ABB ACH480 - Operation principle and hardware description; Contents of this chapter; Operation principle

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Operation principle and

hardware description

Contents of this chapter

This chapter briefly describes the operation principle and construction of the drive.

Operation principle

The ACH480 is a drive for controlling asynchronous AC induction motors, permanent

magnet synchronous motors and ABB synchronous reluctance motors (SynRM

motors). The drive is optimized for cabinet installation.

Operation principle and hardware description 29

Main Page

Table of contents5
Safety instructions15
- Contents of this chapter15
- Use of warnings and notes15
- General safety in installation, start-up and maintenance16
- Electrical safety in installation, start-up and maintenance18
- General safety in operation21
- Additional instructions for permanent magnet motor drives21
  - Safety in installation, start-up, maintenance21
  - Safety in operation22
Introduction to the manual23
- Contents of this chapter23
- Applicability23
- Target audience23
- Categorization by frame size23
- Quick installation and commissioning flowchart24
- Terms and abbreviations26
- Related manuals27
Operation principle and hardware description29
- Contents of this chapter29
- Operation principle29
  - Simplified main circuit diagram30
- Product variants30
  - IEC and UL (NEC) product types30
- Layout31
- Control connections32
  - Standard unit (with RIIO‑01)32
  - Base unit33
- Option modules33
- Control panel options34
- UL Type 1 kits34
- Drive labels35
  - Type designation label35
  - Software information label36
- Type designation key36
  - Basic code36
  - Option codes36
Mechanical installation39
- Contents of this chapter39
- Installation alternatives39
- Examining the installation site40
- Required tools40
- Unpacking the delivery41
- Installing the drive41
  - To install the drive with screws41
  - To install the drive to a DIN installation rail42
Guidelines for planning the electrical installation45
- Contents of this chapter45
- Limitation of liability45
  - North America45
- Selecting the main supply disconnecting device45
- Selecting the main contactor46
- Checking the compatibility of the motor and drive46
- Selecting the power cables47
- Grounding requirements52
  - Additional grounding requirements – IEC53
  - Additional grounding requirements – UL (NEC)54
- Selecting the control cables54
- Routing the cables55
- Implementing short-circuit and thermal overload protection58
- Implementing a motor temperature sensor connection60
- Protecting the drive against ground faults60
  - Residual current device compatibility60
- Implementing the Emergency stop function60
- Implementing the Safe torque off function61
- Using a safety switch between the drive and the motor61
- Implementing the control of a contactor between drive and motor61
- Protecting the contacts of relay outputs61
Electrical installation – IEC63
- Contents of this chapter63
- Required tools63
- Measuring the insulation resistance - IEC64
- Grounding system compatibility check – IEC65
- Connecting the power cables – IEC (shielded cables)71
  - Connection diagram71
  - Connection procedure72
- Connecting the control cables - IEC74
- Auxiliary voltage connection85
- Connecting a PC86
- Installing options86
  - Installing a front option87
  - Installing a side option88
Electrical installation – North America91
- Contents of this chapter91
- Required tools91
- Measuring the insulation resistance - North America92
- Grounding system compatibility check – North America93
- Connecting the power cables – North America (wiring in conduits)99
  - Connection diagram99
  - Connection procedure100
- Connecting the control cables - North America102
- Auxiliary voltage connection113
- Connecting a PC114
- Installing options114
  - Installing a front option115
  - Installing a side option116
Installation checklist119
- Contents of this chapter119
- Checklist119
Maintenance123
- Contents of this chapter123
- Maintenance intervals123
  - Description of symbols123
  - Recommended maintenance intervals after start-up124
- Functional safety components125
- Cleaning the heatsink125
- Replacing the cooling fans126
  - Replacing the cooling fan, frames R1…R3126
  - Replacing the cooling fan, frame R4127
- Capacitors129
  - Reforming the capacitors129
Technical data131
