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ABB DRIVES FOR HVAC
ACH480 drives
Hardware manual
Table of contents
1 Safety instructions
15Contents of this chapter ......................................................................................
15Use of warnings and notes .................................................................................
16General safety in installation, start-up and maintenance ....................................
17Electrical safety in installation, start-up and maintenance ..................................
17Electrical safety precautions ........................................................................
18Additional instructions and notes .................................................................
18Printed circuit boards ........................................................................
18Grounding ....................................................................................................
20General safety in operation .................................................................................
20Additional instructions for permanent magnet motor drives ................................
20Safety in installation, start-up, maintenance ................................................
21Safety in operation .......................................................................................
2 Introduction to the manual
23Contents of this chapter ......................................................................................
23Applicability .........................................................................................................
23Target audience ..................................................................................................
23Categorization by frame size ..............................................................................
24Quick installation and commissioning flowchart .................................................
25Terms and abbreviations .....................................................................................
26Related manuals .................................................................................................
3 Operation principle and hardware description
29Contents of this chapter ......................................................................................
29Operation principle ..............................................................................................
30Simplified main circuit diagram ....................................................................
30Product variants ..................................................................................................
30IEC and UL (NEC) product types .................................................................
31Layout .................................................................................................................
32Control connections ............................................................................................
32Standard unit ................................................................................................
33Base unit ......................................................................................................
33Option modules ...................................................................................................
34Control panel options ..........................................................................................
34UL Type 1 kits .....................................................................................................
35Type designation label ........................................................................................
Table of contents 5
36Type designation key ..........................................................................................
36Basic code ....................................................................................................
36Option (plus) codes ......................................................................................
4 Mechanical installation
39Contents of this chapter ......................................................................................
39Installation alternatives .......................................................................................
40Examining the installation site ............................................................................
40Required tools .....................................................................................................
41Unpacking the delivery ........................................................................................
41Installing the drive ...............................................................................................
41To install the drive with screws .....................................................................
42To install the drive to a DIN installation rail ..................................................
5 Guidelines for planning the electrical installation
45Contents of this chapter ......................................................................................
45Limitation of liability .............................................................................................
45Selecting the main supply disconnecting device ................................................
45European Union ...........................................................................................
46North America ..............................................................................................
46Other regions ...............................................................................................
46Selecting the main contactor ..............................................................................
46Checking the compatibility of the motor and drive ..............................................
46Selecting the power cables .................................................................................
46General guidelines .......................................................................................
47Typical power cable sizes ............................................................................
48Power cable types ........................................................................................
48Preferred power cable types .............................................................
49Alternate power cable types .............................................................
50Not allowed power cable types .........................................................
50Additional guidelines, North America ...........................................................
51Metal conduit ....................................................................................
51Power cable shield .......................................................................................
52Selecting the control cables ................................................................................
52Shielding ......................................................................................................
52Signals in separate cables ...........................................................................
52Signals that can be run in the same cable ...................................................
52Relay cable ..................................................................................................
52Control panel to drive cable .........................................................................
52PC tool cable ................................................................................................
53Routing the cables ..............................................................................................
53General guidelines – IEC .............................................................................
53General guidelines – North America ............................................................
6 Table of contents
54
Continuous motor cable shield/conduit or enclosure for equipment on the
motor cable ..................................................................................................
55Separate control cable ducts .......................................................................
55Implementing short-circuit and thermal overload protection ...............................
55Protecting the drive and input power cable in short-circuits .........................
55Protecting the motor and motor cable in short-circuits .................................
55
Protecting the drive, and the input power and motor cables against thermal
overload .......................................................................................................
56Protecting the motor against thermal overload ............................................
56
Protecting the motor against overload without thermal model or temperature
sensors .........................................................................................................
56Implementing a motor temperature sensor connection ......................................
57Protecting the drive against ground faults ..........................................................
57Residual current device compatibility ...........................................................
57Implementing the Emergency stop function ........................................................
58Implementing the Safe torque off function ..........................................................
58Using a safety switch between the drive and the motor .....................................
58Implementing the control of a contactor between drive and motor .....................
58Protecting the contacts of relay outputs ..............................................................
6 Electrical installation – IEC
61Contents of this chapter ......................................................................................
61Warnings .............................................................................................................
61Required tools .....................................................................................................
62Measuring the insulation .....................................................................................
62Measuring the insulation of the drive ...........................................................
62Measuring the insulation of the input power cable .......................................
