—

ABB MACHINERY DRIVES

ACS380 drives
Hardware manual
ACS380 drives
Hardware manual

Table of contents

1. Safety instructions

4. Mechanical installation

6. Electrical installation – IEC

7. Electrical installation – North

America

3AXD50000029274 Rev G
EN
Original instructions
EFFECTIVE: 2024-04-10
 Table of contents 5

Table of contents

1 Safety instructions
Contents of this chapter ......................................................................................... 17
Use of warnings and notes ..................................................................................... 17
General safety in installation, start-up and maintenance ................................ 18
Electrical safety in installation, start-up and maintenance ............................. 20
Electrical safety precautions .......................................................................... 20
Additional instructions and notes ................................................................. 21
Printed circuit boards .......................................................................... 21
Grounding ........................................................................................................... 22
General safety in operation .................................................................................... 23
Additional instructions for permanent magnet motor drives ........................ 23
Safety in installation, start-up, maintenance .............................................. 23
Safety in operation ........................................................................................... 24

2 Introduction to the manual

Contents of this chapter ......................................................................................... 25
Applicability ............................................................................................................... 25
Target audience ........................................................................................................ 25
Categorization by frame size ................................................................................. 25
Quick installation and commissioning flowchart .............................................. 26
Terms and abbreviations ........................................................................................ 28
Related manuals ....................................................................................................... 29

3 Operation principle and hardware description

Contents of this chapter ......................................................................................... 31
Operation principle .................................................................................................. 31
Simplified main circuit diagram ..................................................................... 32
Product variants ....................................................................................................... 32
Layout ......................................................................................................................... 33
Control connections ................................................................................................ 34
Standard variant (I/O and Modbus) (ACS380-04xS) ................................. 34
Configured variant (ACS380-04xC) ............................................................... 35
Base variant (ACS380-04xN) ........................................................................... 36
Option modules ........................................................................................................ 36
Control panel options .............................................................................................. 37
UL Type 1 kits ............................................................................................................ 38
Drive labels ................................................................................................................. 38
Model information label ................................................................................... 38
6 Table of contents

Type designation label ..................................................................................... 39

Type designation key ............................................................................................... 39
Basic code ........................................................................................................... 39
Option codes ...................................................................................................... 40
Control panel ............................................................................................................. 42
Home view .......................................................................................................... 43
Status icons ........................................................................................... 44
Message view ..................................................................................................... 44
Options view ...................................................................................................... 44
Menu .................................................................................................................... 45

4 Mechanical installation
Contents of this chapter ......................................................................................... 47
Installation alternatives .......................................................................................... 47
Examining the installation site .............................................................................. 48
Required tools ........................................................................................................... 48
Unpacking the delivery ............................................................................................ 49
Installing the drive .................................................................................................... 49
To install the drive with screws ...................................................................... 49
To install the drive to a DIN installation rail ................................................ 50

5 Guidelines for planning the electrical installation

Contents of this chapter ......................................................................................... 53
Limitation of liability ............................................................................................... 53
North America .................................................................................................... 53
Selecting the main supply disconnecting device ............................................... 53
Selecting the main contactor ................................................................................. 54
Checking the compatibility of the motor and drive .......................................... 54
Selecting the power cables .................................................................................... 55
General guidelines ............................................................................................ 55
Typical power cable sizes ................................................................................ 55
Power cable types ............................................................................................. 56
Preferred power cable types .............................................................. 56
Alternate power cable types ............................................................... 57
Not allowed power cable types .......................................................... 58
Additional guidelines – North America ......................................................... 58
Metal conduit ......................................................................................... 59
Power cable shield ............................................................................................ 59
Grounding requirements ........................................................................................ 60
Additional grounding requirements – IEC .................................................... 61
Additional grounding requirements – UL (NEC) ......................................... 62
Selecting the control cables ................................................................................... 62
Shielding ............................................................................................................. 62
Signals in separate cables ............................................................................... 62
 Table of contents 7

Signals that can be run in the same cable .................................................... 62

Relay cable .......................................................................................................... 63
Control panel to drive cable ............................................................................ 63
PC tool cable ...................................................................................................... 63
Routing the cables ................................................................................................... 63
General guidelines – IEC ................................................................................... 63
General guidelines – North America .............................................................. 64
Continuous motor cable shield/conduit and metal enclosure for
equipment on the motor cable ....................................................................... 65
Separate control cable ducts .......................................................................... 66
Implementing short-circuit and thermal overload protection ........................ 66
Protecting the drive and input power cable in short-circuits .................. 66
Protecting the motor and motor cable in short-circuits .......................... 66
Protecting the drive, and the input power and motor cables against
thermal overload ............................................................................................... 67
Protecting the motor against thermal overload ........................................ 67
Protecting the motor against overload without thermal model or
temperature sensors ........................................................................................ 67
Implementing a motor temperature sensor connection ................................. 68
Protecting the drive against ground faults ......................................................... 68
Residual current device compatibility .......................................................... 68
Implementing the Emergency stop function ...................................................... 68
Implementing the Safe torque off function ........................................................ 69
Using a safety switch between the drive and the motor ................................. 69
Implementing the control of a contactor between drive and motor ............. 69
Protecting the contacts of relay outputs ............................................................ 69

6 Electrical installation – IEC

Contents of this chapter ......................................................................................... 71
Required tools ........................................................................................................... 71
Measuring the insulation resistance - IEC ........................................................... 72
Measuring the insulation resistance of the drive ....................................... 72
Measuring the insulation resistance of the input power cable ............... 72
Measuring the insulation resistance of the motor and motor cable ...... 72
Measuring the insulation resistance of the brake resistor circuit .......... 73
Grounding system compatibility check – IEC ..................................................... 73
EMC filter ............................................................................................................ 73
Ground-to-phase varistor ................................................................................ 74
Compatibility of EMC filter and ground-to-phase varistor with the
grounding system ............................................................................................. 74
Disconnecting the EMC filter or ground-to-phase varistor ...................... 76
EMC/VAR screw location ..................................................................... 76
Guidelines for installing the drive to a TT system ...................................... 76
Identifying the grounding system of the electrical power network ....... 77
8 Table of contents

Connecting the power cables – IEC (shielded cables) ...................................... 78

Connection diagram ......................................................................................... 78
Connection procedure ..................................................................................... 79
Connecting the control cables - IEC ..................................................................... 80
Default I/O connection diagram (ABB standard macro) .......................... 80
Fieldbus connection diagram ......................................................................... 82
Control cable connection procedure ............................................................. 83
Additional information on the control connections .................................. 84
Embedded EIA-485 fieldbus connection .......................................... 84
PNP configuration for digital inputs ................................................. 86
NPN configuration for digital inputs ................................................ 87
Connection examples of two-wire and three-wire sensors ......... 87
AI and AO (or AI, DI and +10 V) as PTC motor temperature sensor
interface .................................................................................................. 88
AI1 and AI2 as Pt100, Pt1000, Ni1000, KTY83 and KTY84 sensor
inputs ...................................................................................................... 90
Safe torque off ...................................................................................... 91
Auxiliary voltage connection .................................................................................. 91
Connecting a PC ....................................................................................................... 92
Installing options ...................................................................................................... 92
Installing a front option ................................................................................... 93
Installing a side option ..................................................................................... 94

7 Electrical installation – North America

Contents of this chapter ......................................................................................... 97
Required tools ........................................................................................................... 97
Measuring the insulation resistance - North America ...................................... 98
Measuring the insulation resistance of the drive ....................................... 98
Measuring the insulation resistance of the input power cable ............... 98
Measuring the insulation resistance of the motor and motor cable ...... 98
Measuring the insulation resistance of the brake resistor circuit .......... 99
Grounding system compatibility check – North America ................................. 99
EMC filter ............................................................................................................ 99
Ground-to-phase varistor ................................................................................ 100
Compatibility of EMC filter and ground-to-phase varistor with the
grounding system ............................................................................................. 100
Disconnecting the ground-to-phase varistor, or connecting the EMC
filter ..................................................................................................................... 102
EMC/VAR screw location ..................................................................... 102
Guidelines for installing the drive to a TT system ...................................... 102
Identifying the grounding system of the electrical power network ....... 103
Connecting the power cables – North America (wiring in conduits) ............. 104
Connection diagram ......................................................................................... 104
Connection procedure ..................................................................................... 105
 Table of contents 9

Connecting the control cables - North America ................................................. 107

Default I/O connection diagram (ABB standard macro) .......................... 107
Fieldbus connection diagram ......................................................................... 109
Control cable connection procedure ............................................................. 110
Additional information on the control connections .................................. 111
Embedded EIA-485 fieldbus connection .......................................... 111
PNP configuration for digital inputs ................................................. 113
NPN configuration for digital inputs ................................................ 114
Connection examples of two-wire and three-wire sensors ......... 114
AI and AO (or AI, DI and +10 V) as PTC motor temperature sensor
interface .................................................................................................. 115
AI1 and AI2 as Pt100, Pt1000, Ni1000, KTY83 and KTY84 sensor
inputs ...................................................................................................... 117
Safe torque off ...................................................................................... 118
Auxiliary voltage connection .................................................................................. 118
Connecting a PC ....................................................................................................... 119
Installing options ...................................................................................................... 119
Installing a front option ................................................................................... 120
Installing a side option ..................................................................................... 121

8 Installation checklist
Contents of this chapter ......................................................................................... 123
Checklist ..................................................................................................................... 123

9 Maintenance
Contents of this chapter ......................................................................................... 127
Maintenance intervals ............................................................................................. 127
Description of symbols .................................................................................... 127
Recommended maintenance intervals after start-up ............................... 127
Functional safety components .............................................................................. 128
Cleaning the heatsink .............................................................................................. 129
Replacing the cooling fans ..................................................................................... 129
Replacing the cooling fan, frames R1…R3 ................................................... 130
Replacing the cooling fan, frame R4 ............................................................. 132
Capacitors .................................................................................................................. 133
Reforming the capacitors ................................................................................ 133

10 Technical data
Contents of this chapter ......................................................................................... 135
Electrical ratings ....................................................................................................... 135
IEC ratings .......................................................................................................... 135
UL (NEC) ratings ................................................................................................ 137
UL Listed multiple drive ratings ......................................................... 138
10 Table of contents

Definitions .......................................................................................................... 139

Sizing ................................................................................................................... 140
Output derating ........................................................................................................ 140
Surrounding air temperature derating ......................................................... 142
Altitude derating ............................................................................................... 142
Switching frequency derating ........................................................................ 143
Derating in case of a phase loss .................................................................... 145
Fuses ........................................................................................................................... 145
IEC fuses ............................................................................................................. 145
gG fuses .................................................................................................. 145
gR fuses .................................................................................................. 147
UL (NEC) fuses ................................................................................................... 148
Alternative short-circuit protection ..................................................................... 151
Miniature circuit breakers (IEC) ..................................................................... 151
Miniature circuit breakers (UL) ...................................................................... 153
Manual self-protected combination motor controller – Type E USA
(UL (NEC)) ........................................................................................................... 154
Dimensions and weights ........................................................................................ 157
Dimensions – IP20 / UL open type ................................................................. 157
Dimensions – Drive with UL Type 1 kit .......................................................... 158
Weights ............................................................................................................... 159
Free space requirements ........................................................................................ 159
Losses, cooling data and noise ............................................................................. 159
Typical power cable sizes ....................................................................................... 161
Terminal data for the power cables ...................................................................... 162
Terminal data for the control cables .................................................................... 166
Electrical power network specification ............................................................... 166
Motor connection data ............................................................................................ 167
Motor cable length ............................................................................................ 167
Operational functionality and motor cable length ........................ 167
EMC compatibility and motor cable length ..................................... 168
Control connection data ......................................................................................... 169
Brake resistor connection data ............................................................................. 171
Energy efficiency data (ecodesign) ...................................................................... 171
Protection classes .................................................................................................... 171
Ambient conditions ................................................................................................. 172
Storage conditions ................................................................................................... 173
Color ............................................................................................................................ 173
Materials ..................................................................................................................... 173
Drive ..................................................................................................................... 173
Drive package .................................................................................................... 173
Package materials for options, accessories and spare parts .................. 174
Materials of manuals ........................................................................................ 174
Disposal ...................................................................................................................... 174
Applicable standards ............................................................................................... 175
 Table of contents 11

Markings ..................................................................................................................... 175

Compliance with the harmonic current limits in a public network (IEC/EN
61000 3-2, IEC/EN 61000-3-12) .............................................................................. 177
3-phase 230 V, 400 V or 480 V drive with the input choke ....................... 177
3-phase 230 V, 400 V or 480 V drive without the input choke ................. 177
1-phase 230 V drive with or without the input choke ................................ 177
EMC compliance (IEC/EN 61800-3:2004 + A1:2012) .......................................... 178
Definitions .......................................................................................................... 178
Category C1 ........................................................................................................ 178
Category C2 ........................................................................................................ 179
Category C3 ........................................................................................................ 179
Category C4 ........................................................................................................ 180
UL checklist ................................................................................................................ 181
Disclaimers ................................................................................................................ 182
Generic disclaimer ............................................................................................ 182
Cyber security disclaimer ................................................................................ 182

11 Dimension drawings
Contents of this chapter ......................................................................................... 183
Frame R0 .................................................................................................................... 184
Frame R0, 1-phase 230 V, IP20 ........................................................................ 184
Frame R0, 1-phase 230 V, IP20, with side option ........................................ 185
Frame R0, 1-phase 230 V, UL Type 1 .............................................................. 186
Frame R0, 1-phase 230 V, UL Type 1, with side option .............................. 187
Frame R0, 3-phase 400/480 V, IP20 .............................................................. 188
Frame R0, 3-phase 400/480 V, IP20, with side option .............................. 189
Frame R0, 3-phase 400/480 V, UL Type 1 .................................................... 190
Frame R0, 3-phase 400/480 V, UL Type 1, with side option .................... 191
Frame R1 ..................................................................................................................... 192
Frame R1, 1-phase 230 V, IP20 ........................................................................ 192
Frame R1, 1-phase 230 V, IP20, with side option ......................................... 193
Frame R1, 1-phase 230 V, UL Type 1 ............................................................... 194
Frame R1, 1-phase 230 V, UL Type 1, with side option ............................... 195
Frame R1, 3-phase 230 V and 400/480 V, IP20 ............................................ 196
Frame R1, 3-phase 230 V and 400/480 V, IP20, with side option ............ 197
Frame R1, 3-phase 230 V and 400/480 V, UL Type 1 .................................. 198
Frame R1, 3-phase 230 V and 400/480 V, UL Type 1, with side option ... 199
Frame R2 ..................................................................................................................... 200
Frame R2, 1-phase 230 V, IP20 ........................................................................ 200
Frame R2, 1-phase 230 V, IP20, with side option ........................................ 201
Frame R2, 1-phase 230 V, UL Type 1 ............................................................... 202
Frame R2, 1-phase 230 V, UL Type 1, with side option ............................... 203
Frame R2, 3-phase 230 V and 400/480 V, IP20 ........................................... 204
Frame R2, 3-phase 230 V and 400/480 V, IP20, with side option ........... 205
Frame R2, 3-phase 230 V and 400/480 V, UL Type 1 .................................. 206
12 Table of contents

Frame R2, 3-phase 230 V and 400/480 V, UL Type 1, with side option ... 207
Frame R3 ..................................................................................................................... 208
Frame R3, 3-phase 230 V and 400/480 V, IP20 ........................................... 208
Frame R3, 3-phase 230 V and 400/480 V, IP20, with side option ........... 209
Frame R3, 3-phase 230 V and 400/480 V, UL Type 1 .................................. 210
Frame R3, 3-phase 230 V and 400/480 V, UL Type 1, with side option ... 211
Frame R4 .................................................................................................................... 212
Frame R4, 3-phase 230 V and 400/480 V, IP20 ........................................... 212
Frame R4, 3-phase 230 V and 400/480 V, IP20, with side option ........... 213
Frame R4, 3-phase 230 V and 400/480 V, UL Type 1 ................................. 214
Frame R4, 3-phase 230 V and 400/480 V, UL Type 1, with side option ... 215

12 Input chokes
Contents of this chapter ......................................................................................... 217
When is an input choke necessary? ...................................................................... 217
Maximum input current ........................................................................................... 217
Selecting an input choke ......................................................................................... 218
Guidelines for installing an input choke .............................................................. 220
Connection diagram ......................................................................................... 221
Dimensions ................................................................................................................ 221

13 External EMC filters

Contents of this chapter ......................................................................................... 223
Selecting the external EMC filter ........................................................................... 223

14 Resistor braking
Contents of this chapter ......................................................................................... 225
Safety .......................................................................................................................... 225
Operation principle .................................................................................................. 225
Selecting the brake resistor ................................................................................... 225
Reference brake resistors ............................................................................... 227
Definitions .............................................................................................. 228
Selecting and routing the brake resistor cables ................................................ 228
Minimizing electromagnetic interference .................................................... 229
Maximum cable length ..................................................................................... 229
Selecting the installation location for the brake resistors .............................. 229
Protecting the system in brake circuit fault situations .................................... 229
Protecting the system in cable and brake resistor short-circuit
situations ............................................................................................................ 229
Protecting the system against thermal overload ....................................... 230
Mechanical and electrical installation of brake resistor ................................... 231
Mechanical installation .................................................................................... 231
 Table of contents 13

Electrical installation ........................................................................................ 231

Measuring the insulation ..................................................................... 231
Connecting power cables .................................................................... 231
Connection the control cables ........................................................... 231
Start-up ...................................................................................................................... 231

15 The Safe torque off function

Contents of this chapter ......................................................................................... 233
Description ................................................................................................................ 233
Compliance with the European Machinery Directive and the UK Supply
of Machinery (Safety) Regulations ................................................................ 234
Wiring .......................................................................................................................... 235
Connection principle ........................................................................................ 235
Single ACS380 drive, internal power supply .................................... 235
Single ACS380 drive, external power supply ................................... 236
Single-channel connection of activation switch ............................. 237
Wiring examples ................................................................................................ 238
Single ACS380 drive, internal power supply .................................... 238
Single ACS380 drive, external power supply ................................... 238
Multiple ACS380 drives, internal power supply .............................. 239
Multiple ACS380 drives, external power supply ............................. 240
Activation switch ............................................................................................... 240
Cable types and lengths .................................................................................. 241
Grounding of protective shields .................................................................... 241
Operation principle .................................................................................................. 242
Start-up including validation test ......................................................................... 243
Competence ....................................................................................................... 243
Validation test reports ..................................................................................... 243
Validation test procedure ............................................................................... 243
Use ............................................................................................................................... 245
Maintenance .............................................................................................................. 247
Competence ....................................................................................................... 247
Fault tracing .............................................................................................................. 248
Safety data ................................................................................................................. 249
Terms and abbreviations ................................................................................. 251
TÜV certificate ................................................................................................... 252
Declarations of conformity ............................................................................. 253

16 BTAC-02 pulse encoder interface module

Contents of this chapter ......................................................................................... 255
Safety instructions ................................................................................................... 255
Hardware description .............................................................................................. 255
Product overview .............................................................................................. 255
Layout .................................................................................................................. 256
14 Table of contents

Mechanical installation ............................................................................................ 256

Electrical installation ............................................................................................... 256
Wiring – General ................................................................................................. 256
Terminal designations ......................................................................... 257
Wiring – Encoder power supply interface .................................................... 258
Wiring – Encoder ............................................................................................... 259
Phasing ................................................................................................... 259
Encoder output types .......................................................................... 260
Wiring diagrams – Push-pull type encoder output ........................ 261
Differential connection ........................................................................ 261
Single-ended connection ..................................................................... 262
Wiring diagrams – Open collector (sinking) encoder output ....... 263
Wiring diagrams – Open emitter (sourcing) encoder output ...... 264
Apply power ........................................................................................... 265
Start-up ...................................................................................................................... 265
Feedback selection ........................................................................................... 265
Encoder adapter settings ................................................................................ 267
Encoder configuration ......................................................................... 267
Diagnostics ................................................................................................................ 267
Technical data ........................................................................................................... 268
Encoder interface .............................................................................................. 268
Encoder type .......................................................................................... 268
Encoder interface connectors ............................................................ 268
Cable ........................................................................................................ 268
Encoder and BTAC module power supply ........................................ 268
Back-up power supply for the drive .............................................................. 269
Internal connectors ........................................................................................... 269
Dimensions ......................................................................................................... 269

17 BRES-01 resolver interface module

Contents of this chapter ......................................................................................... 271
Safety instructions ................................................................................................... 271
Hardware description .............................................................................................. 271
Product overview .............................................................................................. 271
Functional description ..................................................................................... 272
Layout .................................................................................................................. 273
Mechanical installation ............................................................................................ 273
Electrical installation ............................................................................................... 273
Terminal designations ..................................................................................... 273
Resolver input (X103, X104) ................................................................ 274
External power supply (X105) ............................................................. 275
Connecting the resolver cable ........................................................................ 276
Start-up ...................................................................................................................... 276
 Table of contents 15

Technical data ........................................................................................................... 276

Resolver interface ............................................................................................. 276
Resolver type ......................................................................................... 276
Resolver interface connectors (X103, X104) .................................... 277
Resolver cable ........................................................................................ 277
Power supply connection (X105) ....................................................... 277
Back-up power supply for the drive .............................................................. 277
Internal connectors ........................................................................................... 277
Dimensions ......................................................................................................... 278

18 BREL-01 relay output extension module

Contents of this chapter ......................................................................................... 279
Safety instructions ................................................................................................... 279
Hardware description .............................................................................................. 279
Product overview .............................................................................................. 279
Layout .................................................................................................................. 280
Mechanical installation ............................................................................................ 280
Electrical installation ............................................................................................... 280
Start-up ...................................................................................................................... 281
Configuration parameters ...................................................................................... 281
Technical data ........................................................................................................... 284

19 BAPO-01 auxiliary power extension module

Contents of this chapter ......................................................................................... 285
Safety instructions ................................................................................................... 285
Hardware description .............................................................................................. 285
Layout .................................................................................................................. 286
Mechanical installation ............................................................................................ 287
Electrical installation ............................................................................................... 287
Start-up ...................................................................................................................... 288
Technical data ........................................................................................................... 288

20 BIO-01 I/O extension module

Contents of this chapter ......................................................................................... 289
Safety instructions ................................................................................................... 289
Hardware description .............................................................................................. 289
Product overview .............................................................................................. 289
Layout .................................................................................................................. 290
Mechanical installation ............................................................................................ 290
Terminal configuration ............................................................................................ 290
Electrical installation ............................................................................................... 291
Start-up ...................................................................................................................... 291
Technical data ........................................................................................................... 292
16 Table of contents

Further information
 Safety instructions 17

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.
18 Safety instructions

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 dust inside the drive.
• Make sure that debris from drilling, cutting and grinding does not go into the
drive during installation. Electrically conductive debris inside the drive can
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/UL 61800-5-1, subclause 6.5.3,
for example, "THIS MACHINE STARTS AUTOMATICALLY".
• The maximum number of drive power-ups is five in ten minutes. Too frequent
power-ups 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.
 Safety instructions 19

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.
• If the drive is in remote control mode, you cannot stop or start the drive with
the control panel.
• Only authorized persons are allowed to repair a malfunctioning drive.
20 Safety instructions

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.
Do these steps before you begin any installation or maintenance work.

