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ACH480 drives

Hardware manual

Table of contents

1. Safety instructions

4. Mechanical installation

6. Electrical installation – IEC

7. Electrical installation – North

America

3AXD50000245949 Rev D

Original instructions

EFFECTIVE: 2024-05-20

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 - Page 3

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