62Measuring the insulation of the motor and motor cable ...............................
63Measuring the insulation of the brake resistor circuit ...................................
63Earthing system compatibility check – IEC .........................................................
64EMC filter .....................................................................................................
64Ground-to-phase varistor .............................................................................
64When to disconnect EMC filter or ground-to-phase varistor ........................
66Disconnecting the EMC filter or ground-to-phase varistor ...........................
66EMC/VAR screw location ..................................................................
67Guidelines for installing the drive to a TT system ........................................
67Identifying the earthing system of the electrical power network ...................
69Connecting the power cables – IEC (shielded cables) .......................................
69Connection diagram .....................................................................................
70Connection procedure ..................................................................................
72Connecting the control cables ............................................................................
72Default I/O connection diagrams (HVAC default) .........................................
74Default fieldbus connection diagram ............................................................
75Control cable connection procedure ............................................................
Table of contents 7
75Additional information on the control connections .......................................
75Connecting EIA-485 fieldbus cable to the drive ................................
76PNP configuration for digital inputs ..................................................
77NPN configuration for digital inputs ..................................................
77Connection for obtaining 0 … 10 V from analog output 2 (AO2) ......
78Connection examples of two-wire and three-wire sensors ...............
78
AI and AO (or AI, DI and +10 V) as PTC motor temperature sensor
interface ............................................................................................
80
AI1 and AI2 as Pt100, Pt1000, Ni1000, KTY83 and KTY84 sensor
inputs ................................................................................................
81Safe torque off ..................................................................................
81Auxiliary voltage connection ...............................................................................
82Connecting a PC .................................................................................................
82Installing options .................................................................................................
83Installing a front option .................................................................................
84Installing a side option .................................................................................
7 Electrical installation – North America
87Contents of this chapter ......................................................................................
87Warnings .............................................................................................................
87Required tools .....................................................................................................
88Measuring the insulation .....................................................................................
88Measuring the insulation of the drive ...........................................................
88Measuring the insulation of the input power cable .......................................
88Measuring the insulation of the motor and motor cable ...............................
89Measuring the insulation of the brake resistor circuit ...................................
89Earthing system compatibility check – North America ........................................
90EMC filter .....................................................................................................
90Ground-to-phase varistor .............................................................................
90When to disconnect ground-to-phase varistor, or connect EMC filter ..........
92Disconnecting the ground-to-phase varistor, or connecting the EMC filter ...
92EMC/VAR screw location ..................................................................
93Guidelines for installing the drive to a TT system ........................................
93Identifying the earthing system of the electrical power network ...................
94Connecting the power cables – North America (wiring in conduits) ...................
95Connection diagram .....................................................................................
95Connection procedure ..................................................................................
96Connecting the control cables ............................................................................
96Default I/O connection diagrams (HVAC default) .........................................
98Default fieldbus connection diagram ............................................................
99Control cable connection procedure ............................................................
100Additional information on the control connections .......................................
100Connecting EIA-485 fieldbus cable to the drive ................................
101PNP configuration for digital inputs ..................................................
101NPN configuration for digital inputs ..................................................
8 Table of contents
102Connection for obtaining 0 … 10 V from analog output 2 (AO2) ......
102Connection examples of two-wire and three-wire sensors ...............
103
AI and AO (or AI, DI and +10 V) as PTC motor temperature sensor
interface ............................................................................................
104
AI1 and AI2 as Pt100, Pt1000, Ni1000, KTY83 and KTY84 sensor
inputs ................................................................................................
105Safe torque off ..................................................................................
105Auxiliary voltage connection ...............................................................................
106Connecting a PC .................................................................................................
106Installing options .................................................................................................
107Installing a front option .................................................................................
108Installing a side option .................................................................................
8 Installation checklist of the drive
111Contents of this chapter ......................................................................................
111Checklist .............................................................................................................
9 Maintenance
115Contents of this chapter ......................................................................................
115Maintenance intervals .........................................................................................
116Cleaning the heatsink .........................................................................................
117Replacing the cooling fans ..................................................................................
117To replace the cooling fan for frame sizes R1, R2 and R3 ...........................
119To replace the cooling fan for frame R4 .......................................................
121Capacitors ...........................................................................................................
121Reforming the capacitors .............................................................................
10 Technical data
123Contents of this chapter ......................................................................................
123Electrical ratings ..................................................................................................
123IEC ratings ...................................................................................................
124UL (NEC) ratings ..........................................................................................
125Definitions ....................................................................................................