1. Prepare for the work.

• Make sure that you have a work order.
• Do an on-site risk assessment or job hazard analysis.
• Make sure that you have the correct tools available.
• Make sure that the workers are qualified.
• Select the correct personal protective equipment (PPE).
• Stop the motor(s).
2. Clearly identify the work location and equipment.
3. 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.
• Open the main isolating device of the drive.
• Disconnect all 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.
4. Protect other energized parts in the work location against contact and take
special precautions when close to bare conductors.
5. Measure that the installation is de-energized. Use a quality voltage tester.
• Before and after you measure the installation, verify the operation of the
voltage tester on a known voltage source.
• Make sure that the voltage between the drive input power terminals (L1,
L2, L3) and the grounding (PE) busbar is zero.
• Make sure that the voltage between the drive output terminals (T1/U, T2/V,
T3/W) and the grounding (PE) busbar is zero.
• Make sure that the voltage between the drive DC terminals (UDC+ and
UDC-) and the grounding (PE) terminal is zero.
 Safety instructions 21

Note: If cables are not connected to the drive DC terminals, measuring the
voltage from the DC terminal screws can give incorrect results.

6. Install temporary grounding as required by the local regulations.

7. Ask for a permit to work from the person in control of the electrical installation
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:
• When the drive is connected to the input power, the motor cable terminals
and the DC bus are at a dangerous voltage.
The brake circuit, including the brake chopper and brake resistor (if installed)
are also at a dangerous voltage.
After disconnecting the drive from the input power, these remain at a
dangerous voltage until the intermediate circuit capacitors have discharged.
• 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 wristband when you handle printed circuit boards. Do not
touch the boards unnecessarily. The boards contain components sensitive
to electrostatic discharge.
22 Safety instructions

￭ 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.
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.
• Make sure that the conductivity of the protective earth (PE) conductors is
sufficient and that other requirements are met. See the electrical planning
instructions of the drive. Obey the applicable national and local regulations.
• When using shielded cables, make a 360° grounding of the cable shields at the
cable entries to reduce electromagnetic emission and interference.
• In a multiple-drive installation, connect each drive separately to the protective
earth (PE) busbar of the power supply.
 Safety instructions 23

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/UL 61800-5-1, subclause 6.5.3,
for example, "THIS MACHINE STARTS AUTOMATICALLY".

Note:
• The maximum number of drive power-ups is five in ten minutes. Too frequent
power-ups 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 or the fieldbus interface.
• If the drive is in remote control mode, you cannot stop or start the drive with
the control panel.

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.
24 Safety instructions

• 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.
Before installation, start-up and maintenance work on the drive:
• Stop the drive.
• Disconnect the motor from the drive with a safety switch or by other means.
• If you cannot disconnect the motor, make sure that the motor cannot rotate
during work. Make sure that no other system, like hydraulic crawling drives,
can rotate the motor directly or through any mechanical connection like belt,
nip, rope, etc.
• Do the steps in section Electrical safety precautions (page 20).
• Install temporary grounding to the drive output terminals (T1/U, T2/V, T3/W).
Connect the output terminals together as well as to the PE.
During the start-up:
• Make sure that the motor cannot run overspeed, for example, driven by the
load. Motor overspeed causes overvoltage that can damage or destroy the
capacitors in the intermediate circuit of the drive.

￭ Safety in operation
WARNING!
Make sure that the motor cannot run overspeed, for example, driven by the
load. Motor overspeed causes overvoltage that can damage or destroy the
capacitors in the intermediate circuit of the drive.
 Introduction to the manual 25

2
Introduction to the manual

Contents of this chapter

The chapter describes the applicability, target audience and purpose of the manual.
The chapter contains a list of related manuals and a flowchart for installation and
commissioning.

Applicability
This manual is applicable to ACS380 drives.

Target audience
This manual is intended for people who plan the installation, install, commission
and do maintenance work on the drive, or create instructions for the end user of
the drive concerning the installation and maintenance of the drive.
Read the manual before you work on the drive. You are expected to know the
fundamentals of electricity, wiring, electrical components and electrical schematic
symbols.

Categorization by frame size

The drives are manufactured in frame sizes (for example, R1). The information that
is applicable only to specific frames is identified with the frame size. The frame
size is shown on the type designation label.
26 Introduction to the manual

Quick installation and commissioning flowchart

Task See

Identify the frame size: R0, R1, R2, etc. Type designation key (page 39)

Plan the installation. Guidelines for planning the electrical installa-

Check the ambient conditions, ratings and tion (page 53)
required cooling air flow. Technical data (page 135)

Unpack and check the delivery. Unpacking the delivery (page 49)

If the supply network is not a symmetrically Grounding system compatibility check –

grounded TN-S system, make sure that the IEC (page 73)
drive is compatible with the grounding sys-
tem. Grounding system compatibility check –
North America (page 99)

Install the drive. Installing the drive (page 49)

Route the cables. Routing the cables (page 63)

Measure the insulation of the input cable, Measuring the insulation resistance -
motor and motor cable. IEC (page 72)
Measuring the insulation resistance - North
America (page 98)

Connect the power cables. Connecting the power cables – IEC (shielded
cables) (page 78)
Connecting the power cables – North America
(wiring in conduits) (page 104)

Connect the control cables. Connecting the control cables - IEC (page 80)
Connecting the control cables - North Amer-
ica (page 107)

Examine the installation. Installation checklist (page 123)

 Introduction to the manual 27

Task See

Commission the drive. Refer to ACS380 Quick installation and start-

up guide (3AXD50000018553 [English]) and
ACS380 Firmware manual (3AXD50000029275
[English]).
28 Introduction to the manual

Terms and abbreviations

Term Description

ACS-AP-I Industrial assistant non-Bluetooth control panel

ACS-AP-S Standard assistant control panel
ACS-AP-W Industrial assistant control panel with Bluetooth interface
ACS-BP-S Basic control panel
BAPO Optional auxiliary power extension module
BCAN Optional CANopen® adapter module
BCBL-01 Optional USB to RJ45 cable
BIO-01 Optional I/O extension module. Can be installed to the drive together
with a fieldbus adapter module.
BMIO-01 I/O & Modbus extension module
Brake chopper Conducts the surplus energy from the intermediate circuit of the
drive to the brake resistor when necessary. The chopper operates
when the DC link voltage exceeds a certain maximum limit. The
voltage rise is typically caused by deceleration (braking) of a high
inertia motor.
Brake resistor Dissipates the drive surplus braking energy conducted by the brake
chopper to heat
BREL Optional relay output extension module
BRES Optional resolver interface module
BTAC Optional encoder interface module
Capacitor bank The capacitors connected to the DC link
CCA-01 Configuration adapter
Control unit The part in which the control program runs.
DC link DC circuit between rectifier and inverter
DC link capacitors Energy storage which stabilizes the intermediate circuit DC voltage
Drive Frequency converter for controlling AC motors
EFB Embedded fieldbus
EMC Electromagnetic compatibility
FBA Fieldbus adapter
FCAN-01 Optional CANopen® adapter module
FCNA-01 Optional ControlNet™ adapter module
FDNA-01 Optional DeviceNet™ adapter module
FECA-01 Optional EtherCAT® adapter module
FEIP-21 Optional Ethernet adapter module for EtherNet/IP™
FEPL-02 Optional Ethernet POWERLINK adapter module
FMBT-21 Optional Ethernet adapter module for Modbus TCP protocol
FPBA-01 Optional PROFIBUS DP® adapter module
FPNO-21 Optional PROFINET IO adapter module
Frame, frame size Physical size of the drive or power module
 Introduction to the manual 29

Term Description

FSPS-21 Optional functional safety module

IGBT Insulated gate bipolar transistor
Intermediate circuit DC circuit between rectifier and inverter
Inverter Converts direct current and voltage to alternating current and
voltage.
Macro A pre-defined set of default values of parameters in a drive control
program.
NETA-21 Remote monitoring tool
Network control With fieldbus protocols based on the Common Industrial Protocol
(CIP™), such as DeviceNet and Ethernet/IP, denotes the control of
the drive using the Control Supervisor and AC/DC drive objects of
the ODVA AC/DC Drive Profile. For more information, see
www.odva.org.
Parameter In the drive control program, user-adjustable operation instruction
to the drive, or signal measured or calculated by the drive.
In some (for example fieldbus) contexts, a value that can be accessed
as an object. For example, variable, constant, or signal.
PLC Programmable logic controller
Rectifier Converts alternating current and voltage to direct current and voltage
RFI Radio-frequency interference
SIL Safety integrity level (1…3) (IEC 61508, IEC 62061, IEC 61800-5-2)
STO Safe torque off (IEC/EN 61800-5-2)

Related manuals
You can find manuals on the Internet. See below for the relevant code/link. For
more documentation, go to www.abb.com/drives/documents.

ACS380 manuals link list

30
 Operation principle and hardware description 31

3
Operation principle and
hardware description

Contents of this chapter

This chapter briefly describes the operation principle and construction of the drive.

Operation principle
The ACS380 is a drive for controlling asynchronous AC induction motors, permanent
magnet synchronous motors and ABB synchronous reluctance motors (SynRM
motors). The drive is optimized for cabinet installation.
32 Operation principle and hardware description

￭ Simplified main circuit diagram

1 2 3
L1 T1/U
L2 T2/V
L3 T3/W

4 5

R- R+
UDC+ UDC-

1 Rectifier. Converts alternating current and voltage to direct current and voltage.
2 DC link. DC circuit between rectifier and inverter.
3 Inverter. Converts direct current and voltage to alternating current and voltage.
4 Brake chopper. Conducts energy from the intermediate DC circuit of the drive to the
brake resistor when it is necessary and if an external brake resistor is connected to
the drive. The chopper operates when the DC link voltage exceeds a certain maximum
limit. The voltage rise is typically caused by deceleration (braking) of a motor. The user
obtains and installs the brake resistor when necessary.
5 DC connection (UDC+, UDC-).

Product variants
The drive has three primary product variants:
• Standard variant (ACS380-04xS) with BMIO-01 I/O & Modbus extension module
• Configured variant (ACS380-04xC) for which the extension module, such as
the fieldbus adapter, is chosen when ordering
• Base variant (ACS380-04xN) without extension modules.
 Operation principle and hardware description 33

Layout

1
4
6
5

16

7 17
2
11

15

8 12 14

13
9

3
10

1 Front option modules 10 PE connection (motor)

2 Input power terminals 11 Control panel, display and status LED
3 Motor and brake resistor terminals 12 Control terminals
4 Cooling fan (on frames R1…R4) 13 Front option slot
5 Panel and PC tool port (RJ45) 14 Cold configuration connection for
CCA-01
6 Model information label 15 Side option module
7 EMC filter grounding screw 16 Front cover
8 Type designation label 17 QR code to ecodesign tool. Refer to En-
ergy efficiency data (eco-
design) (page 171).
9 Varistor grounding screw
34 Operation principle and hardware description

Control connections
In addition to the fixed control connections in the base unit, the other control
connections depend on the drive variant.

￭ Standard variant (I/O and Modbus) (ACS380-04xS)

The standard variant has a type code as follows: ACS380-04xS. It is supplied with
the BMIO-01 I/O and Modbus extension module.

Connections on the base unit:

1. Auxiliary voltage outputs
2. Digital inputs
3. Safe torque off connections
4. Relay output connection
5. Cold configuration connection for CCA-01
Connections on BMIO-01:
6. Digital inputs and outputs
2 7. Analog inputs and outputs
+24V DGND DCOM SGND S+

1 DI1
4
DI2
RC
8. EIA-485 Modbus RTU
S1
RA 5
3 S2
RB
BGND
Shield
AGND
AGND
DIO 1
DIO 2
DI 4

B+
AI 2

A-
AO
DIO COM
DIO SRC

8
AGND
+10V
SCR
DI 3

AI 1

6 7
 Operation principle and hardware description 35

￭ Configured variant (ACS380-04xC)

The configured variant has a type code as follows: ACS380-04xC followed by an
option code that indicates the extension module. Use the configured variant to
order a product with a specific fieldbus extension module.

Connections:
1. Auxiliary voltage outputs
2. Digital inputs
3. Safe torque off connections
4. Relay output connection
5. Cold configuration connection for CCA-01
6. Fieldbus connections depending on the
module

2
+24V DGND DCOM SGND S+

DI1
1 DI2
4
RC
S1
3 S2
RA 5
RB

HOST

CHASSIS NETWORK MODULE

X1 LINK

6
36 Operation principle and hardware description

￭ Base variant (ACS380-04xN)

The base variant has a type code as follows: ACS380-04xN. It is supplied without
an extension module.

Connections:
1. Auxiliary voltage outputs
2. Digital inputs
3. Safe torque off connections
4. Relay output connection
5. Cold configuration connection for CCA-01
6. Option module slot 1

2
+24V DGND DCOM SGND S+

1 DI1 4
DI2
RC
S1
RA 5
3 S2
RB

Option modules
The drive supports option modules (optional extension modules). For a list of
option modules, refer to Type designation key (page 39).
You can connect the drive to a fieldbus with an optional fieldbus adapter module.
Refer to Type designation key (page 39) for the available adapters
 Operation principle and hardware description 37

You can use I/O option modules to increase the number of inputs and outputs on
the drive. The table shows a comparison between the base unit and different
option modules.

I/O Base unit BMIO-01 BIO-01 BREL-01

(ACS380-04xx) (ACS380-04xS)

Inputs
Digital inputs 2 4 3 -
(DI1, DI2) (DI3, DI4, DIO1, (DI3, DI4, DI5)
DIO2)
Frequency inputs - 2 2 -
(DI3, DI4) (DI4, DI5)
Counter inputs - 1 1 -
(DI3) (DI4)
Analog inputs - 2 1 -
(AI1, AI2) (AI1)
Outputs
Relay outputs 1 - - 4
(RO1) (RO4, RO5, RO6,
RO7)
Digital outputs - 2 1 -
(DIO1, DIO2) (DIO1)
Frequency out- - 2 1 -
puts (DIO1, DIO2) (DIO1)
Analog outputs - 1 1 -
(AO1) (AO1)

Note: The number of inputs and outputs depends on the configuration. For
example, DIO can be configured as digital input or output.

Control panel options

The drive supports these control panels:
• integrated control panel
• ACS-AP-S assistant control panel
• ACS-AP-W assistant control panel with Bluetooth
• ACS-AP-I assistant control panel
• ACS-BP-S basic control panel
38 Operation principle and hardware description

In addition, you can order a control panel platform for cabinet door installation.
These panel platforms are available:

Type Description

DPMP-01 Control panel mounting platform (flush mounting) and cable

DPMP-02 Control panel mounting platform (surface mounting) and cable

UL Type 1 kits
There are UL Type 1 kit options available for the drive. For the ordering codes and
installation instructions, refer to the table that follows.

Frame size Option code Installation instructions

R0 3AXD50000187034
UL Type 1 kit for ACS380, ACS480 and
R1 3AXD50000176779 ACH480 installation guide, frames R0 to R2
(3AXD50000235254)
R2 3AXD50000178780

R3 3AXD50000179220 UL Type 1 kit for ACS380, ACS480 and

ACH480 installation guide, frames R3 to R4
R4 3AXD50000179336 (3AXD50000242375)

Note: UL Type 1 kits are not applicable with BRES-01 resolver interface module.

Drive labels
The drive has two labels:
• model information label on the top of the drive
• type designation label on the left side of the drive.
Example labels are shown in this section.

￭ Model information label

1
ACS380 Register with
Drivebase app
3~ 400/480 V (Frame R1)
2 Pld: 1.5 kW (2 hp) 4
Phd: 1.1 kW (1.5 hp)
3 S/N: M171300003
 Operation principle and hardware description 39

1 Drive type
2 Frame size and ratings
3 Serial number
4 QR code to register the drive

￭ Type designation label

1
3 4

5
8
6 7

1 Type designation
2 Frame (size)
3 Nominal ratings
4 Valid markings
5 Degree of protection
6 Losses according to IEC 61800-9-2
7 S/N: Serial number of format MYYWWXXXXX, where
M: Manufacturer
YY: Year of manufacture: 19, 20, 21, … for 2019, 2020, 2021, …
WW: Week of manufacture: 01, 02, 03, … for week 1, week 2, week 3, …
XXXX: Running item number that starts each week from 0001.
8 QR code to product information page

Type designation key

The type designation key shows the specifications and the configuration of the
drive.

￭ Basic code
Type code example: ACS380-042S-02A6-4.
40 Operation principle and hardware description

Code Description

ACS380 Product series

042S 04 Construction:
• 04 = Module.
When there are no options selected: module optimized for cabinet installa-
tion, degree of protection IP20 (UL open type), bottom cable entry, Safe
torque off, brake chopper, coated boards, quick installation and start-up
guide, user interface guide and safety instructions.

2 EMC filter variant:

• 0 = Low filtering level, EN 61800-3 category C3 (400 V) or C4 (230 V). 1)
• 2 = High filtering level, EN 61800-3 category C2. 2)

S Connectivity:
• S = Standard variant with BMIO-01 I/O and Modbus module.
• C = Configured variant with I/O or fieldbus module, selected with an
option code.
• N = Base variant without I/O or fieldbus module.

02A6 Size. See the ratings table in the technical data.

4 Input voltage:
• 1 = 1-phase 200 … 240 V AC
• 2 = 3-phase 200 … 240 V AC
• 4 = 3-phase 380 … 480 V AC.
1) 230 V drives with low filtering level do not have an internal EMC filter. 400 V drives have a category C3
filter.
2) High filtering level is not available for 3-phase 230 V drives.

￭ Option codes
Option codes are separated by plus signs. The table below gives the option codes.

Code Description

Fieldbus adapters

K451 FDNA-01 DeviceNet

K454 FPBA-01 PROFIBUS DP

K457 FCAN-01 CANopen

K462 FCNA-01 ControlNet

K469 FECA-01 EtherCAT

K470 FEPL-02 Ethernet POWERLINK

 Operation principle and hardware description 41

Code Description

K490 FEIP-21 EtherNet/IP

K491 FMBT-21 Modbus/TCP

K492 FPNO-21 PROFINET IO

K495 BCAN-11 CANopen

I/O

L511 BREL-01 External relay option (4x relay) (side option)

L515 BIO-01 I/O extension module (front option, can be used together with fieldbus)

L516 BRES-01 resolver interface module (side option)

L534 BAPO-01 External 24 V DC (side option)

L535 BTAC-02 HTL encoder interface + External 24 V DC (side option)

L538 BMIO-01 I/O & Modbus extension module (front option, not available with other
front options)

Services

P992 Pre-assembled options (front and side options), only with C-variant

Functional safety

Q986 FSPS-21 PROFIsafe with PROFINET IO

Documentation 1)

R700 English

R701 German

R702 Italian

R703 Dutch

R704 Danish

R705 Swedish

R706 Finnish

R707 French
42 Operation principle and hardware description

Code Description

R708 Spanish

R709 Portuguese (Portugal)

R711 Russian

R712 Chinese

R713 Polish

R714 Turkish

1) The option code determines the language variants of the hardware manual and firmware manual
delivered as printed with the drive. The product package includes the user interface guide and quick
installation and start-up guide in English, French, German, Italian and Spanish, and in the local language
(if available).

Control panel
The drive has an integrated control panel with a display and control keys.
For quick reference, there is a ACS380 User interface guide (3AXD50000022224
[English]) under the main cover of the drive.
Refer to the ACS380 Firmware manual (3AXD50000029275 [English]) for information
on how to use the interface, start-up the drive and modify settings and parameters.

7 1
a c
b

d
e e

2 3

4
5 6
 Operation principle and hardware description 43

1 Display (Home view):

a) Control location: local or remote
b) Status icons
c) Reference target value
d) Actual measured value
e) Left and right softkey actions
2 Back key (opens the Options view in the Home view)
3 OK key (opens the Menu in the Home view)
4 Arrow keys (menu navigation and setting values)
5 Stop key (when the drive is locally controlled)
6 Start key (when the drive is locally controlled)
7 Status LED:
• Steady green: Normal operation
• Blinking green: Active warning
• Steady red: Active fault
• Blinking red: Active fault, set power to off to reset

The user interface in brief:

• In the Home view, push the Back key to open the Options view.
• In the Home view, push the OK key to open the Menu.
• Navigate the views with the arrow keys.
• Push the OK key to open the highlighted setting or item.
• Use the left and right arrow keys to highlight a value.
• Use the up and down keys to set a value.
• Push the Back key to cancel a setting or return to the previous view.

￭ Home view
The Home view shows the reading of one of three measured signals. Select the
page with the left and right arrow keys.
The status bar at the top of the Home view shows:
• The control location (Loc for local control and Rem for remote control)
• The status icons
• The reference target value
From the Home view, push the Back key to open the Options view and push the
OK key to open the Menu.
Adjust the current reference value with the up and down arrow keys.
44 Operation principle and hardware description

Status icons

Icon Animation Description

None Local Start/Stop enabled

None Stopped

None Stopped, start inhibited

Blinks Stopped, start commanded but inhibited

Rotates Running at reference

Rotates Running but not at reference

Blinks Running at reference, but reference = 0

Blinks Drive fault

None Local reference setting enabled

￭ Message view
When a fault or warning occurs, the display shows the Message view. The Message
view shows either the active fault as an icon and fault code, or a list of the most
recent warnings codes.
Refer to the ACS380 User interface guide (3AXD50000022224 [English]) or ACS380
Quick installation and start-up guide (3AXD50000018553 [English]) for a list of
the most typical faults and warnings.
For more detailed fault and warning information, refer to the ACS380 Firmware
manual (3AXD50000029275 [English]).
To reset a fault, push the OK key (with the soft-key label Reset?).

￭ Options view
To open the Options view, push the Back key in the Home view.
In the Options view, you can:
• Set the control location
• Set the direction of the motor
 Operation principle and hardware description 45

• Set the reference

• View the active fault
• View a list of the active warnings.

