drives

Hardware manual

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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	3BFE64059629
NETA-21 remote monitoring tool user’s manual	3AUA00000969391
NETA-21 remote monitoring tool installation and start-up guide	3AUA0000096881

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.

ACH480 manuals

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 high- resistance-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 high- resistance-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 mm2 Cu or 16 mm2 Al,

or

•install a device which automatically disconnects the supply if the protective earth conductor breaks.

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

Identify the frame size: R0, R1, R2, etc.

Plan the installation.

Check the ambient conditions, ratings and required cooling air flow.

Unpack and check the drive.

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.

Route the cables.

Measure the insulation of the input cable, motor and motor cable.

Connect the power cables.

Connect the control cables.

Examine the installation.

Commission the drive.

Refer to

Type designation key on page 32.

Planning the electrical installation on page 41. Technical data on page 83.

Unpacking the delivery on page 37.

Type designation key on page 32. Compatibility with IT (ungrounded) and corner-grounded TN systems on page 57.

Installing the drive on page 38.

Routing the cables on page 49.

Measuring insulation on page 56.

Connecting the power cables on page 59.

Connecting the control cables on page 62.

Installation checklist on page 73.

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
	communication with the drive.
BACnet™	BACnet™ is a registered trademark of American Society of Heating,
	Refrigerating and Air-Conditioning Engineers (ASHRAE).
Brake chopper	Conducts the surplus energy from the intermediate circuit of the drive to
	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.
Brake resistor	Dissipates the drive surplus braking energy conducted by the brake
	chopper to heat. Essential part of the brake circuit. Refer to Brake
	chopper.
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
	PROFINET IO protocols
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

	Introduction to the manual 23
Term/abbreviation	Explanation
Frame (size)	Refers to drive physical size, for example, R0 and R1. The type
	designation label attached to the drive shows the frame of the drive,
	refer to Type designation key on page 32.
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
	macro is intended for a specific application.
NETA-21	Optional remote monitoring tool
Network control	With fieldbus protocols based on the Common Industrial Protocol
	(CIPTM), such as DeviceNet and Ethernet/IP, denotes the control of the
	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]).
Parameter	User-adjustable operation instruction to the drive, or signal measured or
	calculated by the drive
PLC	Programmable logic controller
PROFIBUS,	Registered trademarks of PI - PROFIBUS & PROFINET International
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.

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

Hardware overview

11

	2
1	4
6
	5
7	3

8	12
13	14	16
9
15
10
		17

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
			(I/O module or fieldbus module)
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

Hardware description 27

Control connections

There are fixed control connections on the base unit and optional control connections based on the installed option module.

 Standard unit

		+24V	2
	1	DGND	D 1
			DI2
		DCOM
			IN1
		SGND
	3		IN2
		OUT1

	4	5
	RO C
	RO1A
	RO1B

RO2C

R02A

RO2B

8

RO3C

R 3A

RO3B

RELAYS MAX

250V AC 30 DC 2A

							ON
10	24V	DGND	DCOM	D 3	6	D 6	11

1

AI2	AGND	A01	A02	GNDA	B +	A -	DGND	9
7

SCR

AI1

AGND

+10V

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

 Base unit

		+24V	1
	1	2
		DCOM	IN1
		SGND
	3		IN2

4	5
RO C
RO1A
RO1B

6

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

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

1 AC,480-04-04A1-4

2

3 S/N: 1170301940

No. Description

1Drive type

2Bar code

3Serial number

Software information label

	1	AC,480-04-04A1-4
	2	3~400V/480 V (frame R1)
	3	Pld: 1.5 kW (2 hp)
	4	Phd: 1.1 kW (1.5 hp)
	5	SW v2.02.0.8
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