125Sizing ...........................................................................................................
125Output derating ...................................................................................................
128Surrounding air temperature derating ..........................................................
128Altitude derating ...........................................................................................
128Switching frequency derating .......................................................................
130Fuses ..................................................................................................................
130IEC fuses ......................................................................................................
130gG fuses (IEC) ..................................................................................
131gR fuses (IEC) ..................................................................................
Table of contents 9
131UL (NEC) fuses ............................................................................................
132UL (NEC) fuse alternatives ...............................................................
134Alternate short-circuit protection .........................................................................
134Miniature circuit breakers (IEC) ...................................................................
135
Manual self-protected combination motor controller – Type E USA
(UL (NEC)) ...................................................................................................
137Dimensions and weights .....................................................................................
138Free space requirements ....................................................................................
138Losses, cooling data and noise ..........................................................................
139Typical power cable sizes ...................................................................................
140Terminal data for the power cables .....................................................................
141Terminal data for the control cables ....................................................................
142External EMC filters ............................................................................................
143Electrical power network specification ................................................................
143Motor connection data ........................................................................................
144Motor cable length ........................................................................................
144Operational functionality and motor cable length .............................
144EMC compatibility and motor cable length .......................................
145Brake resistor connection data ...........................................................................
145Control connection data ......................................................................................
146Efficiency .............................................................................................................
146Protection classes ...............................................................................................
146Ambient conditions ..............................................................................................
147Materials .............................................................................................................
147Disposal ..............................................................................................................
148Applicable standards ...........................................................................................
148Markings .............................................................................................................
149EMC compliance (IEC/EN 61800-3:2004 + A1:2012) ........................................
149Definitions ....................................................................................................
150Category C1 .................................................................................................
150Category C2 .................................................................................................
151Category C3 .................................................................................................
151Category C4 .................................................................................................
152UL checklist .........................................................................................................
153Disclaimers .........................................................................................................
153Generic disclaimer .......................................................................................
154Cybersecurity disclaimer ..............................................................................
11 Dimension drawings
155Contents of this chapter ......................................................................................
156Frame R1 ............................................................................................................
156Frame R1 (front & side) - IP20 / UL open type ............................................
157Frame R1 (bottom & rear) - IP20 / UL open type .........................................
158Frame R1 (front & side) - UL Type 1 kit installed .........................................
159Frame R1 (bottom & rear) - UL Type 1 kit installed .....................................
10 Table of contents
160Frame R2 ............................................................................................................
160Frame R2 (front & side) - IP20 / UL open type ............................................
161Frame R2 (bottom & rear) - IP20 / UL open type .........................................
162Frame R2 (front & side) - UL Type 1 kit installed .........................................
163Frame R2 (bottom & rear) - UL Type 1 kit installed .....................................
164Frame R3 ............................................................................................................
164Frame R3 (front & side) - IP20 / UL open type ............................................
165Frame R3 (bottom & rear) - IP20 / UL open type .........................................
166Frame R3 (front & side) - UL Type 1 kit installed .........................................
167Frame R3 (bottom & rear) - UL Type 1 kit installed .....................................
168Frame R4 ............................................................................................................
168Frame R4 (front & side) - IP20 / UL open type ............................................
169Frame R4 (bottom & rear) - IP20 / UL open type .........................................
170Frame R4 (front & side) - UL Type 1 kit installed .........................................
171Frame R4 (bottom & rear) - UL Type 1 kit installed .....................................
12 Resistor braking
173Contents of this chapter ......................................................................................
173Safety ..................................................................................................................
173Operation principle ..............................................................................................
173Selecting the brake resistor ................................................................................
175Reference brake resistors ............................................................................
176Definitions .........................................................................................
176Selecting and routing the brake resistor cables ..................................................
176Minimizing electromagnetic interference ......................................................
176Maximum cable length .................................................................................
176Placing the brake resistors .................................................................................
177Protecting the system in brake circuit fault situations .........................................
177Protecting the system in cable and brake resistor short-circuit situations ....
177Protecting the system against thermal overload ..........................................
178Mechanical and electrical installation of brake resistor .......................................
178Mechanical installation .................................................................................
179Electrical installation .....................................................................................
179Measuring the insulation ...................................................................
179Connecting power cables .................................................................
179Connection the control cables ..........................................................
179Start-up ...............................................................................................................
13 The Safe torque off function
181Contents of this chapter ......................................................................................
181Description ..........................................................................................................