￭ Menu
To open the Menu, push the OK key in the Home view.
To navigate in the Menu, push the up and down arrow keys to move between menu
items.
Menu items:
• Motor data view: Enter the motor specifications.
• Motor control view: Set the motor control settings.
• Control macros view: Select the connection parameter macro.
• Diagnostics view: Read the active faults and warnings.
• Energy efficiency view: Monitor the efficiency of the drive.
• Parameters view: Open and edit the full list of parameters.
For detailed information on the user interface, refer to the ACS380 Firmware
manual (3AXD50000029275 [English]).
46
 Mechanical installation 47

4
Mechanical installation

Contents of this chapter

This chapter tells how to examine the installation site, unpack and examine the
delivery and install the drive mechanically.

Installation alternatives
You can install the drive:
• with screws on to a wall
• with screws on to an assembly plate
• on to a DIN installation rail (IEC/EN 60715, top hat type, width 35 mm [1.4 in]
× height 7.5 mm [0.3 in]).
Installation requirements:
• The drive is designed for cabinet installation and has a degree of protection
of IP20 / UL open type as standard. A UL Type 1 kit is available as an option.
• Make sure that there is a minimum of 75 mm (3 in) of free space at the top and
bottom of the drive (at the cooling air inlet and outlet), measured from the
frame.
With the optional UL Type 1 kit, make sure that there is a minimum of 50 mm
(2 in) of free space at the top (measured from the top of the hood) and 75 mm
(3 in) at the bottom of the drive.
• You can install several drives side by side.
• Install R0 drives vertically, because they do not have a cooling fan.
48 Mechanical installation

• You can install frames R1, R2, R3 and R4 tilted to a maximum of 90 degrees,
from vertical to fully horizontal orientation.
• Do not install the drive upside down.

• Make sure that the hot exhaust air from a drive does not flow into the cooling
inlet of other drives or equipment.
• Drives equipped with the optional UL Type 1 kits: If you install the drives
side-by-side, make sure that their air outlets do not face each other.

Examining the installation site

Examine the installation site. Make sure that:
• The installation site is sufficiently ventilated or cooled to remove heat from
the drive. See the technical data.
• The ambient conditions of the drive meet the specifications. See the technical
data.
• The material behind, above and below the drive is non-flammable.
• The installation surface is as close to vertical as possible and strong enough
to support the drive.
• There is sufficient free space around the drive for cooling, maintenance, and
operation. See the free space specifications for the drive.
• Make sure that 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.

Required tools
To install the drive mechanically, you need these tools:
• a drill and suitable drill bits
• a screwdriver or wrench with a set of suitable bits
• a tape measure and spirit level
• personal protective equipment.
 Mechanical installation 49

Unpacking 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
• BMIO-01 I/O module (in standard variant) or other extension module (in
configured variant)
• mounting template (drives with frame size R3 or R4 only)
• installation accessories (cable clamps, cable ties, hardware)
• multilingual warning sticker sheet (residual voltage warning)
• safety instructions
• quick installation and start-up guide
• user interface guide (behind the drive front cover)
• hardware and firmware manuals, if ordered with an option code.
Make sure that there are no signs of damage to the items.

Installing the drive

￭ To install the drive with screws
1. Make marks onto the surface for the mounting holes. Use the included
mounting template for frames R3 and R4. For other frames, see the dimension
drawings.
2. Drill the holes for the mounting screws.
3. If necessary, install anchors or plugs into the holes.
4. Install the mounting screws into the holes. Leave a gap between the screw
head and installation surface.
M2

M1
50 Mechanical installation

5. Put the drive onto the mounting screws.

6. Tighten the mounting screws.

￭ To install the drive to a DIN installation rail

Use an IEC/EN 60715 top hat type installation rail, width × height = 35 × 7.5 mm
(1.4 × 0.3 in).
1. Move the locking part to the left.

2. Push and hold the locking button down.

3. Put the top tabs of the drive onto the top edge of the DIN installation rail.
4. Put the drive against the bottom edge of the DIN installation rail.
5. Release the locking button.
 Mechanical installation 51

6. Move the locking part to the right.

7. Make sure that the drive is correctly installed.
To remove the drive, use a flat-head screwdriver to open the locking part.
52
 Guidelines for planning the electrical installation 53

5
Guidelines for planning the
electrical installation

Contents of this chapter

This chapter contains guidelines for planning the electrical installation of the drive.

Limitation of liability
The installation must always be designed and made according to applicable local
laws and regulations. ABB does not assume any liability whatsoever for any
installation which breaches the local laws and/or other regulations. Furthermore,
if the recommendations given by ABB are not followed, the drive may experience
problems that the warranty does not cover.

￭ North America
Installations must be compliant with NFPA 70 (NEC)1) and/or Canadian Electrical
Code (CE) along with state and local codes for your location and application.
1) National Fire Protection Association 70 (National Electric Code).

Selecting the main supply disconnecting device

You must equip the drive with a main supply disconnecting device which meets
the local safety regulations. You must be able to lock the disconnecting device to
the open position for installation and maintenance work.
54 Guidelines for planning the electrical installation

To comply with European Union directives and United Kingdom regulations related
to standard EN 60204-1, the disconnecting device must be one of these types:
• switch-disconnector of utilization category AC-23B (IEC 60947-3)
• disconnector that has an auxiliary contact that in all cases causes switching
devices to break the load circuit before the opening of the main contacts of
the disconnector (EN 60947-3)
• circuit-breaker suitable for isolation in accordance with IEC 60947-2.

Selecting the main contactor

You can equip the drive with a main contactor.
Follow these guidelines when you select a customer-defined main contactor:
• Dimension the contactor according to the nominal voltage and current of the
drive. Also consider the environmental conditions such as surrounding air
temperature.
• IEC installations: Select contactor with utilization category AC-1 (number of
operations under load) according to IEC 60947-4.
• Consider the application life time requirements.

Checking the compatibility of the motor and drive

Use asynchronous AC induction motor, permanent magnet synchronous motor or
ABB synchronous reluctance motor (SynRM motors) with the drive. Multiple
induction motors can be connected to the drive at a time when using the scalar
motor control mode.
Make sure that the motor(s) and the drive are compatible according to the rating
table in the technical data.
 Guidelines for planning the electrical installation 55

Selecting the power cables

￭ General guidelines
Select the input power and motor cables according to local regulations.
• Current: Select a cable capable of carrying the maximum load current and
suitable for the prospective short-circuit current provided by the supply
network. The method of installation and ambient temperature affect the cable
current carrying capacity. Obey local regulations and laws.
• Temperature: For an IEC installation, select a cable rated for at least 70 °C
(158 °F) maximum permissible temperature of conductor in continuous use.
For North America, select a cable rated for at least 75 °C (167 °F).
Important: For certain product types or option configurations higher
temperature rating may be required. See the technical data for details.
• Voltage: 600 V AC cable is accepted for up to 500 V AC. 750 V AC cable is
accepted for up to 600 V AC. 1000 V AC cable is accepted for up to 690 V AC.
To comply with the EMC requirements of the CE mark, use one of the preferred
cable types. See Preferred power cable types (page 56).
Symmetrical shielded cable reduces electromagnetic emission of the whole drive
system as well as the stress on motor insulation, bearing currents and wear.
Metal conduit reduces electromagnetic emission of the whole drive system.

￭ Typical power cable sizes

See the technical data.
56 Guidelines for planning the electrical installation

￭ Power cable types

Preferred power cable types
This „
section shows the preferred cable types. Make sure that the selected cable
„
type also complies with local/state/country electrical codes.

Cable type Use as input power cabling Use as motor cabling and as
brake resistor cabling

PE Yes Yes

Symmetrical shielded (or ar-

mored) cable with three
phase conductors and con-
centric PE conductor as
shield (or armor)

„ PE Yes Yes

Symmetrical shielded (or ar-

mored) cable with three
phase conductors and sym-
metrically constructed PE
conductor and a shield (or
armor)

Yes Yes

PE

Symmetrical shielded (or ar-

mored) cable with three
phase conductors and a
„ (or armor), and separ-
shield
ate PE conductor/cable 1)

1) A separate PE conductor is required if the conductivity of the shield (or armor) is not sufficient for the
PE use.
 Guidelines for planning the electrical installation 57

Alternate power cable types

Cable type Use as input power cabling Use as motor cabling and as
brake resistor cabling

Yes with phase conductor Yes with phase conductor

smaller than 10 mm2 (8 AWG) smaller than 10 mm2 (8 AWG)
Cu. Cu, or motors up to 30 kW
(40 hp).
Note: Shielded or armored
Four-conductor cable in
cable, or cabling in metal
plastic jacket (three phase
conduit is always recommen-
conductors and PE)
ded to minimize radio fre-
quency interference.

Yes Yes with phase conductor

smaller than 10 mm2 (8 AWG)
Cu, or motors up to 30 kW
(40 hp)

Four-conductor armored
cable (three phase conduct-
ors and PE)

Yes Yes with motors up to 100 kW

(135 hp). A potential equaliza-
tion between the frames of
motor and driven equipment
is required.
Shielded (Al/Cu shield or ar-
mor) 1) four-conductor cable
(three phase conductors and
a PE)

1) Armor may act as an EMC shield, as long as it provides the same performance as a concentric EMC
shield of a shielded cable. To be effective at high frequencies, the shield conductivity must be at least
1/10 of the phase conductor conductivity. The effectiveness of the shield can be evaluated based on
the shield inductance, which must be low and only slightly dependent on frequency. The requirements
are easily met with a copper or aluminum shield/armor. The cross-section of a steel shield must be
ample and the shield helix must have a low gradient. A galvanized steel shield has a better high-frequency
conductivity than a non-galvanized steel shield.
58 Guidelines for planning the electrical installation

Not allowed power cable types

Cable type Use as input power cabling Use as motor cabling and as
brake resistor cabling

PE
No No

Symmetrical shielded cable

„ individual shields for
with
each phase conductor

￭ Additional guidelines – North America

ABB recommends the use of metallic conduit for power wiring. ABB also
recommends the use of symmetrical shielded VFD cable between drive and
motor(s).
This table shows examples of methods for wiring the drive. Refer to NFPA 70 (NEC)
along with state and local codes for the appropriate methods for your application.

Wiring method Notes

Conduit - Metallic 1) 2)
Electrical metallic tubing: Type EMT Prefer symmetrical shielded VFD cable.
Rigid metal conduit: Type RMC Use separate conduit run for each motor.
Liquid-tight flexible metal electrical conduit: Do not run input power wiring and motor
Type LFMC wiring in the same conduit.

Conduit - Non-metallic 2) 3)
Prefer symmetrical shielded VFD cable.
Liquid-tight flexible non-metallic conduit: Use separate conduit run for each motor.
Type LFNC Do not run input power wiring and motor
wiring in the same conduit.

Wireways 2)
Prefer symmetrical shielded VFD cable.
Separate motor wiring from input power
wiring and other low voltage wiring.
Metallic
Do not run outputs of multiple drives parallel.
Bundle each cable (wiring) together and use
separators where possible.
 Guidelines for planning the electrical installation 59

Wiring method Notes

Free air 2)
Prefer symmetrical shielded VFD cable.
Enclosures, air handlers, etc. Allowed internally in enclosures when in ac-
cordance with UL.
1) Metallic conduit may be used as an additional ground path, provided this path is a solid path capable
of handling ground currents.
2) See NFPA NFPA 70 (NEC), UL, and local codes for your application.
3) Non-metallic conduit use underground is allowed; however, these installations inherently have an
increased chance for nuisance problems due to the potential for water/moisture in the conduit.
Water/moisture in the conduit increases the likelihood of VFD faults or warnings. Proper installation
is required to make sure there is no intrusion of water/moisture.

Metal conduit
Couple separate parts of a metal conduit together: bridge the joints with a ground
conductor bonded to the conduit on each side of the joint. Also bond the conduits
to the drive enclosure and motor frame. Use separate conduits for input power,
motor, brake resistor, and control wiring. Do not run motor wiring from more than
one drive in the same conduit.

￭ Power cable shield

If the cable shield is used as the sole protective earth (PE) conductor, make sure
that its conductivity agrees with the PE conductor requirements.
To effectively suppress radiated and conducted radio-frequency emissions, the
cable shield conductivity must be at least 1/10 of the phase conductor conductivity.
The requirements are easily met with a copper or aluminum shield. The minimum
requirement of the motor cable shield of the drive is shown below. It consists of
a concentric layer of copper wires with an open helix of copper tape or copper
wire. The better and tighter the shield, the lower the emission level and bearing
currents.
60 Guidelines for planning the electrical installation

1 2 3 4 5

1 Insulation jacket

2 Helix of copper tape or copper wire

3 Copper wire shield

4 Inner insulation

5 Cable core

Grounding requirements
This section gives general requirements for grounding the drive. When you plan
the grounding of the drive, obey all the applicable national and local regulations.
The conductivity of the protective earth conductor(s) must be sufficient.
Unless local wiring regulations state otherwise, the cross-sectional area of the
protective earth conductor must agree with the conditions that require automatic
disconnection of the supply required in 411.3.2 of IEC 60364-4-41:2005 and be
capable of withstanding the prospective fault current during the disconnection
time of the protective device. The cross-sectional area of the protective earth
conductor must be selected from the table below or calculated according to 543.1
of IEC 60364-5-54.
The table shows the minimum cross-sectional area of the protective earth
conductor related to the phase conductor size according to IEC/UL 61800-5-1
when the phase conductor(s) and the protective earth conductor are made of the
same metal. If they are different metals, the cross-sectional area of the protective
 Guidelines for planning the electrical installation 61

earth conductor must be determined in a manner which produces a conductance

equivalent to that which results from the application of this table.

Cross-sectional area of the phase conduct- Minimum cross-sectional area of the corres-
ors ponding protective earth conductor
S (mm2) Sp (mm2)

S ≤ 16 S 1)

16 < S ≤ 35 16

35 < S S/2

1) For the minimum conductor size in IEC installations, refer to Additional grounding requirements – IEC.

If the protective earth conductor is not part of the input power cable or input
power cable enclosure, the minimum permitted cross-sectional area is:
• 2.5 mm2 if the conductor is mechanically protected,
or
• 4 mm2 if the conductor is not mechanically protected. If the equipment is
cord-connected, the protective earth conductor must be the last conductor
to be interrupted if there is a failure in the strain relief mechanism.

￭ Additional grounding requirements – IEC

This section gives grounding requirements according to standard IEC/EN 61800-5-1.
Because the normal touch current of the drive is more than 3.5 mA AC or 10 mA DC:
• the minimum size of the protective earth conductor must comply with the
local safety regulations for high protective earth conductor current equipment,
and
• you must use one of these connection methods:
1. a fixed connection and:
• a protective earth conductor with a minimum cross-sectional area of
10 mm2 Cu or 16 mm2 Al (as an alternative when aluminum cables are
permitted),
or
• a second protective earth conductor of the same cross-sectional area
as the original protective earth conductor,
or
• a device that automatically disconnects the supply if the protective
earth conductor is damaged.
2. a connection with an industrial connector according to IEC 60309 and a
minimum protective earth conductor cross-section of 2.5 mm2 as part of
a multi-conductor power cable. Sufficient strain relief must be provided.
 62 Guidelines for planning the electrical installation

If the protective earth conductor is routed through a plug and socket, or similar
means of disconnection, it must not be possible to disconnect it unless power is
simultaneously removed.
Note: You can use power cable shields as protective earth conductors only when
their conductivity is sufficient.

￭ Additional grounding requirements – UL (NEC)

This section gives grounding requirements according to standard UL 61800-5-1.
The protective earth conductor must be sized as specified in Article 250.122 and
table 250.122 of the National Electric Code, ANSI/NFPA 70.
For cord-connected equipment, it must not be possible to disconnect the protective
earth conductor before power is removed.

Selecting the control cables

￭ Shielding
Only use shielded control cables.
Use a double-shielded twisted pair cable for analog signals. ABB recommends this
type of cable also for the pulse encoder signals. Use one individually shielded pair
for each signal. Do not use common return for different analog signals.
A double-shielded cable (a) is the best alternative for low-voltage digital signals,
but single-shielded (b) twisted pair cable is also acceptable.

a b

￭ Signals in separate cables

„
Run analog and digital signals in separate, shielded cables. Do not mix 24 V DC
and 115/230 V AC signals in the same cable.

￭ Signals that can be run in the same cable

„ If their voltage does not exceed 48 V, relay-controlled signals can be run in the
same cables as digital input signals. The relay-controlled signals should be run as
twisted pairs.

„
 Guidelines for planning the electrical installation 63

￭ Relay cable
The cable type with braided metallic shield (for example ÖLFLEX by LAPPKABEL,
Germany) has been tested and approved by ABB.

￭ Control panel to drive cable

Use EIA-485, Cat 5e (or better) cable with male RJ-45 connectors. The maximum
length of the cable is 100 m (328 ft).

￭ PC tool cable
Connect the Drive Composer PC tool to the drive through the USB port of the
control panel. Use a USB Type A (PC) - Type Mini-B (control panel) cable. The
maximum length of the cable is 3 m (9.8 ft).

Routing the cables

￭ General guidelines – IEC
• Route the motor cable away from other cables. Motor cables of several drives
can be run in parallel installed next to each other.
• Install the motor cable, input power cable and control cables on separate trays.
• Avoid long parallel runs of motor cables with other cables.
• Where control cables must cross power cables, make sure that they are
arranged at an angle as near to 90 degrees as possible.
• Do not run extra cables through the drive.
• Make sure that the cable trays have good electrical bonding to each other and
to the grounding electrodes. Aluminum tray systems can be used to improve
local equalizing of potential.
The following figure illustrates the cable routing guidelines with an example drive.
Note: When motor cable is symmetrical and shielded and it has short parallel runs
with other cables (< 1.5 m / 5 ft), distances between the motor cable and other
cables can be reduced by half.
64 Guidelines for planning the electrical installation

1
min. 300 mm (12 in)
2 4

4
min. 300 mm (12 in) min. 500 mm (20 in)
2
3

90°
3 1
min. 200 mm (8 in)
min. 500 mm (20 in)
2
3

1 Motor cable

2 Input power cable

3 Control cable

4 Brake resistor or chopper cable (if any)

￭ General guidelines – North America

Make sure that the installation is in accordance with national and local codes. Obey
these general guidelines:
• Use separate conduits for the input power, motor, brake resistor (optional),
and control cabling.
• Use separate conduit for each motor cabling.
The following figure illustrates the cable routing guidelines with an example drive.
 Guidelines for planning the electrical installation 65

1 1 1

3 3 3
1

2
2 3
2
2

3
3

1 Input power cabling

2 Motor cabling

3 Conduit

￭ Continuous motor cable shield/conduit and metal enclosure for

equipment on the motor cable
To minimize the emission level when safety switches, contactors, connection boxes
or similar equipment are installed on the motor cable between the drive and the
motor:
• Install the equipment in a metal enclosure.
• Use either a symmetrical shielded cable, or install the cabling in a metal conduit.
• Make sure that there is a good and continuous galvanic connection in the
shield/conduit between drive and motor.
• Connect the shield/conduit to the protective ground terminal of the drive and
the motor.
66 Guidelines for planning the electrical installation

￭ Separate control cable ducts

Put 24 V DC and 230 V AC (120 V AC) control cables in separate ducts, unless the
24 V DC cable is insulated for 230 V AC (120 V AC) or insulated with an insulation
sleeving for 230 V AC (120 V AC).

230 V AC 24 V DC
(120 V AC)
230 V AC
24 V DC (120 V AC)

Implementing short-circuit and thermal overload protection

￭ Protecting the drive and input power cable in short-circuits
Use the fuses specified for the drive in the technical data. Make sure that also the
electric power supply network meets the specification (minimum allowed
short-circuit current that the fuse selection is based on).
The fuses restrict drive damage and prevent damage to adjoining equipment in
case of a short-circuit inside the drive. When located at the distribution board, the
fuses also protect the input power cable against short circuits.
See the drive technical data for alternative short-circuit protections.

￭ Protecting the motor and motor cable in short-circuits

The drive protects the motor cable and motor in a short-circuit situation when:
• the motor cable is sized correctly
• the motor cable type complies with the motor cable selection guidelines by
ABB
• the cable length does not exceed the allowed maximum length specified for
the drive
• the setting of parameter 99.10 Motor nominal power in the drive is equal with
the value given on the motor rating plate.
The electronic power output short-circuit protection circuitry meets the
requirements of IEC 60364-4-41 2005/AMD1.
 Guidelines for planning the electrical installation 67

￭ Protecting the drive, and the input power and motor cables against
thermal overload
If the cables have the correct size for the nominal current, the drive protects itself
and the input and motor cables against thermal overload. No additional thermal
protection devices are needed.

WARNING!
If the drive is connected to multiple motors, use a separate motor thermal
overload device for protecting each motor cable and motor against overload.
The drive overload protection is for the sum of the total motor load. It may
not trip due to an overload in one motor.

￭ Protecting the motor against thermal overload

According to regulations, the motor must be protected against thermal overload
and the current must be switched off when overload is detected. The drive includes
a motor thermal protection function that protects the motor and switches off the
current when necessary. Depending on a drive parameter value, the function either
monitors a calculated temperature value (based on a motor thermal model) or an
actual temperature indication given by motor temperature sensors.
The motor thermal protection model supports thermal memory retention and
speed sensitivity. The user can tune the thermal model further by feeding in
additional motor and load data.
The most common temperature sensor types are PTC or Pt100.
For more information, see the firmware manual.

￭ Protecting the motor against overload without thermal model or

temperature sensors
Motor overload protection protects the motor against overload without using
motor thermal model or temperature sensors.
Motor overload protection is required and specified by multiple standards including
the US National Electric Code (NEC) and the common UL/IEC 61800-5-1 standard
in conjunction with UL/IEC 60947-4-1. The standards allow for motor overload
protection without external temperature sensors.
The protection feature of the drive allows the user to specify the class of operation
in the same manner as the overload relays are specified in standards
UL/IEC 60947-4-1 and NEMA ICS 2.
The motor overload protection supports thermal memory retention and speed
sensitivity.
For more information, see drive firmware manual.
68 Guidelines for planning the electrical installation

Implementing a motor temperature sensor connection

WARNING!
IEC 61800-5-1 requires double or reinforced insulation between live parts
and accessible parts when:
• the accessible parts are not conductive, or
• the accessible parts are conductive, but not connected to the protective
earth.
Obey this requirement when you plan the connection of the motor
temperature sensor to the drive.

You have these implementation alternatives:

1. If there is double or reinforced insulation between the sensor and the live parts
of the motor: You can connect the sensor directly to the analog/digital input(s)
of the drive. See the control cable connection instructions. Make sure that the
voltage is not more than the maximum allowed voltage over the sensor.
2. If there is basic insulation between the sensor and the live parts of the motor,
or if the insulation type is not known: You can connect a sensor to a digital
input of the drive via an external relay. The sensor and the relay must form a
double or reinforced insulation between the motor's live parts and the digital
input of the drive. Make sure that the voltage does not exceed the maximum
allowed voltage over the sensor.

