The provided document is a hardware manual for the ABB ACS480 general purpose drives. It details the installation, operation, and maintenance of these drives, along with their technical specifications and safety instructions.
Function Description
The ABB ACS480 is a series of general-purpose drives designed for controlling asynchronous AC induction motors, permanent magnet synchronous motors, and ABB synchronous reluctance motors (SynRM motors). The drive is optimized for cabinet installation and converts alternating current and voltage to direct current and voltage (rectifier), then back to alternating current and voltage (inverter) to control the motor. It includes a DC link for energy storage to stabilize the intermediate circuit DC voltage. A brake chopper is integrated to conduct surplus energy from the intermediate DC circuit to an external brake resistor during deceleration, preventing overvoltage. The drive also features a Safe Torque Off (STO) function, which disables the control voltage for the power semiconductors of the drive output stage, preventing the drive from generating torque and causing the motor to coast to a stop if activated. This STO function is designed with a redundant architecture for safety and complies with standards like IEC 60204-1:2016 and EN ISO 13849-1:2015.
Important Technical Specifications
The ACS480 drives are available in various frame sizes (R0 to R4) and product types (IEC and UL/NEC).
- Input Voltage Range:
- 1-phase 200…240 V AC (-15%…+10%) for ACS480-04-xxxx-1 drives.
- 3-phase 200…240 V AC (-15%…+10%) for ACS480-04-xxxx-2 drives.
- 3-phase 380…480 V AC (-15%…+10%) for ACS480-04-xxxx-4 drives.
- Frequency: 47…63 Hz, maximum rate of change 2%/s.
- Imbalance: Max. ±3% of nominal phase-to-phase input voltage.
- Fundamental Power Factor (cos phi): 0.98 (at nominal load).
- Motor Output: 0…500 Hz, 3-phase symmetrical.
- Switching Frequency: Configurable to 2, 4, 8, or 12 kHz. Derating of output current is necessary for higher switching frequencies.
- Protection Classes: IP20 (UL open type), Overvoltage category III, Protective class I.
- Ambient Conditions:
- Installation Altitude: 0…4000 m (0…13123 ft) above sea level for 400/480 V drives (with output derating above 1000 m [3281 ft]). Max 2000 m (6562 ft) for corner-grounded delta, midpoint-grounded delta, IT (ungrounded) systems.
- Surrounding Air Temperature: -10…+60 °C (14…140 °F). Output current derates by 1% for each additional 1 °C (1.8 °F) above 50 °C (122 °F) for R1-R3 frames, and by 1% or 2% for R4 frames depending on the specific model.
- Relative Humidity: 5…95%, no condensation permitted. Max 60% in presence of corrosive gases.
- EMC Filter: Internal EMC filter is standard. For UL/NEC types, it is disconnected by default. External EMC filters are available.
- Ground-to-Phase Varistor: Standard, can be connected to symmetrically grounded TN-S systems.
- Control Cable Terminal Data: 0.14…1.5 mm² (26…16 AWG), tightening torque 0.5…0.6 N·m (4.4…5.3 lbf·in).
- Power Cable Terminal Data: Varies by drive type and frame size, e.g., 0.5/0.5 mm² to 25/16 mm² for IEC, and 18 AWG to 2 AWG for UL/NEC.
- Maximum Motor Cable Length: 100 m (328 ft) for standard drive without external options. For EMC compliance (4 kHz switching frequency), lengths vary by category (C1, C2, C3) and frame size, e.g., 10 m (33 ft) for C1/C2 on R0-R2, up to 40 m (131 ft) for C1/C2/C3 on R1-R4 (3-phase 380…480 V).
- Auxiliary Voltage Output: +24 V DC ±10%, max. 250 mA (from base unit and/or RIIO-01 module).
- Relay Output: 1 form C (NO + NC), max. switching voltage 250 V AC / 30 V DC, max. switching current 2 A (non-inductive).
Usage Features
- Control Panel Options: Supports ACS-AP-S (Standard assistant), ACS-AP-W (assistant with Bluetooth), ACS-AP-I (industrial assistant), and ACS-BP-S (basic) control panels. Blank panels (RDUM-01) and panel bus adapters (CDPI-02) are also available.
- I/O Extension Modules: Supports optional modules like BAPO-01 (auxiliary power extension), BIO-01 (I/O extension), and BREL-01 (relay output extension).
- PC Connectivity: Can be connected to a PC via USB for communication using software like Drive Composer.
- Motor Thermal Protection: Includes a function to protect the motor against thermal overload, monitoring either a calculated temperature value or actual temperature from sensors (PTC or Pt100).
- Ground Fault Protection: Equipped with an internal ground fault protective function for the unit, motor, and motor cable. Compatible with residual current devices of Type B.
- Emergency Stop: The Safe Torque Off function can be used to implement emergency stop.
- Brake Chopper: Built-in as standard, with options for external brake resistors.
Maintenance Features
- Maintenance Intervals: Detailed tables provide recommended annual actions, including inspections for connections, environment, tightness of terminals, dustiness, corrosion, temperature, and cleaning the heatsink.
- Cooling Fan Replacement: Instructions are provided for replacing cooling fans on frames R1-R4. R0 frames do not have cooling fans.
- Capacitor Reforming: Electrolytic capacitors in the DC link may need reforming if the drive has not been powered for a year or more. Instructions are available in a separate manual.
- Functional Safety Components: Mission time for functional safety components is 20 years. Proof testing of safety functions is required periodically (e.g., monthly or annually depending on SIL/PL).
- Fault Tracing: The drive provides indications for STO function status, and diagnostics cross-compare STO channels to detect malfunctions.
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