182Compliance with the European Machinery Directive ...................................
Table of contents 11
183Wiring ..................................................................................................................
183Connection principle ....................................................................................
183Single ACH480 drive, internal power supply ....................................
184Single ACH480 drive, external power supply ...................................
185Wiring examples ...........................................................................................
185Single ACH480 drive, internal power supply ....................................
185Single ACH480 drive, external power supply ...................................
186Multiple ACH480 drives, internal power supply ................................
187Multiple ACH480 drives, external power supply ...............................
187Activation switch ...........................................................................................
188Cable types and lengths ..............................................................................
188Grounding of protective shields ...................................................................
189Operation principle ..............................................................................................
190Start-up including acceptance test ......................................................................
190Competence .................................................................................................
190Acceptance test reports ...............................................................................
190Acceptance test procedure ..........................................................................
192Use ......................................................................................................................
193Maintenance .......................................................................................................
193Competence .................................................................................................
194Fault tracing ........................................................................................................
195Safety data ..........................................................................................................
196Abbreviations ...............................................................................................
197TÜV certificate ..............................................................................................
198Declaration of conformity .............................................................................
14 BAPO-01 auxiliary power extension module
199Contents of this chapter ......................................................................................
199Safety instructions ...............................................................................................
199Hardware description ..........................................................................................
200Layout ..........................................................................................................
200Mechanical installation ........................................................................................
200Electrical installation ...........................................................................................
201Start-up ...............................................................................................................
201Technical data .....................................................................................................
15 BIO-01 I/O extension module
203Contents of this chapter ......................................................................................
203Safety instructions ...............................................................................................
203Hardware description ..........................................................................................
203Product overview ..........................................................................................
204Layout ..........................................................................................................
204Mechanical installation ........................................................................................
204Electrical installation ...........................................................................................
12 Table of contents
205Start-up ...............................................................................................................
205Technical data .....................................................................................................
16 BREL-01 relay output extension module
207Contents of this chapter ......................................................................................
207Safety instructions ...............................................................................................
207Hardware description ..........................................................................................
207Product overview ..........................................................................................
208Layout ..........................................................................................................
208Mechanical installation ........................................................................................
208Electrical installation ...........................................................................................
209Start-up ...............................................................................................................
209Configuration parameters ...................................................................................
211Technical data .....................................................................................................
Further information
Table of contents 13
14
1
Safety instructions
Contents of this chapter
This chapter contains the safety instructions which you must obey when you install,
start up, operate and do maintenance work on the drive. If you ignore the safety
instructions, injury, death or damage can occur.
Use of warnings and notes
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:
WARNING!
Electricity warning tells about hazards from electricity which can cause injury or
death, or damage to the equipment.
WARNING!
General warning tells about conditions, other than those caused by electricity,
which can cause injury or death, or damage to the equipment.
WARNING!
Electrostatic sensitive devices warning tells you about the risk of electrostatic
discharge which can cause damage to the equipment.
Safety instructions 15
General safety in installation, start-up and maintenance
These instructions are for all personnel who do work on the drive.
WARNING!
Obey these instructions. If you ignore them, injury or death, or damage to the
equipment can occur.
• Keep the drive in its package until you install it. After unpacking, protect the drive
from dust, debris and moisture.
• Use the required personal protective equipment: safety shoes with metal toe cap,
safety glasses, protective gloves and long sleeves, etc. Some parts have sharp
edges.
• Beware of hot surfaces. Some parts, such as heatsinks of power semiconductors,
and brake resistors, remain hot for a while after disconnection of the electrical supply.
• Vacuum clean the area around the drive before the start-up to prevent the drive
cooling fan from drawing the dust inside the drive.
• Make sure that debris from drilling, cutting and grinding does not enter the drive
during the installation. Electrically conductive debris inside the drive may cause
damage or malfunction.
• Make sure that there is sufficient cooling. See the technical data.
• Before you connect voltage to the drive, make sure that all covers are in place. Do
not remove the covers when voltage is connected.
• 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 drive power cycles is five times in ten minutes. Power cycling the
drive too often can damage the charging circuit of the DC capacitors.
• If you have connected safety circuits to the drive (for example, Safe torque off or
emergency stop), validate them at start-up. See separate instructions for the safety
circuits.
• Beware of hot air exiting from the air outlets.
• Do not cover the air inlet or outlet when the drive is running.
16 Safety instructions
3
Note:
• If you select an external source for the start command and it is on, the drive will
start immediately after fault reset unless you configure the drive for pulse start. See
the firmware manual.