Protecting the drive against ground faults

The drive is equipped with an internal ground fault protective function to protect
the unit against ground faults in the motor and motor cable. This function is not
a personnel safety or a fire protection feature. See the firmware manual for more
information.

￭ Residual current device compatibility

The drive is suitable for use with residual current devices of Type B.
Note: As standard, the drive contains capacitors connected between the main
circuit and the frame. These capacitors and long motor cables increase the ground
leakage current and may cause nuisance faults in residual current devices.

Implementing the Emergency stop function

For safety reasons, install the emergency stop devices at each operator control
station and at other operating stations where emergency stop may be needed.
Design the emergency stop according to the applicable standards.
 Guidelines for planning the electrical installation 69

You can use the Safe torque off function of the drive to implement the Emergency
stop function.
Note: Pressing the stop (off) key on the control panel of the drive does not generate
an emergency stop of the motor or separate the drive from dangerous potential.

Implementing the Safe torque off function

See chapter The Safe torque off function (page 233).

Using a safety switch between the drive and the motor

ABB recommends to install a safety switch between the permanent magnet motor
and the drive output. The switch is needed to isolate the motor from the drive
during maintenance work on the drive.

Implementing the control of a contactor between drive and

motor
Implementing the control of the output contactor depends on the motor control
mode and stopping method selected.
When you select the vector motor control mode and the motor ramp stop mode,
use this operation sequence to open the contactor:
1. Give a stop command to the drive.
2. Wait until the drive decelerates the motor to zero speed.
3. Open the contactor.

WARNING!
If vector motor control mode is in use, do not open the output contactor
while the drive controls the motor. The motor control operates faster than
the contactor, and tries to maintain the load current. This can cause damage
to the contactor.

When you select the vector motor control mode and the motor coast stop mode,
you can open the contactor immediately after the drive has received the stop
command. This is the case also if you use the scalar motor control mode.

Protecting the contacts of relay outputs

Inductive loads (relays, contactors, motors) cause voltage transients when switched
off.
It is highly recommended that inductive loads are equipped with noise attenuating
circuits (varistors, RC filters [AC] or diodes [DC]) to minimize the EMC emission at
switch-off. If not suppressed, the disturbances can connect capacitively or
70 Guidelines for planning the electrical installation

inductively to other conductors in the control cable and form a risk of malfunction
in other parts of the system.
Install the protective component as close to the inductive load as possible. Do not
install protective components at the relay outputs.

230 V AC

1
2

230 V AC

+ 24 V DC

1 Relay output

2 Varistor

3 RC filter

4 Diode
 Electrical installation – IEC 71

6
Electrical installation – IEC

Contents of this chapter

This chapter describes how to:
• measure the insulation
• do the grounding system compatibility check
• change the EMC filter or ground-to-phase varistor connection
• connect the power and control cables
• install optional modules
• connect a PC.

Required tools
To do the electrical installation, you need the following tools:
• wire stripper
• screwdriver or wrench with a set of suitable bits. For motor cable terminals,
the recommended screwdriver shaft length is 150 mm (5.9 in).
• short flat head screwdriver for the I/O terminals
• torque wrench
• multimeter and voltage detector
• personal protective equipment.
72 Electrical installation – IEC

Measuring the insulation resistance - IEC

￭ Measuring the insulation resistance of the drive
WARNING!
Do not do voltage withstand or insulation resistance tests on the drive. The
tests can cause damage to the drive. Every drive is tested for insulation
between the main circuit and the chassis at the factory. Also, there are
voltage-limiting circuits inside the drive which cut down the testing voltage
automatically.

￭ Measuring the insulation resistance of the input power cable

Before you connect the input power cable to the drive, measure its insulation
resistance according to local regulations.

￭ Measuring the insulation resistance of the motor and motor cable

WARNING!
Obey the safety instructions of the drive. 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, commissioning or
maintenance work.

1. Do the steps in section Electrical safety precautions (page 20) before you start
the work.
2. Make sure that the motor cable is disconnected from the drive output terminals.
3. Measure the insulation resistance between each phase conductor and the
protective earth conductor. Use a measuring voltage of 1000 V DC. The
insulation resistance of an ABB motor must be more than 100 Mohm (reference
value at 25 °C [77 °F]). For the insulation resistance of other motors, refer to
the manufacturer’s instructions.
Note: Moisture inside the motor reduces the insulation resistance. If you think
that there is moisture in the motor, dry the motor and do the measurement
again.

U1
M
U1-PE, V1-PE, W1-PE
V1
1000 V DC, 3~
ohm W1
> 100 Mohm PE
 Electrical installation – IEC 73

￭ Measuring the insulation resistance of the brake resistor circuit

WARNING!
Obey the safety instructions of the drive. 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, commissioning or
maintenance work.

1. Stop the drive and do the steps in section Electrical safety

precautions (page 20) before you start the work.
2. Make sure that the resistor cable is connected to the resistor and disconnected
from the drive output terminals.
3. At the drive end, connect the R+ and R- conductors of the resistor cable
together. Measure the insulation resistance between the conductors and the
PE conductor with a measuring voltage of 1000 V DC. The insulation resistance
must be more than 1 Mohm.

R+

R-
ohm
1000 V DC,
> 1 Mohm
PE

Grounding system compatibility check – IEC

￭ EMC filter
Some drive types have an internal EMC filter as standard. You can install a drive
that has the internal EMC filter connected to a symmetrically grounded TN-S system
(center-grounded wye). For other systems, refer to Compatibility of EMC filter and
ground-to-phase varistor with the grounding system (page 74).
Note: 200 … 240 V drives with low filtering level (type ACS380-040x, EMC category
C4) do not have an internal EMC filter.

Note: If you disconnect the EMC filter, the electromagnetic compatibility of the
drive decreases.
74 Electrical installation – IEC

WARNING!
Do not install a drive with the internal EMC filter connected to a grounding
system that the EMC filter is not compatible with (for example, an IT system).
The supply network becomes connected to ground potential through the
internal EMC filter capacitors, which can cause danger or damage to the
drive.

￭ Ground-to-phase varistor
The drive has a ground-to-phase varistor circuit as standard. You can install a drive
that has the varistor circuit connected to a symmetrically grounded TN-S system
(center-grounded wye). For other systems, refer to Compatibility of EMC filter and
ground-to-phase varistor with the grounding system (page 74). In some product
variants, the varistor circuit is disconnected at the factory.

WARNING!
Do not install the drive with the ground-to-phase varistor connected to a
system that the varistor is not suitable for. It can cause damage to the
varistor circuit.

￭ Compatibility of EMC filter and ground-to-phase varistor with the

grounding system
WARNING!
If you do not obey these instructions, injury to personnel or damage to the
drive can occur.

A metal EMC screw is used to connect the internal EMC filter, and a metal VAR
screw is used to connect the ground-to-phase varistor. The screws are installed
at the factory. The material of the screws (plastic or metal) depends on the product
 Electrical installation – IEC 75

variant. Before you connect the drive to the input power, examine the screws and
do the necessary actions shown in the table.

Screw Screw material When to remove EMC screw or VAR screw

label
Symmetrically Corner-grounded IT systems (un-
grounded TN-S sys- delta (B1), mid- grounded or high-
tems, i.e, center- point-grounded resistance groun-
grounded wye (A) delta (B2) and ded) (C)
TT (D) systems

EMC Metal Do not remove Remove Remove

Plastic Do not remove 1) Do not remove Do not remove

VAR Metal Do not remove Do not remove Remove

Plastic Do not remove Do not remove Do not remove

A B1 C
L1 L1 L1
L2 L2
L3 L3
N L2
L3
PE PE

A B2 D
L1 L1 L1
L2
L3
L2
L2 N
L3
PE
L3
N
PE

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

For the locations of the screws, refer to Disconnecting the EMC filter or
ground-to-phase varistor (page 76).
76 Electrical installation – IEC

￭ Disconnecting the EMC filter or ground-to-phase varistor

Before you continue, refer to Compatibility of EMC filter and ground-to-phase
varistor with the grounding system (page 74).
• To disconnect the EMC filter, remove the metal EMC screw.
• To disconnect the ground-to-phase varistor, remove the metal VAR screw.

EMC/VAR screw location

￭ Guidelines for installing the drive to a TT system

You can install the drive to a TT system under these conditions:
1. There is a residual current device in the supply system
2. The internal EMC filter is disconnected. If the EMC filter is not disconnected,
its leakage current will cause the residual current device to trip.

Note:
• ABB does not guarantee the EMC performance, because the internal EMC filter
is disconnected.
• ABB does not guarantee the functioning of the ground leakage detector built
inside the drive.
• In large systems the residual current device can trip without a real reason.
 Electrical installation – IEC 77

￭ Identifying the grounding system of the electrical power network

WARNING!
Only a qualified electrical professional may do the work instructed in this
section. Depending on the installation site, the work may even be categorized
as live working. Continue only if you are an electrical professional certified
for the work. Obey the local regulations. If you ignore them, injury or death
can occur.

To identify the grounding system, examine the supply transformer connection.

See the applicable electrical diagrams of the building. If that is not possible,
measure these voltages at the distribution board, and use the table to define the
grounding system type.
1. input voltage line to line (UL-L)
2. input voltage line 1 to ground (UL1-G)
3. input voltage line 2 to ground (UL2-G)
4. input voltage line 3 to ground (UL3-G).
The table below shows the line-to-ground voltages in relation to the line-to-line
voltage for each grounding system.

UL-L UL1-G UL2-G UL3-G Electrical power system type

X 0.58·X 0.58·X 0.58·X TN-S system (symmetrically grounded)

Corner-grounded delta system (nonsym-
X 1.0·X 1.0·X 0
metrical)
Midpoint-grounded delta system (non-
X 0.866·X 0.5·X 0.5·X
symmetrical)
IT systems (ungrounded or high-resist-
Varying level Varying level Varying level
X ance-grounded [>30 ohms]) nonsymmet-
versus time versus time versus time
rical
TT system (the protective earth connec-
tion for the consumer is provided by a
Varying level Varying level Varying level
X local earth electrode, and there is anoth-
versus time versus time versus time
er independently installed at the gener-
ator)
78 Electrical installation – IEC

Connecting the power cables – IEC (shielded cables)

￭ Connection diagram

1
R+ T1/ T2/ T3/
L1 L2 L3 R- UDC-
PE UDC+ U V W

8 8

5 3 6
7

4 V1
9 U1 W1
M PE
3
2

PE L1 L2 L3
(L) (N)

1 Drive
2 Disconnecting device
3 Input power cable
4 Two protective earth (ground) conductors. Drive safety standard IEC/EN 61800-5-1
requires two PE conductors for a fixed connection, 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.
5 Separate PE cable (line side). 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.
6 Motor cable

Note: ABB recommends to use a symmetrical shielded cable (VFD cable) as the motor
cable.
7 Separate PE cable (motor side). Use a separate grounding cable for the motor side,
if the conductivity of the shield is not sufficient, or if there is no symmetrically con-
structed PE conductor in the cable.
8 360-degree grounding of the cable shield. Required for the motor cable and brake
resistor cable (if used), recommended for the input power cable.
9 Brake resistor (optional)
 Electrical installation – IEC 79

￭ Connection procedure
WARNING!
Obey the safety instructions of the drive. 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, commissioning or
maintenance work.

Refer to Terminal data for the power cables (page 162) for the tightening torques.
1. Do the steps in section Electrical safety precautions (page 20) before you start
the work.
2. Remove the screw on the drive front cover, then remove the front cover.

3. Attach the residual voltage warning sticker in the local language to the drive.
4. Strip the motor cable.
5. Ground the motor cable shield under the grounding clamp for 360-degree
grounding.

6. Twist the motor cable shield into a bundle, mark it with yellow-green insulation
tape, install a cable lug, and connect it to the grounding terminal.
7. Connect the phase conductors of the motor cable to terminals T1/U, T2/V and
T3/W.
80 Electrical installation – IEC

8. If you use a brake resistor, connect the brake resistor cable to terminals R-
and UDC+. Use shielded cable and ground the shield under the grounding
clamp for 360-degree grounding.
9. Make sure that the R- and UDC+ terminal screws are tightened. Do this step
also if you do not connect cables to the terminals.
10. Strip the input power cable.
11. If the input power cable has a shield, ground the shield under the clamp for
360-degree grounding. Twist the shield also into a bundle, mark it with
yellow-green insulation tape, install a cable lug, and connect it to the grounding
terminal.

12. Connect the protective earth (ground) conductor(s) of the input power cable
to the grounding terminal.
13. Connect the phase conductors of the input power cable to the drive as follows:
• 1-phase drives: connect the phase and neutral conductors to terminals L1
and L2. For example, connect phase to L1 and neutral to L2.
• 3-phase drives: connect the phase conductors to terminals L1, L2, and L3.
14. Mechanically attach all of the cables on the outside of the drive.

Connecting the control cables - IEC

Before you connect the control cables, make sure that all option modules are
installed.

￭ Default I/O connection diagram (ABB standard macro)

This connection diagram is valid for drives with the BMIO-01 I/O & Modbus
extension module:
• Standard variant (ACS380-04xS)
 Electrical installation – IEC 81

• Configured variant (ACS380-04xC) with the BMIO-01 I/O & Modbus extension
module (option +L538)

Connection Term. Description 1)

Digital I/O and relay output connections

+24V Aux. voltage output +24 V DC, max. 250 mA ×
+24V
DGND Aux. voltage output common ×
DGND
DCOM DCOM Digital input common ×
DI1 DI1 Stop (0) / Start (1) ×
DI2 DI2 Forward (0) / Reverse (1) ×
DI3
DI3 Speed selection
DI4
DIO1 DI4 Speed selection
DIO2 DIO1 Digital input: Ramp set 1 (0) / Ramp set 2 (1)
DIO SRC DIO2 Digital output: Not ready (0) / Ready run (1)
DIO COM
DIO SRC Digital output auxiliary voltage
DIO COM Digital input/output common
RC
RC Relay output 1 ×
RA
No fault [Fault (-1)]
RB RA ×
RB ×
Analog inputs and outputs

1…10 kohm
AI1 Output frequency/Speed reference (0 … 10 V)

AI1 AGND Analog input/output circuit common

AGND AI2 Not configured
AI2 AGND Analog input/output circuit common
Max. 500 ohm AGND
AO AO Output frequency (0 … 20 mA)

AGND AGND Analog input/output circuit common

SCR SCR Signal cable shield (screen)
+10V
+10V Reference voltage
Safe torque off (STO)
S+ Safe torque off function. Factory connection. ×
S+ Both circuits must be closed for the drive to
SGND ×
SGND start.
S1 S1 ×
S2 S2 ×
82 Electrical installation – IEC

Connection Term. Description 1)

EIA-485 Modbus RTU

B+ Embedded Modbus RTU (EIA-485)
B+
A-
A-
BGND BGND
Shield Shield
Termina-
tion & bi-
as
1) × = base unit, empty = BMIO-01 module

Note: This note is applicable to BMIO-01 option module (material code:

3AXD50000021262), revision D or earlier. The revision is shown on the type label
of the module.
The status of the drive main input voltage has an effect on the operation of digital
and analog outputs of the BMIO-01 option module:
• Digital output (DIO1/DIO2 configured as output) will be at a high state for a
short time (<20 ms) after the main input voltage (L1, L2, L3) is connected.
• Digital output (DIO1/DIO2 configured as output) will be at a high state
continuously when the main input voltage (L1, L2, L3) is not connected and an
external 24 V DC supply is used for digital output source (DIO SRC).
• Analog output (AO) will be at the maximum voltage reference level (+10 V) for
a short time (<20 ms) after the main input voltage (L1, L2, L3) is connected.

￭ Fieldbus connection diagram

This connection diagram is valid for drives with a fieldbus extension module. The
type code is ACS380-04xC followed by an option code that designates the extension
module.
 Electrical installation – IEC 83

Connection Term. Description

Digital I/O and relay output connections

+24V Aux. voltage output +24 V DC, max. 250 mA
+24V
DGND Aux. voltage output common
DGND
DCOM DCOM Digital input common
DI1 DI1 Fault reset (operates also through the fieldbus inter-
DI2 face)
DI2 Not configured
RC RC Relay output 1
RA No fault [Fault (-1)]
RA
RB
RB
Safe torque off (STO)
S+ Safe torque off function. Factory connection. Both
S+ circuits must be closed for the drive to start.
SGND
SGND
S1 S1
S2 S2

Fieldbus connection
See the applicable fieldbus Terminal +K451 FDNA-01, DeviceNet
adapter manual. block
DSUB9 +K454 FPBA-01 Profibus DP
DSUB9 +K457 FCAN-01 CANopen
8P8C×2 +K462 FCNA-01 ControlNet
RJ45×2 +K469 FECA-01 EtherCAT
RJ45×2 +K470 FEPL-02, Ethernet Powerlink
RJ45×2 +K490 FEIP-21 Two-port Modbus/IP adapter
RJ45×2 +K491 FMBT-21 Two-port Modbus/TCP adapter
RJ45×2 +K492 FPNO-21 Two-port Profinet IO adapter
Terminal +K495 BCAN-11 CANopen interface
block

￭ Control cable connection procedure

Do the connections according to the control macro (parameter 96.04) used.
Keep the signal wire pairs twisted as near to the terminals as possible to prevent
inductive coupling.
84 Electrical installation – IEC

WARNING!
Obey the safety instructions of the drive. 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, commissioning or
maintenance work.

1. Do the steps in section Electrical safety precautions (page 20) before you start
the work.
2. Remove the screw on the drive front cover, then remove the front cover.
3. Strip a part of the outer shield of the control cable for grounding.
4. Use a cable tie to ground the outer shield to the grounding tab. For 360°
grounding, use metallic cable ties.
5. Strip the control cable conductors.
6. Connect the conductors to the correct control terminals. Torque the terminal
connections to 0.5 … 0.6 N·m (4.4 … 5.3 lbf·in).
7. Connect the shields and grounding wires to the SCR terminal. Torque the
terminal connection to 0.5 … 0.6 N·m (4.4 … 5.3 lbf·in).
8. Mechanically attach the control cables on the outside of the drive.

￭ Additional information on the control connections

Embedded EIA-485 fieldbus connection
The EIA-485 network uses shielded, twisted-pair cable with a characteristic
impedance of 100…130 ohm for data signaling. The distributed capacitance
between conductors is less than 100 pF per meter (30 pF per foot). Distributed
capacitance between conductors and shield is less than 200 pF per meter (60 pF
per foot). Foil or braided shields are acceptable.
 Electrical installation – IEC 85

Connect the cable to the EIA-485 terminal on the BMIO-01 I/O module. Obey these
wiring instructions:
• Attach the cable shields together at each drive, but do not connect them to
the drive.
• Connect the cable shields only to the grounding terminal in the automation
controller.
• Connect the signal ground (BGND) conductor to the signal ground reference
terminal in the automation controller. If the automation controller does not
have a signal ground reference terminal, connect the signal ground conductor
to the cable shield through a 100 ohm resistor, preferably near the automation
controller.
Connection examples are shown below.

With signal ground reference terminal

BGND

BGND

BGND
Shield

Shield

Shield
G R - +
B+

B+

B+
A-

A-

A-
1 2 3 2 3 2 3

Without signal ground reference terminal

100 ohm
BGND

BGND

BGND
Shield

Shield

Shield

G - +
B+

B+

B+
A-

A-

A-

1 2 3 2 3 2 3

1 Automation controller

2 Drive

3 Termination jumpers. The devices at the ends of the fieldbus must have termination
on. All other devices must have termination off.
86 Electrical installation – IEC

PNP configuration for digital inputs

Internal and external +24 V power supply connections for PNP (source) configuration
are shown in the figures below.

WARNING!
If you connect DIO1 or DIO2 as shown in the figures below, make sure that
they are configured as inputs. If they are configured as outputs, it can cause
damage to the equipment.

Internal +24 V power supply External +24 V power supply

+24 V +24 V
DGND 0 V DC DGND
DCOM DCOM
+24 V DC
DI1 DI1
DI2 DI2
DI3 DI3
DI4 DI4
DIO1 DIO1
DIO2 DIO2
 Electrical installation – IEC 87

NPN configuration for digital inputs

Internal and external +24 V power supply connections for NPN (sink) configuration
are shown in the figures below.

WARNING!
If you connect DIO1 or DIO2 as shown in the figures below, make sure that
they are configured as inputs. If they are configured as outputs, it can cause
damage to the equipment.

Internal +24 V power supply External +24 V power supply

+24 V +24 V
DGND +24 V DC DGND
DCOM DCOM
0 V DC
DI1 DI1
DI2 DI2
DI3 DI3
DI4 DI4
DIO1 DIO1
DIO2 DIO2

Connection examples of two-wire and three-wire sensors

The figures give examples of connections for a two-wire or three-wire
sensor/transmitter that is supplied by the auxiliary voltage output of the drive.

- 4…20 mA
P AI2

+ AGND
I

+24V
DGND

AI2 Process actual value measurement or reference, 0(4) … 20 mA, Rin = 137 ohm. If
the sensor power supply comes through its current output circuit, use 4 … 20 mA
AGND
signal, not 0 … 20 mA.
+24V Auxiliary voltage output, non-isolated, +24 V DC, max. 250 mA
DGND
88 Electrical installation – IEC

OUT (0)4…20 mA
P AI2
-
AGND
I
+
+24V
DGND

AI2 Process actual value measurement or reference, 0(4)…20 mA, Rin = 137 ohm
AGND
+24V Auxiliary voltage output, non-isolated, +24 V DC, max. 250 mA
DGND

AI and AO (or AI, DI and +10 V) as PTC motor temperature sensor interface

WARNING!
IEC 61800-5-1 requires double or reinforced insulation between live parts
and accessible parts when:
• the accessible parts are not conductive, or
• the accessible parts are conductive, but not connected to the protective
earth.
Obey this requirement when you plan the connection of the motor
temperature sensor to the drive.

To comply with the drive safety standard IEC 61800-5-1:

If the motor temperature sensor has double or reinforced insulation vs. the motor
windings, you can connect it directly to the drive IO interface. This section shows
two connection alternatives for the direct I/O connection. If the sensor does not
have reinforced insulation, you must use another type of connection to comply
with the safety standard. See Implementing a motor temperature sensor
connection (page 68).
See the firmware manual for information on the related Motor thermal protection
function, and the required parameter settings.

