ABB ACS480 Kurzanleitung für Installation und Inbetriebnahme

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ABB ACS480 Kurzanleitung für Installation und Inbetriebnahme

—

ABB GENERAL PURPOSE DRIVES

ACS480 drives

Quick installation and start-up guide

Safety instructions

WARNING! Obey these instructions. If you ignore them, injury or death,

or damage to the equipment can occur. If you are not a qualified

electrical professional, do not do electrical installation or maintenance

work.

•

Do not do work on the drive, motor cable, motor, or control cables when the

drive is connected to the input power. Before you start the work, isolate the

drive from all dangerous voltage sources and make sure that it is safe to

start the work. Always wait for 5 minutes after disconnecting the input

power to let the intermediate circuit capacitors discharge.

•

Do not do work on the drive when a rotating permanent magnet motor is

connected to it. A rotating permanent magnet motor energizes the drive,

including its input and output terminals.

1. Unpack the delivery

Keep the drive in its package until you are ready to install it. After unpacking,

protect the drive from dust, debris and moisture.

Make sure that these items are included:

•

drive

•

assistant control panel

•

options, if ordered

•

RIIO-01 I/O & EIA-485 module. Note: If a fieldbus adapter is ordered, it

replaces the RIIO-01 module of the standard delivery.

•

mounting template (frames R3 and R4 only)

•

installation accessories (cable clamps, etc.)

•

multilingual warning sticker sheet (residual voltage warning)

•

safety instructions

•

quick installation and start-up guide

•

hardware and firmware manuals, if ordered.

Make sure that there are no signs of damage to the items.

2. Reform the capacitors

If the drive has not been powered up for a year or more, you must reform the DC

link capacitors. The manufacturing date is on the type designation label. Refer

Capacitor reforming instructions

(3BFE64059629

3. Select the cables and fuses

•

Select the power cables. Obey the local regulations.

•

Input power cable: ABB recommends to use symmetrical shielded cable

(VFD cable) for the best EMC performance.

•

Motor cable: Use symmetrical shielded cable (VFD cable) for the best EMC

performance. Symmetrical shielded cable also reduces bearing currents,

wear, and stress on motor insulation.

•

Power cable types: In IEC installations, use copper or aluminum cables (if

permitted). In UL installations, use only copper cables.

•

Current rating: max. load current.

•

Voltage rating: min. 600 V AC.

•

Temperature rating: In IEC installations, select a cable rated for at least

70 °C (158 °F) maximum permissible temperature of conductor in

continuous use. In UL installations, select a cable rated for at least 75 °C

(167 °F).

•

Size: Refer to

Fuses and typical power cable sizes

sizes and to

Terminal data for the power cables

sizes.

•

Select the control cables. Use double-shielded twisted-pair cable for analog

signals. Use double-shielded or single-shielded cable for the digital, relay and

I/O signals. Do not run 24 V and 115/230 V signals in the same cable.

•

Protect the drive and input power cable with the correct fuses. Refer to

Fuses and typical power cable sizes

4. Examine the installation area

The drive is intended for cabinet installation and has a degree of protection of

IP20 / UL open type.

Examine the site where you will install the drive. Make sure that:

•

The installation site is sufficiently ventilated and hot air does not recirculate.

•

There is sufficient free space around the drive for cooling, maintenance, and

operation. For the minimum free space requirements, refer to

requirements

•

The ambient conditions meet the requirements. Refer to

conditions

•

The installation surface is as close to vertical as possible and strong enough

Dimensions and weights

to support the weight of the drive. Refer to

•

The installation surface, floor and materials near the drive are not flammable.

•

There are no sources of strong magnetic fields, such as high-current single-

core conductors or contactor coils near the drive. A strong magnetic field

can cause interference in the operation of the drive.

5. Install the drive

You can install the drive with screws, or to a DIN rail (top hat type, width × height

= 35 mm × 7.5 mm [1.4 in × 0.3 in]).

•

Install R0 drives vertically. R0 drives do not have a cooling fan.

•

You can install drives with frame size R1...R4 tilted by a maximum of

90 degrees, from vertical to fully horizontal orientation.

•

Do not install the drive upside down.

•

You can install several drives side by side.



To install the drive with screws

1. Make marks onto the surface for the

mounting holes. Refer to

weights

. Use the included mounting

template for frames R3 and R4.

