ABB ACS380 Quick Installation And Start-up Manual

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Safety instructionsRead the safety instructions in ACS380 Hardware manual (3AXD50000029274 [EN]).WARNING! Obey these safety instructions to prevent physical injury ordeath, or damage to the equipment. If you are not a qualified electrician, donot do electrical installation or maintenance work.• When you install the drive, make sure that dust does not go into the drive.• When the drive or connected equipment is energized, do not do work onthe drive, motor cable, motor, control cables or control circuits.• After you disconnect the input power, wait for 5 minutes to let theintermediate circuit capacitors discharge.• Make sure that the installation is not energized:• Use a multimeter with an impedance of at least 1 Mohm.• Make sure that the voltage between the drive output terminals (U, V, W)and the ground (PE) is 0 V.• Make sure that the voltage between the drive input power terminals (L1,L2, L3) and the ground (PE) is 0 V.• Make sure that the voltage between the DC and brake resistor terminals(UDC+, UDC- and R-) and the ground (PE) is 0 V.• If you use a permanent magnet synchronous motor, do not do work on thedrive when the motor rotates. A permanent magnet motor that rotatesenergizes the drive and the input power terminals.WARNING! The installation, start-up and operation of this equipmentrequires detailed instructions. Refer to this quick guide and the user interfaceguide in the drive package. Retain the guides with this device at all times.For more information, refer to the hardware manual and firmware manual.You can download these manuals from the ABB website or order hardcopies of the manuals with the delivery.1. Examine the installation areaThe drive is intended for cabinet installation and has an ingress protection rating ofIP20.Make sure that in the installation area:• There is sufficient cooling and hot air does not recirculate.• The ambient conditions are suitable. Refer to Ambient conditions.• The mounting surface is non-flammable and can hold the weight of the drive.Refer to Declaration of conformity.• Materials near the drive are non-flammable.• There is sufficient space above and below the drive for maintenance work. Referto Free space requirements.2. Install the driveYou can install the drive with screws or to a DIN rail.Installation requirements:• Make sure that there is a minimum of 75 mm of free space at the top and bottomof the drive for cooling air.• Install R0 drives upright. R0 drives do not have a fan.• You can install R1, R2, R3 and R4 drives tilted by up to 90 degrees, from verticalto fully horizontal orientation.• You can install several drives side by side. Side-mounted options requireapproximately 20 mm of space on the right side of the drive.WARNING! Do not install the drive upside down. Make sure that the coolingair exhaust (at the top) is always above the cooling air inlet (at the bottom). To install the drive with screws1. Make marks onto the surface for themounting holes. Refer toDeclaration of conformity. The R3and R4 drives contain a mountingtemplate.2. Make the holes for the mountingscrews and install suitable plugs oranchors.3. Start to tighten the screws into themounting holes.4. Install the drive onto the mountingscrews.5. Tighten the mounting screws. To install the drive to a DIN rail1. Move the locking part to the left.2. Push and hold the locking buttondown.3. Put the top tabs of the drive onto thetop edge of the DIN installation rail.4. Put the drive against the bottomedge of the DIN installation rail.5. Release the locking button.6. Move the locking part to the right.7. Make sure that the drive is correctlyinstalled.8. To remove the drive, use a flat-headscrewdriver to open the locking part.3. Measure the insulation resistanceDrive: Do not do voltage tolerance or insulation resistance tests on the drive, becausethis can cause damage to the drive.Input power cable: Before you connect the input power cable, measure theinsulation 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 fromthe drive output terminals T1/U, T2/V and T3/W.2. Use a voltage of 500 V DC to measure theinsulation resistance between each phaseconductor and the protective earth conductor. Theinsulation resistance of an ABB motor must be morethan 100 Mohm (at 25 °C/77 °F). For the insulationresistance of other motors, refer to themanufacturer’s documentation.Moisture in the motor decreases the insulation resistance. If you think that thereis moisture in the motor, dry the motor and do the measurement again.4. Select the cablesInput power cable: For the best EMC performance, use a symmetrical shieldedcable and two grounding conductors.Motor cable: Use a symmetrical shielded cable.Control cable: Use a double-shielded twisted-pair cable for analog signals. Use asingle-shielded cable for digital, relay and I/O signals. Use separate cables for analogand relay signals.5. Connect the power cables Connection diagrama. Two grounding conductors. Use two conductors if the cross-section of groundingconductor is less than 10 mm 2 Cu or 16 mm 2 Al (IEC/EN 61800-5-1). For example,use the cable shield in addition to the fourth conductor.b. Separate grounding cable (line side). Use it if the conductivity of the fourthconductor or shield is not sufficient for the protective grounding.c. Separate grounding cable (motor side). Use it if the conductivity of the shield is