PTC connection 1
1…3 PTC sensors can be connected in series to an analog input and an analog
output. Make sure that the voltage does not exceed the maximum allowed voltage
over the sensor. The analog output feeds a constant excitation current of 1.6 mA
through the sensor. The sensor resistance increases as the motor temperature
rises, as does the voltage over the sensor. The temperature measurement function
calculates the resistance of the sensor and generates an indication if
overtemperature is detected. Leave the sensor end of the cable shield unconnected.
 Electrical installation – IEC 89

AI
4
AGND

3
T T T
1 AO
5
AGND
2

1 Motor winding
2 Double or reinforced insulation
3 1…3 PTC sensors
4 Analog input. Set the analog input type to V (volt) in parameter group 12 Standard AI.
Define the temperature sensor type, signal source, etc. with parameters 35.11…35.24.
For the sensor type, select: PTC analog I/O.
5 Analog output. Select the Excitation mode for the analog output in parameter group
13 Standard AO.

PTC connection 2
If no analog output is available for the PTC connection, it is possible to use a voltage
divider connection. Make sure that the voltage does not exceed the maximum
allowed voltage over the sensor. 1…3 PTC sensors are connected in series with
10 V reference and digital and analog inputs. The voltage over the digital input
internal resistance varies depending on the PTC resistance. The temperature
measurement function reads the digital input voltage through the analog input
and calculates the PTC resistance.
90 Electrical installation – IEC

DI
4
AI

1 +10 V 5
T T T
2 DGND
3 DCOM

1 1…3 PTC sensors

2 Double or reinforced insulation
3 Motor winding
4 Digital input and analog input. Set the analog input type to V (volt) in parameter group
12 Standard AI. Define the temperature sensor type, signal source, etc. with parameters
35.11…35.24. For the sensor type, select: PTC AI/DI Voltage Divider tree. Make sure that
the digital input is not configured to any other use by parameters.
5 10 V reference voltage

AI1 and AI2 as Pt100, Pt1000, Ni1000, KTY83 and KTY84 sensor inputs

WARNING!
IEC 61800-5-1 requires double or reinforced insulation between live parts
and accessible parts when:
• the accessible parts are not conductive, or
• the accessible parts are conductive, but not connected to the protective
earth.
Obey this requirement when you plan the connection of the motor
temperature sensor to the drive.

To comply with the drive safety standard IEC 61800-5-1:

If the motor temperature sensor has double or reinforced insulation vs. the motor
windings, you can connect it directly to the drive IO interface. This section shows
the connection. If the sensor has no reinforced insulation, you must use another
type of connection to comply with the safety standard. See Implementing a motor
temperature sensor connection (page 68).
You can connect temperature measurement sensors (one, two or three Pt100
sensors; one, two or three Pt1000 sensors; or one Ni1000, KTY83 or KTY84) between
an analog input and output as shown below. Make sure that the voltage does not
exceed the maximum allowed voltage over the sensor. Leave the sensor end of
the cable shield unconnected.
 Electrical installation – IEC 91

See the firmware manual for information on the related Motor thermal protection
function.

AI
4
AGND

3
T T T
1 AO
5
AGND
2

1 Motor winding
2 Double or reinforced insulation
3 1…3 × (Pt100 or Pt1000) or 1 × (Ni1000 or KTY83 or KTY84)
4 Analog input. Set the analog input type to V (volt) in parameter group 12 Standard AI.
Define the temperature sensor type, signal source, etc. with parameters 35.11…35.24.
Set the analog input type to V (volt) in parameter group 12 Standard AI.
5 Analog output. Select the Excitation mode for the analog output in parameter group
13 Standard AO.

Safe torque off

For the drive to start, both STO connections (S+ to S1 and S+ to S2) must be closed.
By default, the terminal block has jumpers to close the circuit. Remove the jumpers
before connecting external Safe torque off circuitry to the drive. See chapter The
Safe torque off function.

Auxiliary voltage connection

The drive has 24 V DC (±10%) auxiliary power supply terminals both on the base
unit and on the BMIO-01 module. You can use them:
• to supply auxiliary power from the drive to external control circuits or option
modules
• to supply external auxiliary power to the drive to keep the control and cooling
in operation if there is a power outage.
See the technical data for the specifications for the auxiliary power supply terminals
(input/output).
To supply power to external control circuits or option modules:
1. Connect the load either to the auxiliary power output on the base unit, or on
the BMIO-01 module (+24V and DGND terminals).
2. Make sure that you do not exceed the load capacity of the output, or the sum
load capacity of both outputs.
92 Electrical installation – IEC

To connect an external auxiliary power supply to the drive:

1. Install a BAPO-01 power extension module to the drive. See Installing
options (page 92).
2. Connect an external power supply to the +24V and DGND terminals of the base
unit.
For more information on the BAPO-01 module, see BAPO-01 auxiliary power
extension module (page 285).
+24V DGND DCOM SGND S+

DI1
DI2
RC
S1
RA
S2
RB

Connecting a PC
To connect a PC to the drive, there are two alternatives:
• Use an ACS-AP-I/S/W assistant control panel as a converter. Use a USB type
A – type Mini-B cable. The maximum permitted length of the cable is 3 m (9.8 ft).
• Use a USB to RJ45 converter. You can order it from ABB (BCBL-01,
3AXD50000032449). Connect the cable to the Panel and PC tool port (RJ45).
For information on the Drive Composer PC tool, refer to Drive Composer PC tool
user's manual (3AUA0000094606 [English]).
You can use the CCA-01 cold configuration tool to download software and change
drive parameters without connecting the drive to the input power. The CCA-01
does not operate if the drive is powered. Refer to CCA-01 communication adapter
quick installation guide (3AXD50000018457 [English]) for more information.

Installing options
The drive has two option module slots:
• Front option: Communication module slot under the front cover.
 Electrical installation – IEC 93

• Side option: Multifunction extension module slot on the side of the drive.
Refer also to the applicable fieldbus module manual for the installation instructions.
For other option modules, refer to:
• BTAC-02 pulse encoder interface module (page 255)
• BRES-01 resolver interface module (page 271)
• BREL-01 relay output extension module (page 279)
• BAPO-01 auxiliary power extension module (page 285)
• BIO-01 I/O extension module (page 289).

￭ Installing a front option

WARNING!
Obey the safety instructions of the drive. 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, commissioning or
maintenance work.

1. Do the steps in section Electrical safety precautions (page 20) before you start
the work.
2. Remove the screw on the drive front cover, then remove the front cover.
3. If the option module has a locking tab, pull it up.
4. Carefully align the option module with the option module slot and push it into
position.
94 Electrical installation – IEC

5. Torque the screw to 0.5 N·m (4.4 lbf·in).

6. If the option module has a locking tab, push it down until it locks.

7. Connect the control cables. See the control cable connection instructions.

Note: If you have the BIO-01 option module, you can add one additional fieldbus
module on top of it. Replace the drive front cover with the high cover that comes
with the BIO-01 module.

￭ Installing a side option

WARNING!
Obey the safety instructions of the drive. 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, commissioning or
maintenance work.

1. Do the steps in section Electrical safety precautions (page 20) before you start
the work.
2. Remove the two screws from the front-most grounding clamp at the bottom
of the drive.
3. Carefully align the side option with the connectors on the right side of the
drive.
 Electrical installation – IEC 95

4. Fully push the option module into position.

5. Torque the screw on the option module to 1 N·m (8.8 lbf·in).
6. Attach the grounding bar to the bottom of the side option and to the front
ground tab on the drive. Torque the screws to 1 N·m (8.8 lbf·in).
7. Connect the control cables. See the control cable connection instructions.

3
6 5

4 7

2
96
 Electrical installation – North America 97

7
Electrical installation – North
America

Contents of this chapter

This chapter describes how to:
• measure the insulation
• do the grounding system compatibility check
• change the EMC filter or ground-to-phase varistor connection
• connect the power and control cables
• install optional modules
• connect a PC.

Required tools
To do the electrical installation, you need the following tools:
• wire stripper
• screwdriver or wrench with a set of suitable bits. For motor cable terminals,
the recommended screwdriver shaft length is 150 mm (5.9 in).
• short flat head screwdriver for the I/O terminals
• torque wrench
• multimeter and voltage detector
98 Electrical installation – North America

• personal protective equipment.

Measuring the insulation resistance - North America

￭ Measuring the insulation resistance of the drive
WARNING!
Do not do voltage withstand or insulation resistance tests on the drive. The
tests can cause damage to the drive. Every drive is tested for insulation
between the main circuit and the chassis at the factory. Also, there are
voltage-limiting circuits inside the drive which cut down the testing voltage
automatically.

￭ Measuring the insulation resistance of the input power cable

Before you connect the input power cable to the drive, measure its insulation
resistance according to local regulations.

￭ Measuring the insulation resistance of the motor and motor cable

WARNING!
Obey the safety instructions of the drive. 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, commissioning or
maintenance work.

1. Do the steps in section Electrical safety precautions (page 20) before you start
the work.
2. Make sure that the motor cable is disconnected from the drive output terminals.
3. Measure the insulation resistance between each phase conductor and the
protective earth conductor. Use a measuring voltage of 1000 V DC. The
insulation resistance of an ABB motor must be more than 100 Mohm (reference
value at 25 °C [77 °F]). For the insulation resistance of other motors, refer to
the manufacturer’s instructions.
Note: Moisture inside the motor reduces the insulation resistance. If you think
that there is moisture in the motor, dry the motor and do the measurement
again.
 Electrical installation – North America 99

U1
M
U1-PE, V1-PE, W1-PE
V1
1000 V DC, 3~
ohm W1
> 100 Mohm PE

￭ Measuring the insulation resistance of the brake resistor circuit

WARNING!
Obey the safety instructions of the drive. 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, commissioning or
maintenance work.

1. Stop the drive and do the steps in section Electrical safety

precautions (page 20) before you start the work.
2. Make sure that the resistor cable is connected to the resistor and disconnected
from the drive output terminals.
3. At the drive end, connect the R+ and R- conductors of the resistor cable
together. Measure the insulation resistance between the conductors and the
PE conductor with a measuring voltage of 1000 V DC. The insulation resistance
must be more than 1 Mohm.

R+

R-
ohm
1000 V DC,
> 1 Mohm
PE

Grounding system compatibility check – North America

This section is applicable to North American installations.

￭ EMC filter
Some drive types have an internal EMC filter as standard. In the drives sold in North
America, the filter is disconnected by default. The filter is typically not necessary
in North American installations.
100 Electrical installation – North America

If you are concerned with EMC issues, and install the drive to a symmetrically
grounded TN-S system (center-grounded wye), you can connect the internal EMC
filter. See Disconnecting the ground-to-phase varistor, or connecting the EMC
filter (page 102).
Note: 200 … 240 V drives with low filtering level (type ACS380-040x, EMC category
C4) do not have an internal EMC filter.

Note: When the internal EMC filter is disconnected, the electromagnetic

compatibility of the drive is decreased.

WARNING!
Do not install a drive with the internal EMC filter connected to a grounding
system that the EMC filter is not compatible with (for example, an IT system).
The supply network becomes connected to ground potential through the
internal EMC filter capacitors, which can cause danger or damage to the
drive.

￭ Ground-to-phase varistor
The drive has a ground-to-phase varistor circuit as standard. You can install a drive
that has the varistor circuit connected to a symmetrically grounded TN-S system
(center-grounded wye). For other systems, refer to Compatibility of EMC filter and
ground-to-phase varistor with the grounding system (page 100). In some product
variants, the varistor circuit is disconnected at the factory.

WARNING!
Do not install the drive with the ground-to-phase varistor connected to a
system that the varistor is not suitable for. It can cause damage to the
varistor circuit.

￭ Compatibility of EMC filter and ground-to-phase varistor with the

grounding system
WARNING!
If you do not obey these instructions, injury to personnel or damage to the
drive can occur.

A metal EMC screw is used to connect the internal EMC filter, and a metal VAR
screw is used to connect the ground-to-phase varistor. The screws are installed
at the factory. The material of the screws (plastic or metal) depends on the product
 Electrical installation – North America 101

variant. Before you connect the drive to the input power, examine the screws and
do the necessary actions shown in the table.

Screw Screw material When to remove EMC screw or VAR screw

label
Symmetrically Corner-grounded IT systems (un-
grounded TN-S sys- delta (B1), mid- grounded or high-
tems, i.e, center- point-grounded resistance groun-
grounded wye (A) delta (B2) and ded) (C)
TT (D) systems

EMC Metal Do not remove Remove Remove

Plastic Do not remove 1) Do not remove Do not remove

VAR Metal Do not remove Do not remove Remove

Plastic Do not remove Do not remove Do not remove

A B1 C
L1 L1 L1
L2 L2
L3 L3
N L2
L3
PE PE

A B2 D
L1 L1 L1
L2
L3
L2
L2 N
L3
PE
L3
N
PE

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

For the locations of the screws, refer to Disconnecting the ground-to-phase

varistor, or connecting the EMC filter (page 102).
102 Electrical installation – North America

￭ Disconnecting the ground-to-phase varistor, or connecting the EMC

filter
Before you continue, refer to Compatibility of EMC filter and ground-to-phase
varistor with the grounding system (page 100).
• To disconnect the ground-to-phase varistor, remove the metal VAR screw.
• To connect the EMC filter, remove the plastic EMC screw, and replace it with
the metal screw included in the drive delivery.

EMC/VAR screw location

￭ Guidelines for installing the drive to a TT system

You can install the drive to a TT system under these conditions:
1. There is a residual current device in the supply system
2. The internal EMC filter is disconnected. If the EMC filter is not disconnected,
its leakage current will cause the residual current device to trip.

Note:
• ABB does not guarantee the EMC performance, because the internal EMC filter
is disconnected.
• ABB does not guarantee the functioning of the ground leakage detector built
inside the drive.
• In large systems the residual current device can trip without a real reason.
 Electrical installation – North America 103

￭ Identifying the grounding system of the electrical power network

WARNING!
Only a qualified electrical professional may do the work instructed in this
section. Depending on the installation site, the work may even be categorized
as live working. Continue only if you are an electrical professional certified
for the work. Obey the local regulations. If you ignore them, injury or death
can occur.

To identify the grounding system, examine the supply transformer connection.

See the applicable electrical diagrams of the building. If that is not possible,
measure these voltages at the distribution board, and use the table to define the
grounding system type.
1. input voltage line to line (UL-L)
2. input voltage line 1 to ground (UL1-G)
3. input voltage line 2 to ground (UL2-G)
4. input voltage line 3 to ground (UL3-G).
The table below shows the line-to-ground voltages in relation to the line-to-line
voltage for each grounding system.

UL-L UL1-G UL2-G UL3-G Electrical power system type

X 0.58·X 0.58·X 0.58·X TN-S system (symmetrically grounded)

Corner-grounded delta system (nonsym-
X 1.0·X 1.0·X 0
metrical)
Midpoint-grounded delta system (non-
X 0.866·X 0.5·X 0.5·X
symmetrical)
IT systems (ungrounded or high-resist-
Varying level Varying level Varying level
X ance-grounded [>30 ohms]) nonsymmet-
versus time versus time versus time
rical
TT system (the protective earth connec-
tion for the consumer is provided by a
Varying level Varying level Varying level
X local earth electrode, and there is anoth-
versus time versus time versus time
er independently installed at the gener-
ator)
104 Electrical installation – North America

Connecting the power cables – North America (wiring in

conduits)
Use insulated wires suitable for installation in electrical conduits. See the National
Electric Code and local ordinances.

￭ Connection diagram

1
R+ T1/ T2/ T3/
L1 L2 L3 R- UDC-
UDC+ U V W
PE

PE

4 6

5 V1
U1 W1
M PE
3
7
3

PE L1 L2 L3
(L) (N)

1 Drive
2 Drive enclosure
3 Supply disconnecting device and fuses
4 Input power wiring
5 Protective earth (ground) conductor(s)
6 Motor wiring

Note: ABB recommends to use a symmetrical shielded cable (VFD cable) as the motor
cable.
7 Brake resistor (optional)
 Electrical installation – North America 105

￭ Connection procedure
WARNING!
Obey the safety instructions of the drive. 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, commissioning or
maintenance work.

Refer to Terminal data for the power cables (page 162) for the tightening torques.
1. Do the steps in section Electrical safety precautions (page 20) before you start
the work.
2. Install the conduits, and attach them to the cable entry plate of the enclosure
that the drive is installed in.
3. Make sure that the conduit is correctly grounded at the cable entry.
4. Strip the conductor ends and pull the conductors through the conduits.
5. Remove the screw on the drive front cover, then remove the front cover.

6. Attach the residual voltage warning sticker in the local language to the drive.
7. Connect the protective earth (ground) conductor of the motor wiring to the
grounding terminal.
106 Electrical installation – North America

8. Connect the phase conductors of the motor wiring to terminals T1/U, T2/V
and T3/W.

9. If you use a brake resistor, connect the brake resistor conductors to terminals
R- and UDC+.
10. Make sure that the R- and UDC+ terminal screws are tightened. Do this step
also if you do not connect cables to the terminals.
11. Connect the protective earth (ground) conductor(s) of the input power wiring
to the grounding terminal.
12. Connect the phase conductors of the input power wiring to the drive as follows:
• 1-phase drives: connect the phase and neutral conductors to terminals L1
and L2. For example, connect phase to L1 and neutral to L2.
• 3-phase drives: connect the phase conductors to terminals L1, L2, and L3.
 Electrical installation – North America 107

13. Connect the other ends of the conductors.

Connecting the control cables - North America

Before you connect the control cables, make sure that all option modules are
installed.

￭ Default I/O connection diagram (ABB standard macro)

This connection diagram is valid for drives with the BMIO-01 I/O & Modbus
extension module:
• Standard variant (ACS380-04xS)
• Configured variant (ACS380-04xC) with the BMIO-01 I/O & Modbus extension
module (option +L538)
108 Electrical installation – North America

Connection Term. Description 1)

Digital I/O and relay output connections

+24V Aux. voltage output +24 V DC, max. 250 mA ×
+24V
DGND Aux. voltage output common ×
DGND
DCOM DCOM Digital input common ×
DI1 DI1 Stop (0) / Start (1) ×
DI2 DI2 Forward (0) / Reverse (1) ×
DI3
DI3 Speed selection
DI4
DIO1 DI4 Speed selection
DIO2 DIO1 Digital input: Ramp set 1 (0) / Ramp set 2 (1)
DIO SRC DIO2 Digital output: Not ready (0) / Ready run (1)
DIO COM
DIO SRC Digital output auxiliary voltage
DIO COM Digital input/output common
RC
RC Relay output 1 ×
RA
No fault [Fault (-1)]
RB RA ×
RB ×
Analog inputs and outputs

1…10 kohm
AI1 Output frequency/Speed reference (0 … 10 V)

AI1 AGND Analog input/output circuit common

AGND AI2 Not configured
AI2 AGND Analog input/output circuit common
Max. 500 ohm AGND
AO AO Output frequency (0 … 20 mA)

AGND AGND Analog input/output circuit common

SCR SCR Signal cable shield (screen)
+10V
+10V Reference voltage
Safe torque off (STO)
S+ Safe torque off function. Factory connection. ×
S+ Both circuits must be closed for the drive to
SGND ×
SGND start.
S1 S1 ×
S2 S2 ×
 Electrical installation – North America 109

Connection Term. Description 1)

EIA-485 Modbus RTU

B+ Embedded Modbus RTU (EIA-485)
B+
A-
A-
BGND BGND
Shield Shield
Termina-
tion & bi-
as
1) × = base unit, empty = BMIO-01 module

Note: This note is applicable to BMIO-01 option module (material code:

3AXD50000021262), revision D or earlier. The revision is shown on the type label
of the module.
The status of the drive main input voltage has an effect on the operation of digital
and analog outputs of the BMIO-01 option module:
• Digital output (DIO1/DIO2 configured as output) will be at a high state for a
short time (<20 ms) after the main input voltage (L1, L2, L3) is connected.
• Digital output (DIO1/DIO2 configured as output) will be at a high state
continuously when the main input voltage (L1, L2, L3) is not connected and an
external 24 V DC supply is used for digital output source (DIO SRC).
• Analog output (AO) will be at the maximum voltage reference level (+10 V) for
a short time (<20 ms) after the main input voltage (L1, L2, L3) is connected.

￭ Fieldbus connection diagram

This connection diagram is valid for drives with a fieldbus extension module. The
type code is ACS380-04xC followed by an option code that designates the extension
module.
110 Electrical installation – North America

Connection Term. Description

Digital I/O and relay output connections

+24V Aux. voltage output +24 V DC, max. 250 mA
+24V
DGND Aux. voltage output common
DGND
DCOM DCOM Digital input common
DI1 DI1 Fault reset (operates also through the fieldbus inter-
DI2 face)
DI2 Not configured
RC RC Relay output 1
RA No fault [Fault (-1)]
RA
RB
RB
Safe torque off (STO)
S+ Safe torque off function. Factory connection. Both
S+ circuits must be closed for the drive to start.
SGND
SGND
S1 S1
S2 S2

Fieldbus connection
See the applicable fieldbus Terminal +K451 FDNA-01, DeviceNet
adapter manual. block
DSUB9 +K454 FPBA-01 Profibus DP
DSUB9 +K457 FCAN-01 CANopen
8P8C×2 +K462 FCNA-01 ControlNet
RJ45×2 +K469 FECA-01 EtherCAT
RJ45×2 +K470 FEPL-02, Ethernet Powerlink
RJ45×2 +K490 FEIP-21 Two-port Modbus/IP adapter
RJ45×2 +K491 FMBT-21 Two-port Modbus/TCP adapter
RJ45×2 +K492 FPNO-21 Two-port Profinet IO adapter
Terminal +K495 BCAN-11 CANopen interface
block

￭ Control cable connection procedure

Do the connections according to the control macro (parameter 96.04) used.
Keep the signal wire pairs twisted as near to the terminals as possible to prevent
inductive coupling.
 Electrical installation – North America 111

WARNING!
Obey the safety instructions of the drive. 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, commissioning or
maintenance work.

1. Do the steps in section Electrical safety precautions (page 20) before you start
the work.
2. Remove the screw on the drive front cover, then remove the front cover.
3. Strip a part of the outer shield of the control cable for grounding.
4. Use a cable tie to ground the outer shield to the grounding tab. For 360°
grounding, use metallic cable ties.
5. Strip the control cable conductors.
6. Connect the conductors to the correct control terminals. Torque the terminal
connections to 0.5 … 0.6 N·m (4.4 … 5.3 lbf·in).
7. Connect the shields and grounding wires to the SCR terminal. Torque the
terminal connection to 0.5 … 0.6 N·m (4.4 … 5.3 lbf·in).
8. Mechanically attach the control cables on the outside of the drive.