- Contents of this chapter131
- Electrical ratings131
  - IEC ratings131
  - UL (NEC) ratings133
  - Definitions134
  - Sizing135
- Output derating135
  - Surrounding air temperature derating137
  - Altitude derating137
  - Switching frequency derating138
  - Derating in case of a phase loss141
- Fuses141
  - IEC fuses141
    - gG fuses (IEC)141
    - gR fuses (IEC)143
  - UL (NEC) fuses144
    - UL (NEC) fuse alternatives146
- Alternative short-circuit protection151
  - Miniature circuit breakers (IEC)151
  - Miniature circuit breakers (UL)153
  - Manual self-protected combination motor controller – Type E USA (UL (NEC))154
- Dimensions and weights157
- Free space requirements158
- Losses, cooling data and noise158
- Typical power cable sizes160
- Terminal data for the power cables163
- Terminal data for the control cables166
- Electrical power network specification166
- Motor connection data167
  - Motor cable length168
    - Operational functionality and motor cable length168
    - EMC compatibility and motor cable length168
- Brake resistor connection data169
- Control connection data170
- Energy efficiency data (ecodesign)171
- Protection classes171
- Ambient conditions171
- Storage conditions173
- Materials173
  - Drive173
  - Drive package173
  - Package materials for options, accessories and spare parts173
  - Materials of manuals174
- Disposal174
- Applicable standards174
- Markings175
  - Compliance with the harmonic current limits in a public network (IEC/EN 61000 3-2, IEC/EN 61000-3-12)177
- EMC compliance (IEC/EN 61800-3:2004 + A1:2012)177
  - Definitions177
  - Category C1178
  - Category C2178
  - Category C3179
  - Category C4179
- UL checklist181
- Disclaimers182
  - Generic disclaimer182
  - Cyber security disclaimer182
- Declarations of conformity183
Dimension drawings185
- Contents of this chapter185
- Frame R0186
  - Frame R0 (front & side) - IP20 / UL open type186
  - Frame R0 (bottom & rear) - IP20 / UL open type187
- Frame R1188
- Frame R2192
- Frame R3196
- Frame R4200
Input chokes205
- Contents of this chapter205
- When is an input choke necessary?205
- Maximum input current205
  - IEC206
  - UL (NEC)207
- Selecting an input choke207
- Guidelines for installing an input choke209
  - Connection diagram210
- Dimensions210
External EMC filters213
- Contents of this chapter213
- Selecting the external EMC filter213
Resistor braking217
- Contents of this chapter217
- Safety217
- Operation principle217
- Selecting the brake resistor217
  - Reference brake resistors219
    - Definitions222
- Selecting and routing the brake resistor cables222
  - Minimizing electromagnetic interference222
  - Maximum cable length222
- Selecting the installation location for the brake resistors222
- Protecting the system in brake circuit fault situations223
  - Protecting the system in cable and brake resistor short-circuit situations223
  - Protecting the system against thermal overload223
- Mechanical and electrical installation of brake resistor224
  - Mechanical installation224
  - Electrical installation225
- Start-up225
The Safe torque off function227
- Contents of this chapter227
- Description227
  - Compliance with the European Machinery Directive and the UK Supply of Machinery (Safety) Regulations228
- Wiring229
- Operation principle235
- Start-up including validation test236
- Use238
- Maintenance240
  - Competence240
- Fault tracing241
- Safety data242
  - Terms and abbreviations244
  - TÜV certificate245
BAPO-01 auxiliary power extension module247
- Contents of this chapter247
- Safety instructions247
- Hardware description247
  - Layout248
- Mechanical installation249
- Electrical installation249
- Start-up250
- Technical data250
BIO-01 I/O extension module251
- Contents of this chapter251
- Safety instructions251
- Hardware description251
  - Product overview251
  - Layout252
- Mechanical installation252
- Terminal configuration252
- Electrical installation253
- Start-up253
- Technical data254
BREL-01 relay output extension module257
- Contents of this chapter257
- Safety instructions257
- Hardware description257
  - Product overview257
  - Layout258
- Mechanical installation258
- Electrical installation258
- Start-up259
- Configuration parameters259
- Technical data262
Further information263

ABB ACH480 - Operation principle and hardware description; Contents of this chapter; Operation principle

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