ABB ACS380 Drives: Quick Installation and Start-up Guide

Safety Instructions

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 electrical installation or maintenance work.

• Do not do work on the drive, motor cable, motor, or control cables when the drive is connected to the input power. Before you start the work, isolate the drive from all dangerous voltage sources and make sure that it is safe to start the work. Always wait for 5 minutes after disconnecting the input power to let the intermediate circuit capacitors discharge.
• 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 terminals.

Installation

1. Unpack the delivery

Keep the drive in its package until you are ready to install it. After unpacking, protect the drive from dust, debris and moisture.

Make sure that these items are included:

• drive
• options, if ordered with an option code
• installation accessories (cable clamps, cable ties, hardware, etc.)
• mounting template (frames R3 and R4 only)
• safety instructions
• multilingual warning sticker sheet (residual voltage warning)
• user interface guide (under the drive front cover)
• quick installation and start-up guide
• hardware and firmware manuals, if ordered with an option code.

Make sure that there are no signs of damage to the items.

2. Reform the capacitors

If the drive has not been powered up for a year or more, you must reform the DC link capacitors. The manufacturing date is on the type designation label. Refer to Capacitor reforming instructions (3BFE64059629 [English]).

3. Select the cables and fuses

• Select the power cables. Obey the local regulations.
• Input power cable: ABB recommends to use symmetrical shielded cable (VFD cable) for the best EMC performance.
• Motor cable: Use symmetrical shielded cable (VFD cable) for the best EMC performance. Symmetrical shielded cable also reduces bearing currents, wear, and stress on motor insulation.
• Power cable types: In IEC installations, use copper or aluminum cables (if permitted). In UL installations, use only copper cables.
• Current rating: max. load current.
• Voltage rating: min. 600 V AC.
• Temperature rating: In IEC installations, select a cable rated for at least 70 °C (158 °F) maximum permissible temperature of conductor in continuous use. In UL installations, select a cable rated for at least 75 °C (167 °F).
• Size: Refer to Fuses and typical power cable sizes for the typical cable sizes and to Terminal data for the power cables for the maximum cable sizes.
• Select the control cables. Use double-shielded twisted-pair cable for analog signals. Use double-shielded or single-shielded cable for the digital, relay and I/O signals. Do not run 24 V and 115/230 V signals in the same cable.
• Protect the drive and input power cable with the correct fuses. Refer to Fuses and typical power cable sizes.

4. Examine the installation area

The drive is intended for cabinet installation and has a degree of protection of IP20 / UL open type as standard. Examine the site where you will install the drive. Make sure that:

• The installation site is sufficiently ventilated and hot air does not recirculate.
• There is sufficient free space around the drive for cooling, maintenance, and operation. For the minimum free space requirements, refer to Free space requirements.
• The ambient conditions meet the requirements. Refer to Ambient conditions.
• The installation surface is as close to vertical as possible and strong enough to support the weight of the drive. Refer to Dimensions and weights.
• The installation surface, floor and materials near the drive are not flammable.
• There are no sources of strong magnetic fields such as high-current single-core conductors or contactor coils near the drive. A strong magnetic field can cause interference or inaccuracy in the operation of the drive.

5. Install the drive

You can install the drive with screws, or to a DIN rail (top hat type, width × 7.5 mm [1.4 in × 0.3 in]).

Mounting with screws

1. Make marks onto the surface for the mounting holes. Refer to Dimensions and weights. Use the included mounting template for frames R3 and R4.
2. Drill the holes for the mounting screws. If necessary, install suitable plugs or anchors into the holes.
3. Install the mounting screws into the holes. Leave a gap between the screw head and installation surface.
4. Put the drive onto the mounting screws.
5. Tighten the mounting screws.

Mounting to a DIN rail

1. Move the locking part to the left. If necessary, use a flat-head screwdriver.
2. Push and hold the locking button down.
3. Put the top tabs of the drive onto the top edge of the DIN rail.
4. Put the drive against the bottom edge of the DIN rail.
5. Release the locking button.
6. Move the locking part to the right.
7. Make sure that the drive is correctly installed. To remove the drive, open the locking part and lift the drive from the DIN rail.

Connections

6. Measure the insulation resistance

Drive: Do not do voltage tolerance or insulation resistance tests on the drive, because this can cause damage to the drive.

Input power cable: Before you connect the input power cable, measure the insulation 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 from the drive output terminals T1/U, T2/V and T3/W.
2. Use a voltage of 1000 V DC to measure the insulation resistance between each phase conductor and the protective earth conductor. The insulation resistance of an ABB motor must be more than 100 Mohm (at 25 °C [77 °F]). For the insulation resistance of other motors, refer to the manufacturer’s documentation.