￭ Additional information on the control connections

Embedded EIA-485 fieldbus connection
The EIA-485 network uses shielded, twisted-pair cable with a characteristic
impedance of 100…130 ohm for data signaling. The distributed capacitance
between conductors is less than 100 pF per meter (30 pF per foot). Distributed
capacitance between conductors and shield is less than 200 pF per meter (60 pF
per foot). Foil or braided shields are acceptable.
112 Electrical installation – North America

Connect the cable to the EIA-485 terminal on the BMIO-01 I/O module. Obey these
wiring instructions:
• Attach the cable shields together at each drive, but do not connect them to
the drive.
• Connect the cable shields only to the grounding terminal in the automation
controller.
• Connect the signal ground (BGND) conductor to the signal ground reference
terminal in the automation controller. If the automation controller does not
have a signal ground reference terminal, connect the signal ground conductor
to the cable shield through a 100 ohm resistor, preferably near the automation
controller.
Connection examples are shown below.

With signal ground reference terminal

BGND

BGND

BGND
Shield

Shield

Shield
G R - +
B+

B+

B+
A-

A-

A-
1 2 3 2 3 2 3

Without signal ground reference terminal

100 ohm
BGND

BGND

BGND
Shield

Shield

Shield

G - +
B+

B+

B+
A-

A-

A-

1 2 3 2 3 2 3

1 Automation controller

2 Drive

3 Termination jumpers. The devices at the ends of the fieldbus must have termination
on. All other devices must have termination off.
 Electrical installation – North America 113

PNP configuration for digital inputs

Internal and external +24 V power supply connections for PNP (source) configuration
are shown in the figures below.

WARNING!
If you connect DIO1 or DIO2 as shown in the figures below, make sure that
they are configured as inputs. If they are configured as outputs, it can cause
damage to the equipment.

Internal +24 V power supply External +24 V power supply

+24 V +24 V
DGND 0 V DC DGND
DCOM DCOM
+24 V DC
DI1 DI1
DI2 DI2
DI3 DI3
DI4 DI4
DIO1 DIO1
DIO2 DIO2
114 Electrical installation – North America

NPN configuration for digital inputs

Internal and external +24 V power supply connections for NPN (sink) configuration
are shown in the figures below.

WARNING!
If you connect DIO1 or DIO2 as shown in the figures below, make sure that
they are configured as inputs. If they are configured as outputs, it can cause
damage to the equipment.

Internal +24 V power supply External +24 V power supply

+24 V +24 V
DGND +24 V DC DGND
DCOM DCOM
0 V DC
DI1 DI1
DI2 DI2
DI3 DI3
DI4 DI4
DIO1 DIO1
DIO2 DIO2

Connection examples of two-wire and three-wire sensors

The figures give examples of connections for a two-wire or three-wire
sensor/transmitter that is supplied by the auxiliary voltage output of the drive.

- 4…20 mA
P AI2

+ AGND
I

+24V
DGND

AI2 Process actual value measurement or reference, 0(4) … 20 mA, Rin = 137 ohm. If
the sensor power supply comes through its current output circuit, use 4 … 20 mA
AGND
signal, not 0 … 20 mA.
+24V Auxiliary voltage output, non-isolated, +24 V DC, max. 250 mA
DGND
 Electrical installation – North America 115

OUT (0)4…20 mA
P AI2
-
AGND
I
+
+24V
DGND

AI2 Process actual value measurement or reference, 0(4)…20 mA, Rin = 137 ohm
AGND
+24V Auxiliary voltage output, non-isolated, +24 V DC, max. 250 mA
DGND

AI and AO (or AI, DI and +10 V) as PTC motor temperature sensor interface

WARNING!
IEC 61800-5-1 requires double or reinforced insulation between live parts
and accessible parts when:
• the accessible parts are not conductive, or
• the accessible parts are conductive, but not connected to the protective
earth.
Obey this requirement when you plan the connection of the motor
temperature sensor to the drive.

To comply with the drive safety standard IEC 61800-5-1:

If the motor temperature sensor has double or reinforced insulation vs. the motor
windings, you can connect it directly to the drive IO interface. This section shows
two connection alternatives for the direct I/O connection. If the sensor does not
have reinforced insulation, you must use another type of connection to comply
with the safety standard. See Implementing a motor temperature sensor
connection (page 68).
See the firmware manual for information on the related Motor thermal protection
function, and the required parameter settings.

PTC connection 1
1…3 PTC sensors can be connected in series to an analog input and an analog
output. Make sure that the voltage does not exceed the maximum allowed voltage
over the sensor. The analog output feeds a constant excitation current of 1.6 mA
through the sensor. The sensor resistance increases as the motor temperature
rises, as does the voltage over the sensor. The temperature measurement function
calculates the resistance of the sensor and generates an indication if
overtemperature is detected. Leave the sensor end of the cable shield unconnected.
116 Electrical installation – North America

AI
4
AGND

3
T T T
1 AO
5
AGND
2

1 Motor winding
2 Double or reinforced insulation
3 1…3 PTC sensors
4 Analog input. Set the analog input type to V (volt) in parameter group 12 Standard AI.
Define the temperature sensor type, signal source, etc. with parameters 35.11…35.24.
For the sensor type, select: PTC analog I/O.
5 Analog output. Select the Excitation mode for the analog output in parameter group
13 Standard AO.

PTC connection 2
If no analog output is available for the PTC connection, it is possible to use a voltage
divider connection. Make sure that the voltage does not exceed the maximum
allowed voltage over the sensor. 1…3 PTC sensors are connected in series with
10 V reference and digital and analog inputs. The voltage over the digital input
internal resistance varies depending on the PTC resistance. The temperature
measurement function reads the digital input voltage through the analog input
and calculates the PTC resistance.
 Electrical installation – North America 117

DI
4
AI

1 +10 V 5
T T T
2 DGND
3 DCOM

1 1…3 PTC sensors

2 Double or reinforced insulation
3 Motor winding
4 Digital input and analog input. Set the analog input type to V (volt) in parameter group
12 Standard AI. Define the temperature sensor type, signal source, etc. with parameters
35.11…35.24. For the sensor type, select: PTC AI/DI Voltage Divider tree. Make sure that
the digital input is not configured to any other use by parameters.
5 10 V reference voltage

AI1 and AI2 as Pt100, Pt1000, Ni1000, KTY83 and KTY84 sensor inputs

WARNING!
IEC 61800-5-1 requires double or reinforced insulation between live parts
and accessible parts when:
• the accessible parts are not conductive, or
• the accessible parts are conductive, but not connected to the protective
earth.
Obey this requirement when you plan the connection of the motor
temperature sensor to the drive.

To comply with the drive safety standard IEC 61800-5-1:

If the motor temperature sensor has double or reinforced insulation vs. the motor
windings, you can connect it directly to the drive IO interface. This section shows
the connection. If the sensor has no reinforced insulation, you must use another
type of connection to comply with the safety standard. See Implementing a motor
temperature sensor connection (page 68).
You can connect temperature measurement sensors (one, two or three Pt100
sensors; one, two or three Pt1000 sensors; or one Ni1000, KTY83 or KTY84) between
an analog input and output as shown below. Make sure that the voltage does not
exceed the maximum allowed voltage over the sensor. Leave the sensor end of
the cable shield unconnected.
118 Electrical installation – North America

See the firmware manual for information on the related Motor thermal protection
function.

AI
4
AGND

3
T T T
1 AO
5
AGND
2

1 Motor winding
2 Double or reinforced insulation
3 1…3 × (Pt100 or Pt1000) or 1 × (Ni1000 or KTY83 or KTY84)
4 Analog input. Set the analog input type to V (volt) in parameter group 12 Standard AI.
Define the temperature sensor type, signal source, etc. with parameters 35.11…35.24.
Set the analog input type to V (volt) in parameter group 12 Standard AI.
5 Analog output. Select the Excitation mode for the analog output in parameter group
13 Standard AO.

Safe torque off

For the drive to start, both STO connections (S+ to S1 and S+ to S2) must be closed.
By default, the terminal block has jumpers to close the circuit. Remove the jumpers
before connecting external Safe torque off circuitry to the drive. See chapter The
Safe torque off function.

Auxiliary voltage connection

The drive has 24 V DC (±10%) auxiliary power supply terminals both on the base
unit and on the BMIO-01 module. You can use them:
• to supply auxiliary power from the drive to external control circuits or option
modules
• to supply external auxiliary power to the drive to keep the control and cooling
in operation if there is a power outage.
See the technical data for the specifications for the auxiliary power supply terminals
(input/output).
To supply power to external control circuits or option modules:
1. Connect the load either to the auxiliary power output on the base unit, or on
the BMIO-01 module (+24V and DGND terminals).
2. Make sure that you do not exceed the load capacity of the output, or the sum
load capacity of both outputs.
 Electrical installation – North America 119

To connect an external auxiliary power supply to the drive:

1. Install a BAPO-01 power extension module to the drive. See Installing
options (page 92).
2. Connect an external power supply to the +24V and DGND terminals of the base
unit.
For more information on the BAPO-01 module, see BAPO-01 auxiliary power
extension module (page 285).
+24V DGND DCOM SGND S+

DI1
DI2
RC
S1
RA
S2
RB

Connecting a PC
To connect a PC to the drive, there are two alternatives:
• Use an ACS-AP-I/S/W assistant control panel as a converter. Use a USB type
A – type Mini-B cable. The maximum permitted length of the cable is 3 m (9.8 ft).
• Use a USB to RJ45 converter. You can order it from ABB (BCBL-01,
3AXD50000032449). Connect the cable to the Panel and PC tool port (RJ45).
For information on the Drive Composer PC tool, refer to Drive Composer PC tool
user's manual (3AUA0000094606 [English]).
You can use the CCA-01 cold configuration tool to download software and change
drive parameters without connecting the drive to the input power. The CCA-01
does not operate if the drive is powered. Refer to CCA-01 communication adapter
quick installation guide (3AXD50000018457 [English]) for more information.

Installing options
The drive has two option module slots:
• Front option: Communication module slot under the front cover.
120 Electrical installation – North America

• Side option: Multifunction extension module slot on the side of the drive.
Refer also to the applicable fieldbus module manual for the installation instructions.
For other option modules, refer to:
• BTAC-02 pulse encoder interface module (page 255)
• BRES-01 resolver interface module (page 271)
• BREL-01 relay output extension module (page 279)
• BAPO-01 auxiliary power extension module (page 285)
• BIO-01 I/O extension module (page 289).

￭ Installing a front option

WARNING!
Obey the safety instructions of the drive. 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, commissioning or
maintenance work.

1. Do the steps in section Electrical safety precautions (page 20) before you start
the work.
2. Remove the screw on the drive front cover, then remove the front cover.
3. If the option module has a locking tab, pull it up.
4. Carefully align the option module with the option module slot and push it into
position.
 Electrical installation – North America 121

5. Torque the screw to 0.5 N·m (4.4 lbf·in).

6. If the option module has a locking tab, push it down until it locks.

7. Connect the control cables. See the control cable connection instructions.

Note: If you have the BIO-01 option module, you can add one additional fieldbus
module on top of it. Replace the drive front cover with the high cover that comes
with the BIO-01 module.

￭ Installing a side option

WARNING!
Obey the safety instructions of the drive. 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, commissioning or
maintenance work.

1. Do the steps in section Electrical safety precautions (page 20) before you start
the work.
2. Remove the two screws from the front-most grounding clamp at the bottom
of the drive.
3. Carefully align the side option with the connectors on the right side of the
drive.
122 Electrical installation – North America

4. Fully push the option module into position.

5. Torque the screw on the option module to 1 N·m (8.8 lbf·in).
6. Attach the grounding bar to the bottom of the side option and to the front
ground tab on the drive. Torque the screws to 1 N·m (8.8 lbf·in).
7. Connect the control cables. See the control cable connection instructions.

3
6 5

4 7

2
 Installation checklist 123

8
Installation checklist

Contents of this chapter

This chapter contains a checklist for the mechanical and electrical installation of
the drive.

Checklist
Examine the mechanical and electrical installation of the drive before start-up. Go
through the checklist together with another person.

WARNING!
Obey the safety instructions of the drive. 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, commissioning or
maintenance work.

WARNING!
Stop the drive and do the steps in section Electrical safety
precautions (page 20) before you start the work.

Make sure that …

The ambient operating conditions meet the drive ambient conditions specification
and enclosure rating (IP code).

The supply voltage matches the nominal input voltage of the drive. See the type
designation label.
124 Installation checklist

Make sure that …

The insulation resistance of the input power cable, motor cable and motor is meas-
ured according to local regulations and the manuals of the drive.

The drive is attached securely on an even, vertical and non-flammable wall.

The cooling air can flow freely in and out of the drive.

If the drive is connected to a network other than a symmetrically grounded TN-S

system: You have done all the required modifications (for example, you may need
to disconnect the EMC filter or ground-to-phase varistor) the electrical installation
instructions.

Appropriate AC fuses and main disconnecting device are installed.

There is an adequately sized protective earth (ground) conductor(s) between the

drive and the switchboard, the conductor is connected to correct terminal, and the
terminal is tightened to the correct torque.
Grounding has also been measured according to the regulations.

The input power cable is connected to the correct terminals, the phase order is
correct, and the terminals are tightened to the correct torque.

There is an adequately sized protective earth (ground) conductor between the motor
and the drive. The conductor is connected to the correct terminal, and the terminal
is tightened to the correct torque.
Grounding has also been measured according to the regulations.

The motor cable is connected to the correct terminals, the phase order is correct,
and the terminals are tightened to the correct torque.

The motor cable is routed away from other cables.

No power factor compensation capacitors are connected to the motor cable.

If an external brake resistor is connected to the drive: There is an adequately sized

protective earth (ground) conductor between the brake resistor and the drive, and
the conductor is connected to the correct terminal, and the terminals are tightened
to the correct torque. Grounding has also been measured according to the regula-
tions.

If an external brake resistor is connected to the drive: The brake resistor cable is
connected to the correct terminals, and the terminals are tightened to the correct
torque.

If an external brake resistor is connected to the drive: The brake resistor cable is
routed away from other cables.
 Installation checklist 125

Make sure that …

The control cables are connected to the correct terminals, and the terminals are
tightened to the correct torque.

If a drive bypass connection will be used: The direct-on-line contactor of the motor
and the drive output contactor are either mechanically and/or electrically interlocked,
that is, they cannot be closed at the same time. A thermal overload device must be
used for protection when bypassing the drive. Refer to local codes and regulations.

There are no tools, foreign objects or dust from drilling inside the drive.

The area in front of the drive is clean: the drive cooling fan cannot draw any dust or
dirt inside.

Drive covers and the terminal box cover of the motor are in place.

The motor and the driven equipment are ready for power-up.
126
 Maintenance 127

9
Maintenance

Contents of this chapter

The chapter contains maintenance intervals and instructions.

Maintenance intervals
The tables below show the maintenance tasks which can be done by the end user.
For ABB Service offering, refer to www.abb.com/drivesservices or consult your
local ABB Service representative (www.abb.com/searchchannels).

￭ Description of symbols
Action Description

I Inspection (visual inspection and maintenance action if needed)

P Performance of on/off-site work (commissioning, tests, measurements or

other work)

R Replacement

￭ Recommended maintenance intervals after start-up

Recommended annual actions by the user

Connections and environment

Quality of supply voltage P
128 Maintenance

Recommended annual actions by the user

Spare parts
Spare parts I
DC circuit capacitors reforming for spare modules and spare capacitors P
Inspections by user
Tightness of terminals I
Dustiness, corrosion and temperature I
Heat sink cleaning P

Maintenance task/object Years from start-up

3 6 9 12 15 18 21

Cooling fans

Main cooling fan 1) (R) R (R) R (R) R (R)

(R) (R) (R)
Functional safety
Safety function test I
See the maintenance information of the safety function.
Safety component expiry (Mis- 20 years
sion time TM)
1) (R) = replacement of component in demanding operating conditions, ie. if surrounding air temperature
in continuous operation is over 40 °C (104 °F) or there is a cyclic heavy load.

Note:
• Maintenance and component replacement intervals are based on the
assumption that the equipment is operated within the specified ratings and
ambient conditions. ABB recommends annual drive inspections to ensure the
highest reliability and optimum performance.
• Long term operation near the specified maximum ratings or ambient conditions
may require shorter maintenance intervals for certain components. Consult
your local ABB Service representative for additional maintenance
recommendations.

Functional safety components

The mission time of functional safety components is 20 years which equals the
time during which failure rates of electronic components remain constant. This
applies to the components of the standard Safe torque off circuit as well as any
modules, relays and, typically, any other components that are part of functional
safety circuits.
 Maintenance 129

The expiry of mission time terminates the certification and SIL/PL classification
of the safety function. The following options exist:
• Renewal of the whole drive and all optional functional safety module(s) and
components.
• Renewal of the components in the safety function circuit. In practice, this is
economical only with larger drives that have replaceable circuit boards and
other components such as relays.
Note that some of the components may already have been renewed earlier,
restarting their mission time. The remaining mission time of the whole circuit is
however determined by its oldest component.
Contact your local ABB service representative for more information.

Cleaning the heatsink

The drive module heatsink fins pick up dust from the cooling air. The drive runs
into overtemperature warnings and faults if the heatsink is not clean. When
necessary, clean the heatsink as follows.

WARNING!
Use the required personal protective equipment. Wear protective gloves and
long sleeves. Some parts have sharp edges.

WARNING!
Use a vacuum cleaner with antistatic hose and nozzle, and wear a grounding
wristband. Using a normal vacuum cleaner creates static discharges which
can damage circuit boards.

1. Stop the drive and do the steps in section Electrical safety

precautions (page 20) before you start the work.
2. Remove the module cooling fan(s). See the separate instructions.
3. Protect the adjacent equipment from dust.
4. Blow dry, clean and oil-free compressed air from bottom to top and
simultaneously use a vacuum cleaner at the air outlet to trap the dust.
5. Reinstall the cooling fan.

Replacing the cooling fans

These instructions are applicable only to drives with frame size R1…R4. Drives with
frame size R0 do not have a cooling fan.
Parameter 05.04 Fan on-time counter shows the running time of the cooling fan.
After you replace the fan, reset the fan counter. Refer to the firmware manual.
130 Maintenance

You can get replacement fans from ABB. Use only ABB specified spare parts.

￭ Replacing the cooling fan, frames R1…R3

WARNING!
Obey the safety instructions of the drive. 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, commissioning or
maintenance work.

1. Stop the drive and do the steps in section Electrical safety

precautions (page 20) before you start the work.
2. Use a suitable flat screwdriver to open the fan cover.
3. Carefully lift the fan cover out of the drive. The fan cover holds the cooling fan.

4. Remove the fan power cable from the cable slot in the drive.
5. Disconnect the fan power cable.

6. Free the fan clips and remove the fan from the fan cover.
 Maintenance 131

7. Install the new fan into the fan cover. Make sure that the air flow is in the correct
direction. The air flows in from the bottom of the drive and out from the top
of the drive.

6
7

8. Connect the fan power cable.

9. Put the fan power cable into the cable slot in the drive.

9
8

10. Carefully put the fan cover into position in the drive. Make sure that the fan
power cable is routed correctly.
11. Push the cover to lock into position.

10

11
132 Maintenance

￭ Replacing the cooling fan, frame R4

WARNING!
Obey the safety instructions of the drive. 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, commissioning or
maintenance work.

1. Stop the drive and do the steps in section Electrical safety

precautions (page 20) before you start the work.
2. Use a suitable flat screwdriver to open the fan cover.

3. Lift out the fan cover and set it aside.

4. Lift and pull the fan from its base.

5. Disconnect the fan power cable from the extension cable connector.

5
 Maintenance 133

6. Replace the fan. The arrow indicating the air flow direction must point up.
7. Connect the fan power cable.

6
7

8. Place the fan cover back on the frame.

9. Push the cover to lock into position.

8 9

Capacitors
The intermediate DC circuit of the drive contains several electrolytic capacitors.
Operating time, load, and surrounding air temperature have an effect on the life
of the capacitors. Capacitor life can be extended by decreasing the surrounding
air temperature.
Capacitor failure is usually followed by damage to the unit and an input cable fuse
failure, or a fault trip. If you think that any capacitors in the drive have failed,
contact ABB.

￭ Reforming the capacitors

The capacitors must be reformed if the drive has not been powered (either in
storage or unused) for a year or more. The manufacturing date is on the type
designation label. For information on reforming the capacitors, refer to Capacitor
reforming instructions (3BFE64059629 [English]).
134
 Technical data 135

10
Technical data

Contents of this chapter

This chapter contains the technical specifications of the drive including the ratings,
sizes and technical requirements, provisions for fulfilling the requirements for CE,
UL and other approval marks.