2. Drill the holes for the mounting screws. If

necessary, install suitable plugs or

anchors into the holes.

3. Install the mounting screws into the

holes. Leave a gap between the screw

head and installation surface.

4. Put the drive onto the mounting screws.

5. Tighten the mounting screws.



To install the drive to a DIN rail

1. Move the locking part to the left. If

necessary, use a flat-head screwdriver.

2. Push and hold the locking button down.

3. Put the top tabs of the drive onto the top

edge of the DIN rail.

4. Put the drive against the bottom edge of

the DIN rail.

5. Release the locking button.

6. Move the locking part to the right.

7. Make sure that the drive is correctly

installed.

To remove the drive, open the locking part

and lift the drive from the DIN rail.

6. Measure the insulation resistance

Drive: Do not do voltage tolerance or insulation resistance tests on the drive,

because this can cause damage to the drive.

Input power cable: Before you connect the input power cable, measure the

insulation of the input power cable. Obey the local regulations.

Motor and motor cable:

1. Make sure that the motor cable is connected to the motor and disconnected

from the drive output terminals T1/U, T2/V and T3/W.

2. Use a voltage of 1000 V DC to measure the

insulation resistance between each phase

conductor and the protective earth

conductor. The insulation resistance of an

ABB motor must be more than 100 Mohm (at

25 °C [77 °F]). For the insulation resistance of

other motors, refer to the manufacturer's

documentation. Moisture in the motor

decreases the insulation resistance. If you

think that there is moisture in the motor, dry the motor and do the

measurement again.

7. Make sure that the drive is compatible with the

grounding system

You can connect all drive types to a symmetrically grounded TN-S system

(center-grounded wye). The drive is delivered with the EMC and VAR screws

installed. The material of the screws (plastic or metal) depends on the product

variant. The table shows when to remove the metal EMC screw (disconnect the

internal EMC filter) or metal VAR screw (disconnect the varistor circuit).

Screw

Factory default

label

screw material

EMC

Metal

Plastic

VAR

Metal

Plastic

1) UL (NEC) types have a plastic EMC screw.

2) Can install the metal screw (included in the drive delivery) to connect the internal EMC filter.

8. Connect the power cables



Connection diagram (shielded cables)

[English]).

ACS480

for the typical cable

for the maximum cable

(L)

1. Disconnecting device

2. Two protective earth (ground) conductors. Drive safety standard

IEC/EN 61800-5-1 requires two PE conductors, if the cross-sectional area of

the PE conductor is less than 10 mm

use the cable shield in addition to the fourth conductor.

3. Use a separate grounding cable or a cable with a separate PE conductor for

the line side, if the conductivity of the fourth conductor or shield does not

meet the requirements for the PE conductor.

4. Use a separate grounding cable for the motor side, if the conductivity of the

shield is not sufficient, or if there is no symmetrically constructed PE

conductor in the cable.

5. 360-degree grounding of the cable shield is required for the motor cable and

Free space

brake resistor cable (if used). It is also recommended for the input power

cable.

Ambient

6. Brake resistor and resistor cable (optional).



Connection procedure (shielded cables)

For the tightening torques, refer to

1. Loosen the screw on the front cover.

Then lift the front cover up.

2. Attach the residual voltage warning

sticker in the local language to the drive.

3. Strip the motor cable.

4. Ground the motor cable shield under the

grounding clamp.

5. Twist the motor cable shield into a

bundle, mark it and connect it to the

grounding terminal.

Dimensions and

ohm

U1-PE, V1-PE, W1-PE

Grounding systems

Symmetrically

Corner-grounded

IT systems

grounded TN-S

delta, midpoint-

(ungrounded or

systems (center-

grounded delta and

high-resistance

grounded wye)

TT systems

grounded)

Do not remove

Remove

Do not remove

R+

T1/

T2/

R-

UDC-

UDC+

(N)

Cu or 16 mm

Al. For example, you can

Terminal data for the power cables

6. Connect the phase conductors of the

motor cable to terminals T1/U, T2/V and

T3/W.

7. If used, connect the brake resistor cable

to terminals R- and UDC+. Use a shielded

cable and ground the shield under the

grounding clamp.