Moisture in the motor decreases the insulation resistance. If you think that there is moisture in the motor, dry the motor and do the measurement again.

7. Grounding System Compatibility

You can connect all drive types to a symmetrically grounded TN-S system (center-grounded wye). The drive is delivered with the EMC and VAR screws installed. The material of the screws (plastic or metal) depends on the product variant. The table shows when to remove the metal EMC screw (disconnect the internal EMC filter) or metal VAR screw (disconnect the varistor circuit).

¹⁾ Drives sold in North America have a plastic EMC screw.

²⁾ Can install the metal screw (included in the drive delivery) to connect the internal EMC filter.

8. Connect the power cables

Connection Diagram (shielded cables)

The diagram shows the connections for power cables:

• 1. Disconnecting device.
• 2. Two protective earth (ground) conductors. Drive safety standard IEC/EN 61800-5-1 requires two PE conductors, if the cross-sectional area of the PE conductor is less than 10 mm² Cu or 16 mm² Al. For example, you can use the cable shield in addition to the fourth conductor.
• 3. Use a separate grounding cable or a cable with a separate PE conductor for the line side, if the conductivity of the fourth conductor or shield does not meet the requirements for the PE conductor.
• 4. Use a separate grounding cable for the motor side, if the conductivity of the shield is not sufficient, or if there is no symmetrically constructed PE conductor in the cable.
• 5. 360-degree grounding of the cable shield is required for the motor cable and brake resistor cable (if used). It is also recommended for the input power cable.
• 6. Brake resistor and resistor cable (optional).

The diagram illustrates terminals L1, L2, L3, PE for input power, and T1/U, T2/V, T3/W, R-, R+/UDC+, UDC- for motor and brake resistor connections, with PE for protective earth.

Connection Procedure (shielded cables)

For the tightening torques, refer to Terminal data for the power cables.

1. Remove the screw on the drive front cover, then remove the front cover.
2. Attach the residual voltage warning sticker in the local language to the drive.
3. Strip the motor cable.
4. Ground the motor cable shield under the grounding clamp.
5. Twist the motor cable shield into a bundle, mark it and connect it to the grounding terminal.
6. Connect the phase conductors of the motor cable to terminals T1/U, T2/V and T3/W.
7. If you use a brake resistor, connect the brake resistor cable to terminals R- and UDC+. Use a shielded cable and ground the shield under the grounding clamp.
8. Make sure that the R- and UDC+ terminal screws are tightened. Do this step also if you do not connect cables to the terminals.
9. Strip the input power cable.
10. If the input power cable has a shield, ground the shield under the grounding clamp. Then twist the shield into a bundle, mark it and connect it to the grounding terminal.
11. Connect the PE conductor of the input power cable to the grounding terminal. If necessary, use a second PE conductor.
12. In 3-phase drives, connect the phase conductors of the input power cable to terminals L1, L2 and L3. In 1-phase drives, connect the phase and neutral conductors to terminals L1 and L2.
13. Mechanically attach the cables on the outside of the drive.

9. Connect the control cables

Do the connections according to the default control connections of the application macro that you select. Keep the signal wire pairs twisted as near to the terminals as possible to prevent inductive coupling. The tightening torque for the terminal connections is 0.5 × 0.6 N·m (4.4 × 5.3 lbf·in).

1. Strip a part of the outer shield of the control cable for grounding.
2. Use a cable tie to ground the outer shield to the grounding tab.
3. Use metal cable ties for 360-degree grounding.
4. Strip the control cable conductors.
5. Connect the conductors to the correct control terminals.
6. Connect the shields of the twisted pairs and grounding wires to the SCR terminal.
7. Mechanically attach the control cables on the outside of the drive.

Default I/O connections (ABB standard macro)

The ABB standard macro is the default macro. The connection diagram for the ABB standard macro is shown below. If you have a drive variant that does not have the BMIO-01 module, connect only the terminals that are on the base unit.

¹⁾ x = on base unit, empty = on BMIO-01 module.

Embedded fieldbus connection

You can connect the drive to an EIA-485 serial communication link through the embedded fieldbus interface on the BMIO-01 I/O module. The embedded fieldbus interface supports the Modbus RTU protocol.

To configure Modbus RTU communication with the embedded fieldbus:

1. Connect the fieldbus cables and the necessary I/O signals.
2. Use the jumpers to set the termination and bias settings.
3. Power up the drive and set the necessary parameters.

A connection example is shown below, detailing termination and bias settings for automation controllers and drives.

Start-up

10. Start up the drive

WARNING!

Before you start up the drive, make sure that the installation is completed. Make sure also that it is safe to start the motor. Disconnect the motor from other machinery, if there is a risk of damage or injury.