Electrical ratings
￭ IEC ratings
Type Input current Output ratings Frame
ACS380- size
04xx-… No With Max. Nominal use Light-duty Heavy-duty
choke choke cur- use use
rent

I1n I1n Imax In Pn ILd PLd IHd PHd

A A A A kW A kW A kW

1-phase Un = 230 V
02A4-1 5.3 4.2 3.2 2.4 0.37 2.3 0.37 1.8 0.25 R0
03A7-1 7.0 6.4 4.3 3.7 0.55 3.5 0.55 2.4 0.37 R0
04A8-1 8.9 8.3 6.7 4.8 0.75 4.6 0.75 3.7 0.55 R1
06A9-1 11.5 11.9 8.6 6.9 1.1 6.6 1.1 4.8 0.75 R1
07A8-1 14.7 13.5 12.4 7.8 1.5 7.4 1.5 6.9 1.1 R1
09A8-1 19.8 17.0 14.0 9.8 2.2 9.3 2.2 7.8 1.5 R2
136 Technical data

Type Input current Output ratings Frame

ACS380- size
04xx-… No With Max. Nominal use Light-duty Heavy-duty
choke choke cur- use use
rent

I1n I1n Imax In Pn ILd PLd IHd PHd

A A A A kW A kW A kW

12A2-1 25.6 21.1 17.6 12.2 3.0 11.6 3.0 9.8 2.2 R2
3-phase Un = 230 V
02A4-2 3.4 2.4 3.2 2.4 0.37 2.3 0.37 1.8 0.25 R1
03A7-2 4.5 3.7 4.3 3.7 0.55 3.5 0.55 2.4 0.37 R1
04A8-2 5.7 4.8 6.7 4.8 0.75 4.6 0.75 3.7 0.55 R1
06A9-2 7.8 6.9 8.6 6.9 1.1 6.6 1.1 4.8 0.75 R1
07A8-2 9.3 7.8 12.4 7.8 1.5 7.5 1.5 6.9 1.1 R1
09A8-2 12.8 9.8 14.0 9.8 2.2 9.3 2.2 7.8 1.5 R1
12A2-2 16.0 12.2 17.6 12.2 3.0 11.6 3.0 9.8 2.2 R2
17A5-2 20.7 17.5 22.0 17.5 4.0 16.7 4.0 12.2 3.0 R3
25A0-2 27.2 25.0 31.5 25.0 5.5 24.2 5.5 17.5 4.0 R3
033A-2 35.0 32.0 45.0 32.0 7.5 30.8 7.5 25.0 5.5 R3
032A-2 34.9 32.0 45.0 32.0 7.5 30.8 7.5 25.0 5.5 R4
048A-2 47.8 48.0 57.6 48.0 11.0 46.2 11.0 32.0 7.5 R4
055A-2 60.0 55.0 86.4 55.0 15.0 52.8 15.0 48.0 11.0 R4
3-phase Un = 400 V
01A8-4 2.8 1.8 2.2 1.8 0.55 1.7 0.55 1.2 0.37 R0
02A6-4 3.5 2.6 3.2 2.6 0.75 2.5 0.75 1.8 0.55 R1
03A3-4 4.8 3.3 4.7 3.3 1.1 3.1 1.1 2.6 0.75 R1
04A0-4 6.1 4.0 5.9 4.0 1.5 3.8 1.5 3.3 1.1 R1
05A6-4 8.5 5.6 7.2 5.6 2.2 5.3 2.2 4.0 1.5 R1
07A2-4 10.1 7.2 10.1 7.2 3.0 6.8 3.0 5.6 2.2 R1
09A4-4 12.9 9.4 13.0 9.4 4.0 8.9 4.0 7.2 3.0 R1
12A6-4 16.5 12.6 16.9 12.6 5.5 12.0 5.5 9.4 4.0 R2
17A0-4 23.4 17.0 22.7 17.0 7.5 16.2 7.5 12.6 5.5 R3
25A0-4 31.8 25.0 30.6 25.0 11.0 23.8 11.0 17.0 7.5 R3
033A-4 40.9 32.0 45.0 32.0 15.0 30.5 15.0 25.0 11.0 R3
 Technical data 137

Type Input current Output ratings Frame

ACS380- size
04xx-… No With Max. Nominal use Light-duty Heavy-duty
choke choke cur- use use
rent

I1n I1n Imax In Pn ILd PLd IHd PHd

A A A A kW A kW A kW

032A-4 40.7 32.0 45.0 32.0 15.0 30.5 15.0 25.0 11.0 R4
038A-4 49.0 38.0 57.6 38.0 18.5 36.0 18.5 32.0 15.0 R4
045A-4 55.7 45.0 68.4 45.0 22.0 42.8 22.0 38.0 18.5 R4
050A-4 55.7 50.0 81.0 50.0 22.0 48.0 22.0 45.0 22.0 R4

￭ UL (NEC) ratings
Type Input current Output ratings Frame
ACS380- size
04xx-… No With Max. Light-duty use Heavy-duty use
choke choke current

I1Ld I1Ld Imax ILd PLd IHd PHd

A A A A hp A hp

1-phase U1 = 208…240 V, P and I1 at Un = 208 V

02A4-1 5.5 4.0 3.2 2.3 0.5 1.8 0.33 R0
03A7-1 7.4 6.1 4.3 3.5 0.75 2.3 0.5 R0
04A8-1 9.1 8.0 6.7 4.6 1.0 3.5 0.75 R1
06A9-1 12.6 11.4 8.6 6.6 1.5 4.6 1.0 R1
07A8-1 14.9 12.8 12.4 7.5 2.0 6.6 1.5 R1
09A8-1 14.8 12.8 14.0 9.3 2.0 7.5 2.0 R2
12A2-1 21.0 20.1 17.6 11.6 3.0 9.3 3.0 R2
3-phase U1 = 208…240 V, P and I1 at Un = 208 V
02A4-2 3.5 2.3 3.2 2.3 0.5 1.8 0.33 R1
03A7-2 4.8 3.5 4.3 3.5 0.75 2.4 0.5 R1
04A8-2 5.8 4.6 6.7 4.6 1.0 3.2 0.75 R1
06A9-2 8.4 6.6 8.6 6.6 1.5 4.6 1.0 R1
07A8-2 9.4 7.5 12.4 7.5 2.0 6.6 1.5 R1
09A8-2 9.4 7.5 14.0 9.3 2.0 7.5 2.0 R1
12A2-2 13.1 11.6 17.6 11.6 3.0 9.3 3.0 R2
138 Technical data

Type Input current Output ratings Frame

ACS380- size
04xx-… No With Max. Light-duty use Heavy-duty use
choke choke current

I1Ld I1Ld Imax ILd PLd IHd PHd

A A A A hp A hp

17A5-2 21.0 16.7 22.0 16.7 5.0 11.6 3.0 R3

25A0-2 30.5 24.2 31.5 24.2 7.5 16.7 5.0 R3
033A-2 37.5 30.8 45.0 30.8 10.0 24.2 7.5 R3
032A-2 37.4 30.8 45.0 30.8 10.0 24.2 7.5 R4
048A-2 53.2 46.2 57.6 46.2 15.0 30.8 10.0 R4
055A-2 53.2 46.2 86.4 52.8 15.0 46.2 15.0 R4
3-phase Un = 480 V
01A8-4 2.2 1.6 2.2 1.6 0.75 1.1 0.50 R0
02A6-4 2.7 2.1 3.2 2.1 1.0 1.6 0.75 R1
03A3-4 3.9 3.0 4.7 3.0 1.5 2.1 1.0 R1
04A0-4 4.5 3.4 5.9 3.4 2.0 3.0 1.5 R1
05A6-4 6.6 4.8 7.2 4.8 3.0 3.5 2.0 R1
07A2-4 6.2 6.0 10.1 6.0 3.0 4.8 3.0 R1
09A4-4 9.8 7.6 13.0 7.6 5.0 6.0 3.0 R1
12A6-4 13.9 11.0 16.9 11.0 7.5 7.6 5.0 R2
17A0-4 18.8 14.0 22.7 14.0 10.0 11.0 7.5 R3
25A0-4 26.6 21.0 30.6 21.0 15.0 14.0 10.0 R3
033A-4 33.9 27.0 45.0 27.0 20.0 21.0 15.0 R3
032A-4 33.7 27.0 45.0 27.0 20.0 21.0 15.0 R4
038A-4 41.3 34.0 57.6 34.0 25.0 27.0 20.0 R4
045A-4 46.9 40.0 68.4 40.0 30.0 34.0 25.0 R4
050A-4 46.9 42.0 81.0 42.0 30.0 40.0 30.0 R4

UL Listed multiple drive ratings

National Electric Code (NEC 2020) requires that drive input conductors are sized
based on the drive nameplate input current rating and the output conductors are
sized based on the full load motor current. There are several scenarios where this
sizing procedure is not optimal including multi-motor systems, applications where
a larger replacement drive is substituted in an emergency breakdown, and cases
 Technical data 139

where a motor is undersized for the drive. In these situations, power distribution
components are often oversized to comply with NEC requirements.
ABB has collaborated with Underwriters Laboratories (UL) to create multiple drive
ratings from 50% to 100% in 5% increments for the drive. For more information,
refer to Multiple ratings for ABB ACS380-04, ACS580-01, ACQ580-01 and ACS880-01
drives manual supplement (3AXD50000916184 [English]).

￭ Definitions
The ratings are valid at a maximum surrounding air temperature of 50 °C (122 °F),
with the default drive switching frequency of 4 kHz (parameter 97.01), and with
an installation altitude below 1000 m (3281 ft).
Un Nominal input voltage of the drive. For input voltage range U1, refer
to Electrical power network specification (page 166).
I1n Nominal input current with typical motor power Pn. Continuous rms
input current, for dimensioning cables and fuses. See also Input
chokes (page 217).
I1Ld Light-duty input current (rms) with typical motor power PLd, for
dimensioning cables and fuses.
Imax Maximum output current. Available for 2 seconds every 10 minutes
when the output frequency is less than 9 Hz. Otherwise maximum
current is 1.5 × IHd. Maximum current setting (parameter 30.17) can
also limit the value.
In Nominal output current. Maximum continuous rms output current
(no overload).
Pn Typical motor power in nominal use (no overloading). The kilowatt
ratings are applicable to most IEC 4-pole motors.
ILd Continuous rms output current. Allows 10% overload for 1 minute
every 10 minutes.
PLd Typical motor power in light-duty use (10% overload). The kilowatt
ratings are applicable to most IEC 4-pole motors. The horsepower
ratings are applicable to most NEMA 4-pole motors.
IHd Continuous rms output current. Allows 50% overload for 1 minute
every 10 minutes.
PHd Typical motor power in 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.
140 Technical data

￭ Sizing
ABB recommends the DriveSize tool for selecting the drive, motor and gear
combination (https://new.abb.com/drives/software-tools/drivesize). You can
also use the ratings tables.
The minimum recommended nominal current of the motor is 40% of the drive
nominal output current (In) (50% for drive type ACS380-04xx-01A8-4). If the motor
has a lower nominal current rating than this, the drive cannot accurately measure
the motor current.

Output derating
The load capacity (In, ILd, IHd) decreases in some operation conditions. In such
operation conditions, where full motor power is required, oversize the drive so
that the total derated output current is sufficient for the motor to reach the full
power.
In an environment where more than one type of derating is necessary (for example,
high altitude and high temperature), the effects of derating are cumulative.
Note:
• Imax is not derated.
• It is possible that also the motor load capacity needs to be derated.
• You can also use the DriveSize tool for derating.

See Surrounding air temperature derating (page 142), Altitude derating (page 142)
and Switching frequency derating (page 143) for the derating values.
Example 1, IEC: How to calculate the derated current
The drive type is ACS380-04xx-17A0-4, which has a nominal output current (In) of
17 A at 400 V. Calculate the derated output current at 4 kHz switching frequency,
at 1500 m altitude and at 55 °C surrounding air temperature.
Switching frequency derating: Derating is not necessary at 4 kHz.
Altitude derating: The derating factor for 1500 m is

Surrounding air temperature derating: The derating factor for 55 °C surrounding

air temperature is

Multiply the nominal drive output current by all the applicable derating factors. In
this example, the derated output current becomes
 Technical data 141

Example 1, UL (NEC): How to calculate the derated current

The drive type is ACS380-04xx-17A0-4, which has light-duty output current (ILd) of
14 A at 480 V. Calculate the derated output current at 4 kHz switching frequency,
at 6000 ft altitude and at 131 °F surrounding air temperature.
Switching frequency derating: Derating is not necessary at 4 kHz.
Altitude derating: The derating factor for 6000 ft is

Surrounding air temperature derating: The derating factor for 131 °F surrounding
air temperature is

Multiply the drive output current by all the applicable derating factors. In this
example, the derated output current becomes

Example 2, IEC: How to calculate the required drive

The application requires a nominal motor current of 6.0 A at a switching frequency
of 8 kHz. The supply voltage is 400 V, the altitude is 1800 m and the surrounding
air temperature is 35 °C.
Altitude derating: The derating factor for 1800 m is

Surrounding air temperature derating: Derating is not necessary at 35 °C

surrounding air temperature.
To see if the derated output current of a drive is sufficient for the application,
multiply the nominal output current (In) by all the applicable derating factors. For
example, drive type ACS380-04xx-12A6-4 has a nominal output current of 12.6 A
at 400 V.
Switching frequency derating: The derating factor for this drive type is 0.68 at
8 kHz. Calculate the derated drive output current:

In this example, the derated output current is sufficient, because it is higher than
the required current.
Example 2, UL (NEC): How to calculate the required drive
The application requires a maximum of 12.0 A of motor current with a 10% overload
for one minute every ten minutes (ILd) at a switching frequency of 8 kHz. The supply
voltage is 480 V, the altitude is 5500 ft and the surrounding air temperature is
95 °F.
142 Technical data

Altitude derating: The derating factor for 5500 ft is

Surrounding air temperature derating: Derating is not necessary at 95 °F

surrounding air temperature.
To see if the derated output current of a drive is sufficient for the application,
multiply the drive output current for light-duty use (ILd) by all the applicable derating
factors. For example, drive type ACS380-04xx-25A0-4 has an output current of
21 A at 480 V.
Switching frequency derating:The derating factor for this drive type is 0.67 at
8 kHz. Calculate the derated drive output current:

In this example, the derated output current is sufficient, because it is higher than
the required current.

￭ Surrounding air temperature derating

Frame Temperature Derating

Less than 50 °C No derating

All
(122 °F)
R1…R3 50 … 60 °C Output current decreases by 1% for each additional 1 °C
(122 … 140 °F) (1.8 F).
ACS380-04-033A-2 and ACS380-04-033A-4:
• UL standard installations - output current decreases by
2% for each additional 1 °C (1.8 °F).
• IEC standard installations - output current decreases
by 1% for each additional 1 °C (1.8 F).
R4 50 … 60 °C Output current decreases by 1% for each additional 1 °C
(122 … 140 °F) (1.8 F) on:
• ACS380-04xx-032A-2
• ACS380-04xx-048A-2
• ACS380-04xx-032A-4
• ACS380-04xx-045A-4
Output current decreases by 2% for each additional 1 °C
(1.8 F) on:
• ACS380-04xx-055A-2
• ACS380-04xx-038A-4
• ACS380-04xx-050A-4

￭ Altitude derating
230 V drives: At altitudes 1000 … 2000 m (3281 … 6562 ft) above sea level, the
derating is 1% for each added 100 m (328 ft) above 1000 m (3281 ft).
 Technical data 143

400/480 V drives: At altitudes 1000 … 4000 m (3281 … 13123 ft) above sea level,
the derating is 1% for each added 100 m (328 ft) above 1000 m (3281 ft). In addition:
• A maximum altitude of 4000 m (13123 ft) is permitted for these grounding
systems: TN-S, TT. A maximum altitude of 2000 m (6562 ft) is permitted for
these grounding systems: corner-grounded delta, midpoint-grounded delta,
IT (ungrounded).
• Above 2000 m (6562 ft), the maximum permitted voltage for the relay output
RO1 decreases. At 4000 m (13123 ft), it is 30 V.
• Above 2000 m (6562 ft), the maximum permitted potential difference between
the adjacent relays of the BREL-01 relay extension module (option +L511)
decreases. At 4000 m (13123 ft), it is 30 V.
To calculate the derated output current, multiply the current in the ratings table
with the derating factor k, which for x meters or feet is:

￭ Switching frequency derating

Derating the drive output current is necessary when using high minimum switching
frequencies. If you change parameter 97.02 Minimum switching frequency, calculate
the derated current. Multiply the drive output current with the applicable derating
factor from the table.
Derating is not necessary when changing parameter 97.01 Switching frequency
reference.
Frame R4: If the application is cyclic and the surrounding air temperature is
constantly more than 40 °C (104 °F), keep parameter 97.02 Minimum switching
frequency at its default value (1.5 kHz). Higher switching frequencies decrease the
product life time or the performance in the temperature range 40 … 60 °C
(104 … 140 °F).

Type Derating factor

ACS380-
< 4 kHz 8 kHz 12 kHz
04xx-…

1-phase Un = 230 V
02A4-1 1.0 0.80 0.66
03A7-1 1.0 0.80 0.66
04A8-1 1.0 0.81 0.68
06A9-1 1.0 0.81 0.68
07A8-1 1.0 0.85 0.74
144 Technical data

Type Derating factor

ACS380-
< 4 kHz 8 kHz 12 kHz
04xx-…

09A8-1 1.0 0.85 0.74

12A2-1 1.0 0.82 0.69
3-phase Un = 230 V
02A4-2 1.0 0.84 0.73
03A7-2 1.0 0.84 0.73
04A8-2 1.0 0.84 0.73
06A9-2 1.0 0.84 0.73
07A8-2 1.0 0.83 0.70
09A8-2 1.0 0.83 0.70
12A2-2 1.0 0.76 0.61
17A5-2 1.0 0.76 0.61
25A0-2 1.0 0.75 0.60
033A-2 1.0 0.83 0.70
032A-2 1.0 0.75 0.59
048A-2 1.0 0.74 0.60
055A-2 1.0 0.74 0.60
3-phase Un = 400 V or 480 V
01A8-4 1.0 0.65 0.48
02A6-4 1.0 0.65 0.48
03A3-4 1.0 0.65 0.48
04A0-4 1.0 0.65 0.48
05A6-4 1.0 0.65 0.48
07A2-4 1.0 0.65 0.48
09A4-4 1.0 0.65 0.48
12A6-4 1.0 0.68 0.51
17A0-4 1.0 0.68 0.51
25A0-4 1.0 0.67 0.51
033A-4 1.0 0.77 0.60
032A-4 1.0 0.65 0.49
038A-4 1.0 0.65 0.49
 Technical data 145

Type Derating factor

ACS380-
< 4 kHz 8 kHz 12 kHz
04xx-…

045A-4 1.0 0.66 0.49

050A-4 1.0 0.66 0.49

￭ Derating in case of a phase loss

In case of a phase loss the drive will function according to the settings of parameter
31.21 Supply phase loss.
If No action is selected, the drive will eventually overheat or the supply bridge may
be damaged if one supply phase is lost, unless 50% derating is done when
dimensioning the system.

Fuses
The tables list the fuses for protection against short-circuits in the input power
cable or drive. The operating time depends on the supply network impedance, and
the cross-sectional area and length of the supply cable.
Do not use fuses that have a higher current rating than specified in the table. You
can use fuses from other manufacturers, if they meet the ratings, and if the melting
curve of the fuse does not exceed the melting curve of the fuse mentioned in the
table.

￭ IEC fuses
Either fuse type can be used if it operates rapidly enough.

gG fuses
Make sure that the operating time of the fuse is less than 0.5 seconds. Obey the
local regulations.

Type Min. Fuses

ACS380- short-cir-
04xx-… Nominal Voltage
cuit cur- I2t IEC 60269
rent 1) current rating ABB type
size
A A A2s V

1-phase Un = 230 V
02A4-1 80 10 380 500 OFAF000H10 000
03A7-1 80 10 380 500 OFAF000H10 000
04A8-1 128 16 720 500 OFAF000H16 000
06A9-1 200 20 1500 500 OFAF000H20 000
146 Technical data

Type Min. Fuses

ACS380- short-cir-
04xx-… Nominal Voltage
cuit cur- I2t IEC 60269
rent 1) current rating ABB type
size
A A A2s V

07A8-1 200 25 2500 500 OFAF000H25 000

09A8-1 256 32 2500 500 OFAF000H32 000
12A2-1 320 35 7000 500 OFAF000H35 000
3-phase Un = 230 V
02A4-2 48 6 110 500 OFAF000H6 000
03A7-2 80 10 360 500 OFAF000H10 000
04A8-2 80 10 360 500 OFAF000H10 000
06A9-2 128 16 740 500 OFAF000H16 000
07A8-2 128 16 740 500 OFAF000H16 000
09A8-2 128 16 740 500 OFAF000H16 000
12A2-2 200 25 2500 500 OFAF000H25 000
17A5-2 256 32 4500 500 OFAF000H32 000
25A0-2 400 50 15500 500 OFAF000H50 000
033A-2 504 63 20000 500 OFAF000H63 000
032A-2 504 63 20000 500 OFAF000H63 000
048A-2 800 100 65000 500 OFAF000H100 000
055A-2 800 100 65000 500 OFAF000H100 000
3-phase Un = 400 V
01A8-4 32 4 55 500 OFAF000H4 000
02A6-4 48 6 110 500 OFAF000H6 000
03A3-4 48 6 110 500 OFAF000H6 000
04A0-4 80 10 360 500 OFAF000H10 000
05A6-4 80 10 360 500 OFAF000H10 000
07A2-4 128 16 740 500 OFAF000H16 000
09A4-4 128 16 740 500 OFAF000H16 000
12A6-4 200 25 2500 500 OFAF000H25 000
17A0-4 256 32 4500 500 OFAF000H32 000
25A0-4 400 50 15500 500 OFAF000H50 000
 Technical data 147

Type Min. Fuses

ACS380- short-cir-
04xx-… Nominal Voltage
cuit cur- I2t IEC 60269
rent 1) current rating ABB type
size
A A A2s V

033A-4 504 63 20000 500 OFAF000H63 000

032A-4 504 63 20000 500 OFAF000H63 000
038A-4 640 80 36000 500 OFAF000H80 000
045A-4 800 100 65000 500 OFAF000H100 000
050A-4 800 100 65000 500 OFAF000H100 000
1) Minimum permitted short-circuit current of the electrical power network

gR fuses

Type Min. Fuses

ACS380- short-cir-
04xx-… Nominal Voltage
cuit cur- I2t IEC 60269
rent 1) current rating Bussmann type
size
A A A2s V

1-phase Un = 230 V
02A4-1 80 32 275 690 170M2695 00
03A7-1 80 32 275 690 170M2695 00
04A8-1 128 40 490 690 170M2696 00
06A9-1 200 50 1000 690 170M2697 00
07A8-1 200 63 1800 690 170M2698 00
09A8-1 256 63 1800 690 170M2698 00
12A2-1 320 63 1800 690 170M2698 00
3-phase Un = 230 V
02A4-2 48 25 125 690 170M2694 00
03A7-2 80 32 275 690 170M2695 00
04A8-2 80 32 275 690 170M2695 00
06A9-2 128 40 490 690 170M2696 00
07A8-2 128 40 490 690 170M2696 00
09A8-2 128 40 490 690 170M2696 00
12A2-2 200 50 1000 690 170M2697 00
17A5-2 256 63 1800 690 170M2698 00
148 Technical data

Type Min. Fuses

ACS380- short-cir-
04xx-… Nominal Voltage
cuit cur- I2t IEC 60269
rent 1) current rating Bussmann type
size
A A A2s V

25A0-2 400 80 3600 690 170M2699 00

033A-2 504 100 6650 690 170M2700 00
032A-2 504 100 6650 690 170M2700 00
048A-2 800 160 22500 690 170M2702 00
055A-2 800 160 22500 690 170M2702 00
3-phase Un = 400 V
01A8-4 32 25 125 690 170M2694 00
02A6-4 48 25 125 690 170M2694 00
03A3-4 48 25 125 690 170M2694 00
04A0-4 80 32 275 690 170M2695 00
05A6-4 80 32 275 690 170M2695 00
07A2-4 128 40 490 690 170M2696 00
09A4-4 128 40 490 690 170M2696 00
12A6-4 200 50 1000 690 170M2697 00
17A0-4 256 63 1800 690 170M2698 00
25A0-4 400 80 3600 690 170M2699 00
033A-4 504 100 6650 690 170M2700 00
032A-4 504 100 6650 690 170M2700 00
038A-4 640 125 12000 690 170M2701 00
045A-4 800 160 22500 690 170M2702 00
050A-4 800 160 22500 690 170M2702 00
1) Minimum permitted short-circuit current of the electrical power network

￭ UL (NEC) fuses
The UL listed fuses in the table are the required branch circuit protection. Fuses
must be provided as part of the installation.
 Technical data 149

Type Fuses
ACS380-
04xx-… Nominal cur- Max. fuse rat-
Voltage rating Bussmann/ ing for group
rent Type installation 1)
Edison type
A V A

1-phase Un = 230 V
02A4-1 10 300 JJN/TJN10 UL class T 10
03A7-1 10 300 JJN/TJN10 UL class T 10
04A8-1 15 300 JJN/TJN15 UL class T 25
06A9-1 20 300 JJN/TJN20 UL class T 25
07A8-1 25 300 JJN/TJN25 UL class T 25
09A8-1 20 300 JJN/TJN20 UL class T 35
12A2-1 30 300 JJN/TJN30 UL class T 35
3-phase Un = 208 V
02A4-2 6 600 JJS/TJS6 UL class T 25
03A7-2 10 600 JJS/TJS10 UL class T 25
04A8-2 10 600 JJS/TJS10 UL class T 25
06A9-2 15 600 JJS/TJS15 UL class T 25
07A8-2 15 600 JJS/TJS15 UL class T 25
09A8-2 15 600 JJS/TJS15 UL class T 25
12A2-2 20 600 JJS/TJS20 UL class T 30
17A5-2 30 600 JJS/TJS30 UL class T 40
25A0-2 40 600 JJS/TJS40 UL class T 40
033A-2 50 600 JJS/TJS50 UL class T 60
032A-2 50 600 JJS/TJS50 UL class T 100
048A-2 70 600 JJS/TJS70 UL class T 100
055A-2 70 600 JJS/TJS70 UL class T 100
3-phase Un = 480 V
01A8-4 3 600 JJS/TJS3 UL class T 10
02A6-4 6 600 JJS/TJS6 UL class T 25
03A3-4 6 600 JJS/TJS6 UL class T 25
04A0-4 6 600 JJS/TJS6 UL class T 25
05A6-4 10 600 JJS/TJS10 UL class T 25
150 Technical data

Type Fuses
ACS380-
04xx-… Nominal cur- Max. fuse rat-
Voltage rating Bussmann/ ing for group
rent Type installation 1)
Edison type
A V A

07A2-4 10 600 JJS/TJS10 UL class T 25

09A4-4 15 600 JJS/TJS15 UL class T 25
12A6-4 20 600 JJS/TJS20 UL class T 30
17A0-4 25 600 JJS/TJS25 UL class T 40
25A0-4 35 600 JJS/TJS35 UL class T 40
033A-4 45 600 JJS/TJS45 UL class T 60
032A-4 45 600 JJS/TJS45 UL class T 100
038A-4 60 600 JJS/TJS60 UL class T 100
045A-4 60 600 JJS/TJS60 UL class T 100
050A-4 60 600 JJS/TJS60 UL class T 100
1) Branch circuit short-circuit protection for group installation by fuses: Suitable for motor group
installation on a circuit that is capable of delivering no more than 65000 rms symmetrical amperes,
480 V maximum, when protected by class T fuses. The same fuse size is specified for several consecutive
drive types. This is possible since the physical structure of the drive types is identical.