notsufficient for the protective grounding, or there is no symmetrically constructedgrounding conductor in the cable.d. 360-degree grounding of the cable shield. Required for the motor cable and brakeresistor cable, recommended for the input power cable. Connection procedureWARNING! Obey the safety instructions in the ACS380 Hardware manual(3AXD50000029274 [English]). If you ignore them, injury or death, ordamage to the equipment can occur.WARNING! If the drive is connected to an IT (non-grounded) system or to acorner-grounded TN system, disconnect the EMC filter grounding screw.1. Strip the motor cable.2. Ground the motor cable shield underthe grounding clamp.3. Twist the motor cable shield into abundle, mark it accordingly andconnect it to the grounding terminal.4. Connect the phase conductors ofthe motor cable to the T1/U, T2/Vand T3/W motor terminals. Torquethe terminals to 0.8 N·m (7 lbf·in).5. If it is applicable, connect the brakeresistor cable to the R- and UDC+terminals. Torque the terminals to0.8 N·m (7 lbf·in). Use a shieldedcable and ground the shield underthe grounding clamp.6. Strip the input power cable.7. If the input power cable has a shield,twist it into a bundle, mark it andconnect it to the grounding terminal.8. Connect the PE conductor of theinput power cable to the groundingterminal. If it is necessary, use asecond PE conductor.9. Connect the phase conductors of the input power cable to the L1, L2 and L3 inputterminals. Torque the terminals to 0.8 N·m (7 lbf·in).10. Mechanically attach the cables on the outside of the drive.Make sure that there are no sources of strong magnetic fields such as high-currentsingle-core conductors or contactor coils near the drive. A strong magnetic field cancause interference or inaccuracy in the operation of the drive. If there is interference,move the source of the magnetic field away from the drive.6. Connect the control cables Connection procedureDo the connections according to the default control connections of the applicationmacro that you select. For the connections of the factory default macro (ABB standardmacro), refer to Default I/O connections (ABB standard macro), for the connections offieldbus default macro, refer to Fieldbus connections. For the other macros, refer tothe ACS380 Firmware manual (3AXD50000029275 [English]).Keep the signal wire pairs twisted as near to the terminals as possible to preventinductive coupling.1. Strip a part of the outer shield of thecontrol cable for grounding.2. Use a cable tie to ground the outershield to the grounding tab.3. Use metal cable ties for 360-degreegrounding.4. Strip the control cable conductors.5. Connect the conductors to thecorrect control terminals. Torque theterminals to 0.5 N·m (4.4 lbf·in).6. Connect the shields of the twistedpairs and grounding wires to theSCR terminal. Torque the terminalsto 0.5 N·m (4.4 lbf·in).7. Mechanically attach the control cables on the outside of the drive. Default I/O connections (ABB standard macro)For the standard variant (I/O & Modbus) (type ACS380-04xS). Connecting EIA-485 Modbus RTU terminal to driveConnect the fieldbus to the EIA-485 Modbus RTU terminal on the BMIO-01 modulewhich is attached on the control unit of the drive. The connection diagram is shownbelow. Fieldbus connectionsFor the configured drives with the preconfigured fieldbus protocol(type ACS380-04xC).—ABB MACHINERY DRIVESACS380 driveQuick installation and start-up guideWHab cd dTerminals DescriptionsDigital I/O connectionsAux. +24 V DC, max. 200 mAAux. voltage output commonDigital input commonStop (0) / Start (1)Forward (0) / Reverse (1)Speed selectionSpeed selectionRamp 1 (0) / Ramp 2 (1)Ready (0) / Not ready (1)Digital output auxiliary voltageDigital input/output commonAnalog I/OFreq. ref. / Speed ref. (0...10 V)Analog input circuit commonNot configuredAnalog input circuit commonOutput frequency (0...20 mA)Analog output circuit commonSignal cable shield (screen)Reference voltageSafe torque off (STO)Safe torque off function. Connected at factory.Drive starts only if both circuits are closed.Relay outputRelay output 1No fault [Fault (-1)]EIA-485 Modbus RTUEmbedded Modbus RTU (EIA-485)Terminals DescriptionsDigital I/O connectionsAux. +24 V DC, 200 mAAux. voltage output commonDigital input commonFault resetNot configuredSafe torque off (STO)Safe torque off function. Connected at factory.Drive starts only if both circuits are closed.Relay outputRelay output 1No fault [Fault (-1)]Extension module connections+K457 FCAN-01-M CANopen+K454 FPBA-01-M Profibus DP+K469 FECA-01-M EtherCAT+K475 FENA-21-M Ethernet/IP, Profinet,Modbus TCP+K495 BCAN-11 CANopen interface+K470 FEPL-02 Ethernet power link (RJ45x2)+K451 FDNA-01, DeviceNet (Terminal Block)+24VDGNDDCOMDI1DI2DI3DI4DIO1DIO2DIO SRCDIO COMAI1AGNDAI2AGNDAOAGNDSCR+10VS+SGNDS1S2RCRARBB+A-BGNDShieldTermination1...10 kohmMax. 500 ohm...Process I/O (cyclic)Service messages (acyclic)Data flowControl Word (CW)ReferencesStatus Word (SW)Actual valuesParameter R/Wrequests/responsesFieldbus controllerFieldbusTermination ON (11) The device at both ends on the fieldbus must have termination set to ON.Termination OFFDriveON1ON1ON1B +A -DGNDTermination OFFDriveON1ON1ON1B +A -DGNDDriveTermination ON (1ON1ON1ON1B +A -DGND+24VDGNDDCOMDI1DI2S+SGNDS1S2RCRARBDSUB9DSUB9RJ45 X 2RJ45 X 2RJ45 X 2RJ45 X 2Terminal BlockCANopenProfibus DPEtherCATEthernet IPProfinetModbus TCPCANopen

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