8. Make sure that the R- and UDC+ terminal

screws are tightened. Do this step also if

you do not connect cables to the

terminals.

9. Strip the input power cable.

10. If the input power cable has a shield,

ground the shield under the grounding

clamp. Then twist the shield into a

bundle, mark it and connect it to the

grounding terminal.

11. Connect the PE conductor of the input

power cable to the grounding terminal. If necessary, use a second PE

conductor.

12. In 3-phase drives, connect the phase conductors of the input power cable to

terminals L1, L2 and L3. In 1-phase drives, connect the phase and neutral

conductors to terminals L1 and L2.

13. Mechanically attach the cables on the outside of the drive.

9. Install the communication module

To install the communication module (I/O

module or fieldbus module):

1. Pull out the locking tab of the

communication module.

2. Align the communication module

contacts with the contacts on the drive.

Carefully push the module into position.

3. Push in the locking tab of the

communication module.

4. Tighten the locking screw to fully attach

and electrically ground the

communication module.

10. Connect the control cables

Do the connections according to the application macro that you select. The ABB

standard macro is the default macro. Keep the signal wire pairs twisted as near

to the terminals as possible to prevent inductive coupling. The tightening

torque for the terminal connections is 0.5 ... 0.6 N·m (4.4 ... 5.3 lbf·in).

1. Strip a part of the outer shield of the

control cable for grounding.

2. Use a cable tie to ground the outer shield

to the grounding tab.

3. Strip the control cable conductors.

4. Connect the conductors to the correct

control terminals.

5. Connect the shields of the twisted pairs

and grounding wires to the SCR terminal.

6. Mechanically attach the control cables on

the outside of the drive.



Default I/O connections (ABB standard macro)

Terminal

Description

Reference voltage and analog I/O

1 ... 10 kohm

SCR

Signal cable shield (screen)

AI1

Output freq./speed reference: 0 ... 10 V

AGND Analog input circuit common

+10 V Reference voltage 10 V DC

AI2

Not configured

AGND Analog input circuit common

AO1

Output frequency: 0 ... 20 mA

Remove

AO2

Output current: 0 ... 20 mA

AGND Analog output circuit common

Remove

Max. 500 ohm

Aux. voltage output and programmable digital inputs

+24 V Aux. voltage output +24 V DC, max. 250 mA

DGND Aux. voltage output common

DCOM Digital input common for all

DI1

Stop (0)/Start (1)

DI2

Forward (0)/Reverse (1)

DI3

Constant frequency/speed selection

DI4

Constant frequency/speed selection

DI5

Ramp set 1 (0)/Ramp set 2 (1)

T3/

DI6

Not configured

Relay outputs

RO1C

RO1A

RO1B

RO2C

RO2A

RO2B

RO3C

RO3A

RO3B

Safe torque off

SGND Safe torque off (STO). Both circuits must be closed for the

drive to start. The drawing shows the simplified

IN1

connection of a safety circuit through safety contacts. If

IN2

STO is not used, leave the factory-installed jumpers in

OUT1

place. See also section

1) × = on base unit, empty = on RIIO-01 I/O extension module



Embedded fieldbus connection

You can connect the drive to an EIA-485 serial communication link through the

embedded fieldbus interface on the RIIO-01 module. The embedded fieldbus

interface supports the Modbus RTU protocol.

To configure Modbus RTU communication with the embedded fieldbus:

1. Connect the fieldbus cables and the necessary I/O signals.

2. Use the termination switch to set the correct termination settings.

3. Power up the drive and set the necessary parameters.

A connection example is shown below.

Automation

Drive

controller

Termination OFF

Termination ON

1) The devices at the ends of the fieldbus must have termination set to ON. All other devices

must have termination set to OFF (1).

2) Attach the cable shields together at each drive, but do not connect them to the drive.

Connect the shields only to the grounding terminal in the automation controller.

3) Connect the signal ground (DGND) conductor to the signal ground reference terminal in

the automation controller. If the automation controller does not have a signal ground

reference terminal, you can connect the signal ground to the cable shields through a

100 ohm resistor, preferably near the controller.



Ready run



250 V AC / 30 V DC



2 A



Running

250 V AC / 30 V DC

2 A

Fault (-1)

250 V AC / 30 V DC

2 A



Safe torque off (STO)

Drive

Termination OFF

Termination ON