For information on the user interface, refer to the ACS380 User interface guide (3AXD50000022224 [English]), which is delivered with the drive.

1. Power up the drive. The drive software automatically identifies the connected adapter (BMIO-01 module or some of the fieldbus modules) and sets the applicable parameters.
2. Select the units (international or US). In the Motor data view, select the motor type: AsynM: Asynchronous motor, PMSM: Permanent magnet synchronous motor, SynRM: Synchronous reluctance motor.
3. Set the motor control mode:
   • Vector: Speed reference. This is suitable for most cases.
   • Scalar: Frequency reference. Do not use this mode for permanent magnet synchronous motors. Use this mode when:
     • The number of motors can change.
     • The nominal motor current is less than 20% of the nominal drive current.
4. Set the nominal motor values.
5. Start the motor and check the direction of rotation. If the direction is incorrect, you can:
   • change the Phase order setting, or
   • change the phase order of the motor cable.
   Note: In vector control mode the drive does an automatic standstill ID run at the first start.
6. In the Motor control view, set the start and stop mode.
7. Set the acceleration and deceleration times.
8. Set the maximum and minimum speeds.
9. In the Control macros view, select the applicable macro. To configure fieldbus communications, refer to Fieldbus communication.
10. Tune the drive parameters to the application. You can also use an assistant control panel (ACS-AP-…) or the Drive Composer PC tool.

WARNING!

If 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”.

Fieldbus communication

You can connect the drive to an EIA-485 serial communication link through the embedded fieldbus interface on the BMIO-01 I/O module. The embedded fieldbus interface supports the Modbus RTU protocol.

To configure Modbus RTU communication with the embedded fieldbus:

1. Select Modbus RTU from the Control macros view. The drive changes some parameter values automatically.
2. Configure fieldbus communication from the parameter list. The minimum set of parameters for Modbus RTU configuration are listed below:

For fieldbus communication with a fieldbus adapter module, the drive automatically identifies the connected adapter and selects the correct fieldbus control macro. If necessary, configure the adapter-specific settings. Refer to the applicable fieldbus adapter documentation.

Warnings and Faults

The following table lists common warnings and faults:

Ratings

The following tables provide input and output ratings for various ACS380 drive models.

Input and Output Ratings

1-phase UN = 230 V

3-phase UN = 230 V

3-phase UN = 400 V

3-phase UN = 480 V

Notes: I1 Input current for 230 V and 400 V with motor power PN (kW), and for 480 V with motor power PLd (hp). Imax Maximum output current. Available for 2 seconds every 10 minutes when the output frequency is less than 9 Hz. IN Nominal output current. Maximum continuous rms output current (no overload). ILd Continuous rms output current. Allows 10% overload for 1 minute every 10 minutes. IHd Continuous rms output current. Allows 50% overload for 1 minute every 10 minutes. PN Typical motor power in nominal use (no overload). PLd Typical motor power in light-duty use (10% overload). PHd Typical motor power heavy-duty use (50% overload). The kilowatt ratings are applicable to most IEC 4-pole motors. The horsepower ratings are applicable to most NEMA 4-pole motors.

Fuses and typical power cable sizes

The following table lists recommended fuses and corresponding cable sizes for different drive models and voltage ratings.

¹⁾ The recommended branch protection fuses must be used to maintain the IEC/EN/UL 61800-5-1 listing.

²⁾ The drive is suitable for use on a circuit capable of delivering not more than 100000 symmetrical amperes (rms) at 480 V (480 V drives) or 240 V (240 V drives) maximum when protected by the fuses given in this table.

³⁾ As an alternative to Class T fuses, you can use Class J or Class CF fuses of the same voltage and current rating for branch circuit protection of 3-phase drives.

⁴⁾ Refer to Alternate Fuses, MMPs and Circuit Breakers for ABB Drives (3AXD50000645015 [English]) for additional UL fuses and circuit breakers that can be used as branch circuit protection.

Terminal data for the power cables

This table specifies the terminal connections, wire sizes, and tightening torques for power cables.

Notes: The minimum specified wire size does not necessarily have sufficient current carrying capacity at maximum load. The terminals do not accept a conductor that is one size larger than the maximum specified wire size. The maximum number of conductors per terminal is 1.

Free space requirements

This table outlines the required clearance around the drive for proper ventilation and maintenance.

¹⁾ A side-mounted option requires approximately 20 mm (0.8 in) of space on the right side of the drive.