• Only authorized persons are allowed to repair a malfunctioning drive.
Electrical safety in installation, start-up and maintenance
￭ Electrical safety precautions
These electrical safety precautions 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 electrical professional, do not do installation or
maintenance work.
Go through these steps before you begin any installation or maintenance work.
1. Clearly identify the work location and equipment.
2. Disconnect all possible voltage sources. Make sure that re-connection is not possible.
Lock out and tag out.
• Open the main disconnecting device of the drive.
• If you have a permanent magnet motor connected to the drive, disconnect the
motor from the drive with a safety switch or by other means.
• Disconnect any dangerous external voltages from the control circuits.
• After you disconnect power from the drive, always wait 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 greater than 1 Mohm.
• 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 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 DC terminals (R+/UDC+ and
UDC-) and the grounding terminal (PE) is close to 0 V.
Safety instructions 17
6. Install temporary grounding as required by the local regulations.
7. Ask the person in control of the electrical installation work for a permit to work.
￭ Additional instructions and notes
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 installation or
maintenance work.
• Make sure that the electrical power network, motor/generator, and environmental
conditions agree with the drive data.
• Do not do insulation or voltage withstand tests on the drive.
• If you have a cardiac pacemaker or other electronic medical device, keep away from
the area near motor, drive, and the drive power cabling when the drive is in operation.
There are electromagnetic fields present which can interfere with the function of
such devices. This can cause a health hazard.
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.
• When the input power is on, the drive DC bus is at a dangerous voltage.
If brake chopper and resistor are in use, they are at a dangerous voltage.
• External wiring can supply dangerous voltages to the relay outputs of the control
units of the drive.
• 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.
Printed circuit boards
WARNING!
Use a grounding wrist band when you handle printed circuit boards. Do not touch
the boards unnecessarily. The boards contain components sensitive to electrostatic
discharge.
￭ Grounding
These instructions are for all personnel who are responsible for 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.
18 Safety instructions
3
If you are not a qualified electrical professional, do not do grounding work.
• Always ground the drive, the motor and adjoining equipment. This is necessary for
the personnel safety. Proper grounding also reduces electromagnetic emission and
interference.
• Make sure that the conductivity of the protective earth (PE) conductors is sufficient.
See the electrical planning instructions of the drive. Obey the local regulations.
• Connect the power cable shields to protective earth (PE) terminals of the drive to
make sure of personnel safety.
• Make a 360° grounding of the power and control cable shields at the cable entries
to suppress electromagnetic disturbances.
• In a multiple-drive installation, connect each drive separately to the protective earth
(PE) busbar of the power supply.
Note:
• You can use power cable shields as grounding conductors only when their
conductivity is sufficient.
• 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. The minimum size of the
protective earth conductor must comply with the local safety regulations for high
protective earth conductor current equipment. See standard IEC/EN 61800-5-1
(UL 61800-5-1) and the electrical planning instructions of the drive.
To comply with standard IEC/EN 61800-5-1 (UL 61800-5-1)
• use a protective earth conductor with a minimum cross-sectional area of 10 mm
2
Cu or 16 mm
2
Al (as an alternative when aluminum cables are permitted),
or
• use a second protective earth conductor of the same cross-sectional area as
the original protective earth conductor,
or
• use a device that automatically disconnects the supply if the protective earth
conductor is damaged.
If the protective earth conductor is separate (that is, it does not form part of the input
power cable or the input power cable enclosure), the minimum cross-sectional area
must be:
• 2.5 mm
2
when the conductor is mechanically protected,
or
• 4 mm
2
when the conductor is not mechanically protected.
Safety instructions 19
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.
• If you have a cardiac pacemaker or other electronic medical device, keep away from
the area near motor, drive, and the drive power cabling when the drive is in operation.
There are electromagnetic fields present which can interfere with the function of
such devices. This can cause a health hazard.
• 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 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".
Note:
• The maximum drive power cycles is five times in ten minutes. Power cycling the
drive too often can damage the charging circuit of the DC capacitors. If you need
to start or stop the drive, use the control panel keys or commands through the I/O
terminals of the drive.
Additional instructions for permanent magnet motor drives
￭ Safety in installation, start-up, maintenance
These are additional warnings concerning 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, or damage to the
equipment can occur.
If you are not a qualified electrical professional, do not do installation or
maintenance work.
• 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 power terminals.
20 Safety instructions
3
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