Ambient conditions

The drive is designed for operation under specific ambient conditions:

• Installation site altitude: 230 V drives: 0 … 2000 m (0 … 6562 ft) above sea level. 400/480 V drives: 0 … 4000 m (0 … 13123 ft) above sea level. At altitudes above 2000 m (6562 ft): only TN-S and TT grounding systems are permitted; the maximum permitted voltage for the relay output RO1 decreases. At 4000 m (13123 ft), it is 30 V. Derating: The output current must be derated 1% for each 100 m (328 ft) above 1000 m (3281 ft).
• Surrounding air temperature: Frame R0: -10 … +50 °C (14 … 122 °F). No frost permitted. Frames R1...R4: -10 … +60 °C (14 … 140 °F). No frost permitted. The output current must be derated at temperatures above +50 °C (122 °F) as follows: Types 055A-2, 038A-4 and 050A-4: 2% for each added 1 °C (1.8 °F). Other types: 1% for each added 1 °C (1.8 °F).
• Relative humidity: 5 … 95%. No condensation permitted. Maximum permitted relative humidity is 60% in the presence of corrosive gases.
• Contamination levels: No conductive dust permitted.
• Shock or free fall: Not permitted.

Dimensions and weights

This table provides the physical dimensions and weights for different drive frame sizes.

Markings

The applicable markings are shown on the type label of the product. These include CE, UL, RCM, EAC, UKCA, KC, EIP green, WEEE, and TÜV Nord.

Safe Torque Off (STO)

The drive features a Safe Torque Off (STO) function compliant with IEC/EN 61800-5-2. This function can be used as the final actuator device in safety circuits to stop the drive in dangerous situations, such as an emergency stop.

When activated, the STO function disables the control voltage to the power semiconductors in the drive's output stage, preventing the drive from generating torque to rotate the motor. The control program provides an indication as defined by parameter 31.22. If the motor is running when STO is activated, it will coast to a stop. Closing the activation switch deactivates STO. Any faults must be reset before restarting.

The STO function has a redundant architecture, requiring both channels to be used for safety function implementation. Safety data is calculated for redundant use and does not apply if both channels are not used.

WARNING!

The STO function does not disconnect the voltage from the main and auxiliary circuits of the drive.

Notes:

• If stopping by coasting is not acceptable, stop the drive and machinery using the appropriate stop mode before activating the STO.
• The STO function overrides all other functions of the drive.

Wiring

The safety contacts must open/close within 200 ms of each other. Double-shielded twisted-pair cable is recommended for the connection. The maximum length of the cabling between the switch and the drive control unit is 300 m (1000 ft). Ground the shield of the cable at the control unit only.

Validation

To ensure the safe operation of a safety function, a validation test is required. The test must be carried out by a competent person with adequate expertise and knowledge of the safety function. The test procedures and report must be documented and signed by this person. Validation instructions of the STO function can be found in the drive hardware manual.

Technical data

• Minimum voltage at IN1 and IN2 to be interpreted as “1”: 13 V DC
• STO reaction time (shortest detectable break): 1 ms
• STO response time: 2 ms (typical), 5 ms (maximum)
• Fault detection time: Channels in different states for longer than 200 ms
• Fault reaction time: Fault detection time + 10 ms
• STO fault indication (parameter 31.22) delay: < 500 ms
• STO warning indication (parameter 31.22) delay: < 1000 ms
• Safety integrity level (EN 62061): SIL 3
• Performance level (EN ISO 13849-1): PL e

The drive STO is a type A safety component as defined in IEC 61508-2. For the full safety data, exact failure rates and failure modes of the STO function, refer to the drive hardware manual.

Declarations of Conformity

ABB Oy declares under its sole responsibility that the product, Frequency converter ACS380-04, with regard to the safety functions - Safe Torque Off and Safe stop 1 (SS1-t, with FSPS-21 PROFIsafe module, +Q986), is in conformity with all the relevant safety component requirements of the Supply of Machinery (Safety) Regulations 2008, when the listed safety function is used for safety component functionality.

The following harmonized standards have been applied:

• EN 61800-5-2:2007
• EN 62061:2005 + AC:2010 + A1:2013 + A2:2015
• EN ISO 13849-1:2015
• EN ISO 13849-2:2012
• EN 60204-1:2018

The following other standards have been applied:

• IEC 61508:2010, parts 1-2
• IEC 61800-5-2:2016

The product(s) referred in this declaration of conformity fulfil(s) the relevant provisions of other UK statutory requirements, which are notified in a single declaration of conformity 3AXD10001323213.

Helsinki, May 7, 2021

Signed for and on behalf of: Tuomo Tarula, Local Division Manager, ABB Oy

Mikko Korpinen, Product Unit Manager, ABB Oy

Related Documents

Refer to the following resources for more information:

• ACS380 manual list
• ACS380 online videos
• Ecodesign information (EU 2019/1781)