1. Fuses are required as part of the installation, are not included in the base drive
configuration and must be provided by others.
2. Fuses with a higher current rating than specified must not be used.
3. The UL listed fuses recommended by ABB are the required branch circuit
protection per NEC.
4. The recommended size or smaller UL listed 248 fast acting, time delay, or high
speed fuses must be used to maintain the UL listing of the drive. Additional
protection can be used. Refer to local codes and regulations.
5. A fuse of a different class can be used at the high fault rating where the Ipeak
and I2t of the new fuse is not greater than that of the specified fuse.
6. UL listed 248 fast acting, time delay, or high speed fuses from other
manufacturers can be used if they meet the same class and rating requirements
specified in the rules above.
7. When you install a drive, always obey ABB installation instructions, NEC
requirements and local codes.
8. Alternative fuses can be used if they meet certain characteristics. For permitted
fuses, see Branch Circuit Protection for ABB drives manual supplement
(3AXD50000645015).
 Technical data 151

Alternative short-circuit protection

￭ Miniature circuit breakers (IEC)
Note: Miniature circuit breakers with or without fuses have not been evaluated
for use as short-circuit protection in North American (UL) environments.

The protective characteristics of the circuit breakers depend on the type,

construction and settings of the breakers. There are also limitations pertaining
to the short-circuit capacity of the supply network. Your local ABB representative
can help you in selecting the breaker type when the supply network characteristics
are known.

WARNING!
Due to the inherent operating principle and construction of circuit breakers,
independent of the manufacturer, hot ionized gases can escape from the
breaker enclosure in case of a short-circuit. To ensure safe use, pay special
attention to the installation and placement of the breakers. Obey the
manufacturer’s instructions.

You can use the circuit breakers specified by ABB. You can also use other circuit
breakers with the drive if they provide the same electrical characteristics. ABB
does not assume any liability whatsoever for the correct function and protection
of the circuit breakers not specified by ABB. Furthermore, if the specifications
given by ABB are not obeyed, the drive can experience problems the warranty does
not cover.

Frame Miniature circuit breaker Network

Type
ACS380- SCC 1)
04xx-…
ABB type kA

1-phase Un = 230 V
02A4-1 R0 S 201P-B 10 NA 5
03A7-1 R0 S 201P-B 10 NA 5
04A8-1 R1 S 201P-B 16 NA 5
06A9-1 R1 S 201P-B 20 NA 5
07A8-1 R1 S 201P-B 25 NA 5
09A8-1 R2 S 201P-B 25 NA 5
12A2-1 R2 S 201P-B 32 NA 5
3-phase Un = 230 V
02A4-2 R1 S 203P-Z 6 NA 5
03A7-2 R1 S 203P-Z 8 NA 5
152 Technical data

Frame Miniature circuit breaker Network

Type
ACS380- SCC 1)
04xx-…
ABB type kA

04A8-2 R1 S 203P-Z 10 NA 5
06A9-2 R1 S 203P-Z 16 NA 5
07A8-2 R1 S 203P-Z 16 NA 5
09A8-2 R1 S 203P-Z 25 NA 5
12A2-2 R2 S 203P-Z 25 NA 5
17A5-2 R3 S 203P-Z 32 NA 5
25A0-2 R3 S 203P-Z 50 NA 5
033A-2 R3 S 203P-Z 63 NA 5
032A-2 R4 S 203P-Z 63 NA 5
048A-2 R4 Contact ABB 5
055A-2 R4 Contact ABB 5
3-phase Un = 400 V
01A8-4 R0 S 203P-B 4 5
02A6-4 R1 S 203P-B 6 5
03A3-4 R1 S 203P-B 6 5
04A0-4 R1 S 203P-B 8 5
05A6-4 R1 S 203P-B 10 5
07A2-4 R1 S 203P-B 16 5
09A4-4 R1 S 203P-B 16 5
12A6-4 R2 S 203P-B 25 5
17A0-4 R3 S 203P-B 32 5
25A0-4 R3 S 203P-B 50 5
033A-4 R3 S 203P-B 63 5
032A-4 R4 S 203P-B 63 5
038A-4 R4 S 803S-B 80 5
045A-4 R4 S 803S-B 100 5
050A-4 R4 S 803S-B 100 5
1) Maximum permitted rated conditional short-circuit current (IEC 61800-5-1) of the electrical power
network.
 Technical data 153

￭ Miniature circuit breakers (UL)

ACS380 drives are suitable for use on a circuit capable of delivering not more than
10 kA symmetrical amperes (RMS) at 240 or 480Y/277 V maximum, when protected
by appropriate circuit breakers in the tables below. Additional fuse protection is
not required by UL when using circuit breakers herein. Circuit breakers are not
required to be in the same enclosure as the drive.

Type Frame Miniature circuit breaker Minimum enclosure volume 1) 2)

ACS380-
04xx-… ABB type in3

1-phase Un = 230 V
02A4-1 R0 SU202M-C10 1850
03A7-1 R0 SU202M-C10 1850
04A8-1 R1 SU202M-C20 1850
06A9-1 R1 SU202M-C20 1850
07A8-1 R1 SU202M-C20 1850
09A8-1 R2 SU202M-C32 1850
12A2-1 R2 SU202M-C32 1850
3-phase Un = 230 V
02A4-2 R1 SU203M-C16 1850
03A7-2 R1 SU203M-C16 1850
04A8-2 R1 SU203M-C16 1850
06A9-2 R1 SU203M-C16 1850
07A8-2 R1 SU203M-C25 1850
09A8-2 R1 SU203M-C25 1850
12A2-2 R2 SU203M-C25 1850
17A5-2 R3 SU203M-C50 1850
25A0-2 R3 SU203M-C50 1850
033A-2 R3 SU203M-C50 1850
032A-2 R4 - -
048A-2 R4 - -
055A-2 R4 - -
3-phase Un = 400 V
01A8-4 R0 SU203M-C10 1850
02A6-4 R1 SU203M-C10 1850
154 Technical data

Type Frame Miniature circuit breaker Minimum enclosure volume 1) 2)

ACS380-
04xx-… ABB type in3

03A3-4 R1 SU203M-C10 1850

04A0-4 R1 SU203M-C10 1850
05A6-4 R1 SU203M-C10 1850
07A2-4 R1 SU203M-C16 1850
09A4-4 R1 SU203M-C16 1850
12A6-4 R2 SU203M-C25 1850
17A0-4 R3 SU203M-C50 1850
25A0-4 R3 SU203M-C50 1850
033A-4 R3 SU203M-C50 1850
032A-4 R4 - -
038A-4 R4 - -
045A-4 R4 - -
050A-4 R4 - -
1) Drives that have an Minimum Enclosure Volume listed must be mounted in an enclosure ≥ Minimum
Enclosure Volume specified in this table.
2) When multiple drives that have an Enclosure Minimum Volume specified are installed in the same
enclosure, minimum volume of the enclosure is determined by largest Enclosure Minimum Volume of
the drives to be placed in the enclosure, plus the volume(s) of each additional drive.

￭ Manual self-protected combination motor controller – Type E USA

(UL (NEC))
You can use the ABB Type E manual motor protectors (MMP) MS132 & S1-M3-25,
MS165-xx and MS5100-100 as an alternative to the recommended fuses as a means
of branch circuit protection. This is in accordance with the National Electrical Code
(NEC). When the correct ABB Type E manual motor protector is selected from the
table and used for branch circuit protection, the drive is suitable for use in a circuit
capable of delivering no more than 65 kA rms symmetrical amperes at the maximum
rated voltage of the drive. See the table below for the appropriate MMP types and
minimum enclosure volume of IP20 / UL open type drive mounted in an enclosure.
If you use a manual motor protector for the branch circuit protection of the drive,
install the drive into a metal enclosure.
Note: The UL Listing of drive and MMP combinations applies only to drives that
are mounted in appropriately sized metal enclosures that are capable of containing
any drive component failure. Wall-mounted drives with UL Type 1 kits (optional)
are not covered by the UL combination listing of drives with MMPs.
 Technical data 155

WARNING!
Use fuses for the short-circuit protection of a wall-mounted drive with the
UL Type 1 kit (optional). Serious injury, fire, or damage to equipment can
result from the use of MMPs instead of fuses.

Type ACS380- Minimum enclosure volume 5)

04xx-… Frame 1) MMP type 2) 3) 4)
dm3 in3

1-phase UN = 230 V
02A4-1 R0 MS132-10 & S1-M3-25 6) 30.3 1850

03A7-1 R0 MS132-10 & S1-M3-25 6) 30.3 1850

04A8-1 R1 MS165-20 30.3 1850

06A9-1 R1 MS165-20 30.3 1850
07A8-1 R1 MS165-20 30.3 1850
09A8-1 R2 MS165-32 30.3 1850
12A2-1 R2 MS165-32 30.3 1850
3-phase UN = 230 V
02A4-2 R1 MS132-10 & S1-M3-25 6) 30.3 1850

03A7-2 R1 MS132-10 & S1-M3-25 6) 30.3 1850

04A8-2 R1 MS132-10 & S1-M3-25 6) 30.3 1850

06A9-2 R1 MS132-10 & S1-M3-25 6) 30.3 1850

07A8-2 R1 MS165-16 30.3 1850

09A8-2 R1 MS165-16 30.3 1850
12A2-2 R2 MS165-20 30.3 1850
17A5-2 R3 MS165-42 30.3 1850
25A0-2 R3 MS165-42 30.3 1850
033A-2 R3 MS165-54 30.3 1850
032A-2 R4 MS165-80 75.0 4577
048A-2 R4 MS165-80 75.0 4577
055A-2 R4 MS165-80 75.0 4577
3-phase UN = 480 V
01A8-4 R0 MS132-4.0 & S1-M3-25 6) 30.3 1850

02A6-4 R1 MS132-6.3 & S1-M3-25 6) 30.3 1850

156 Technical data

Type ACS380- Minimum enclosure volume 5)

04xx-… Frame 1) MMP type 2) 3) 4)
dm3 in3

03A3-4 R1 MS132-6.3 & S1-M3-25 6) 30.3 1850

04A0-4 R1 MS132-10 & S1-M3-25 6) 30.3 1850

05A6-4 R1 MS132-10 & S1-M3-25 6) 30.3 1850

07A2-4 R1 MS165-16 30.3 1850

09A4-4 R1 MS165-16 30.3 1850
12A6-4 R2 MS165-20 30.3 1850
17A0-4 R3 MS165-32 30.3 1850
25A0-4 R3 MS165-42 30.3 1850
033A-4 R3 MS165-54 30.3 1850
032A-4 R4 MS165-54 75.0 4577
038A-4 R4 MS165-65 75.0 4577
045A-4 R4 MS5100-100 / MS165-73 75.0 4577
050A-4 R4 MS5100-100 / MS165-80 75.0 4577
1) Enclosures for all frame sizes must have a solid bottom directly below the drive i.e. fans (other than
internal stirring fans), filters or louvers cannot be mounted directly below the drive but can be mounted
in adjacent areas on the bottom of the enclosure.
2) All manual motor protectors listed are Type E self-protected up to 65 kA, except MS165-80 which is
Type E self-protected up to 50 kA. See the ABB manual motor starter catalog (1SBC100214C0201) for
complete technical data on the ABB Type E manual motor protectors. In order for these manual motor
protectors to be used for branch circuit protection, they must be UL listed Type E manual motor
protectors, otherwise they can be used only as an At Motor Disconnect. “At Motor Disconnect” is a
disconnect just ahead of the motor on the load side of the panel.
3) 480Y/277 V wye systems only: Short-circuit protective devices with slash voltage ratings (e.g. 480Y/277 V
AC) can be applied only in solidly grounded networks where the voltage from line-to-ground does not
exceed the lower of the two ratings (e.g. 277 V AC), and the voltage from line-to-line does not exceed
the higher of the two ratings (e.g. 480 V AC).
4) Manual motor protectors may require adjusting the trip limit from the factory setting at or above the
drive input Amps to avoid nuisance tripping. If the manual motor protector is set to the maximum
current trip level and nuisance tripping is occurring, select the next size MMP. (MS132-10 is the highest
size in the MS132 frame size to meet Type E at 65 kA; the next size up is MS165-16.)
5) For all drives, the enclosure must be sized to accommodate the specific thermal considerations of the
application as well as provide free space for cooling. Refer to the technical data. For UL only: The
minimum enclosure volume is specified in the UL listing when applied with the ABB Type E MMP shown
in the table. Fuses must be used for wall-mounted drives installed with a UL Type 1 kit.
6) Requires the use of the S1-M3-25 line side feeder terminal with the manual motor protector to meet
Type E self-protection class.
 Technical data 157

Dimensions and weights

￭ Dimensions – IP20 / UL open type
D
M1
W

H2 H1 H3 M2

M1

Frame Dimensions, IP20 / UL open type

size
H1 H2 H3 W 1) D 2) M1 M2

mm in mm in mm in mm in mm in mm in mm in

R0 205 8.1 223 8.8 170 6.7 70 2.8 176 6.9 50 1.97 191 7.52
R1 205 8.1 223 8.8 170 6.7 70 2.8 176 6.9 50 1.97 191 7.52
R2 205 8.1 223 8.8 170 6.7 95 3.7 176 6.9 75 2.95 191 7.52
R3 205 8.1 241.3 9.5 170 6.7 170 6.7 176 6.9 148 5.83 191 7.52
R4 205 8.1 240 9.45 170 6.7 260 10.2 176 6.9 234 9.21 191 7.52
1) A side option increases the width of the drive.
2) The BIO-01 high cover increases the depth of the drive by 15 mm (0.6 in).

H1 Height back
H2 Height
H3 Height front
W Width
D Depth
M1, M2 Mounting hole distance
158 Technical data

￭ Dimensions – Drive with UL Type 1 kit

M1
W D

H2 H1 H3 M2

M3

M1

Frame Dimensions, drive with UL Type 1 kit

size
H1 H2 H3 W 1) D M1 M2 M3

mm in mm in mm in mm in mm in mm in mm in mm in

R0 205 8.1 285 11.2 247 9.7 70 2.8 191 7.5 50 1.97 191 7.52 32 1.26
R1 205 8.1 293 11.5 247 9.7 70 2.8 191 7.5 50 1.97 191 7.52 32 1.26
R2 205 8.1 293 11.5 247 9.7 95 3.7 191 7.5 75 2.95 191 7.52 32 1.26
R3 205 8.1 329 13.0 261 10.3 170 6.7 191 7.5 148 5.83 191 7.52 36 1.42
R4 205 8.1 391 15.3 312 12.3 260 10.2 196 7.7 234 9.21 191 7.52 38 1.50
1) A side option increases the width of the drive.

H1 Height back
H2 Height
H3 Height front
W Width
D Depth
M1, M2, M3 Mounting hole distance
 Technical data 159

￭ Weights
Frame Weights
size
IP20 / UL open type UL Type 1

kg lb kg lb

R0 1.4 3.1 1.8 4.1

R1 1.4 3.1 1.8 4.1
R2 2.0 4.4 2.5 5.5
R3 3.3 7.3 4.0 8.8
R4 5.3 11.7 6.5 14.4

Free space requirements

Frame Free space requirement

Above 1) Below Sides

mm in mm in mm in

All 75 3 75 3 0 0
1) Drives with the optional UL Type 1 kit: 50 mm (2 in), measured from the top of the hood.

Losses, cooling data and noise

Drives with frame size R0 have natural convection cooling. Drives with frame size
R1…R4 have a cooling fan. The air flow direction is from bottom to top.

Type Typical power loss 1) Air flow Noise Frame

ACS380-
size
04xx-… W BTU/h m3/h CFM dB(A)

1-phase UN = 230 V
02A4-1 33 113 - - < 30 R0
03A7-1 49 167 - - < 30 R0
04A8-1 67 229 57 33 63 R1
06A9-1 93 317 57 33 63 R1
07A8-1 106 362 57 33 63 R1
09A8-1 92 314 63 37 59 R2
12A2-1 115 392 63 37 59 R2
160 Technical data

Type Typical power loss 1) Air flow Noise Frame

ACS380-
size
04xx-… W BTU/h m3/h CFM dB(A)

3-phase UN = 230 V
02A4-2 39 133 57 33 63 R1
03A7-2 57 194 57 33 63 R1
04A8-2 72 246 57 33 63 R1
06A9-2 111 379 57 33 63 R1
07A8-2 105 358 57 33 63 R1
09A8-2 140 478 57 33 63 R1
12A2-2 149 508 63 37 59 R2
17A5-2 265 904 128 75 66 R3
25A0-2 398 1358 128 75 66 R3
033A-2 350 1194 128 75 66 R3
032A-2 350 1194 150 88 69 R4
048A-2 561 1914 150 88 69 R4
055A-2 676 2307 150 88 69 R4
3-phase UN = 400/480 V
01A8-4 28 96 - - <30 R0
02A6-4 44 150 57 33 63 R1
03A3-4 55 188 57 33 63 R1
04A0-4 62 212 57 33 63 R1
05A6-4 91 311 57 33 63 R1
07A2-4 100 341 57 33 63 R1
09A4-4 140 478 57 33 63 R1
12A6-4 165 563 63 37 59 R2
17A0-4 259 884 128 75 66 R3
25A0-4 390 1331 128 75 66 R3
033A-4 396 1351 128 75 66 R3
032A-4 396 1351 150 88 69 R4
038A-4 497 1696 150 88 69 R4
045A-4 582 1986 150 88 69 R4
 Technical data 161

Type Typical power loss 1) Air flow Noise Frame

ACS380-
size
04xx-… W BTU/h m3/h CFM dB(A)

050A-4 672 2293 150 88 69 R4

1) Typical drive losses when it operates at 90% of the motor nominal frequency and 100% of the drive
nominal output current.

Typical power cable sizes

The table in this section gives the typical power cable and conductor sizes for use
at the nominal drive current.
Note: IEC/EN 61800-5-1 requires two separate PE (ground) conductors for a fixed
connection, if the cross-sectional area of the PE conductor is less than 10 mm2 Cu.

Type Cable size, Cu (mm2) 1) Conductor size, Cu (AWG) Frame

ACS380- size
04xx-…

1-phase UN = 230 V
02A4-1 3×1.5 + 1.5 14 R0
03A7-1 3×1.5 + 1.5 14 R0
04A8-1 3×1.5 + 1.5 14 R1
06A9-1 3×1.5 + 1.5 14 R1
07A8-1 3×1.5 + 1.5 14 R1
09A8-1 3×2.5 + 2.5 14 R2
12A2-1 3×2.5 + 2.5 14 R2
3-phase UN = 230 V
02A4-2 3×1.5 + 1.5 14 R1
03A7-2 3×1.5 + 1.5 14 R1
04A8-2 3×1.5 + 1.5 14 R1
06A9-2 3×1.5 + 1.5 14 R1
07A8-2 3×1.5 + 1.5 14 R1
09A8-2 3×2.5 + 2.5 14 R1
12A2-2 3×2.5 + 2.5 14 R2
17A5-2 3×6 + 6 10 R3
25A0-2 3×6 + 6 10 R3
033A-2 3×10 + 10 8 R3
032A-2 3×10 + 10 8 R4
162 Technical data

Type Cable size, Cu (mm2) 1) Conductor size, Cu (AWG) Frame

ACS380- size
04xx-…

048A-2 3×25 + 16 4 R4
055A-2 3×25 + 16 4 R4
3-phase UN = 400 V or 480 V
01A8-4 3×1.5 + 1.5 14 R0
02A6-4 3×1.5 + 1.5 14 R1
03A3-4 3×1.5 + 1.5 14 R1
04A0-4 3×1.5 + 1.5 14 R1
05A6-4 3×1.5 + 1.5 14 R1
07A2-4 3×1.5 + 1.5 14 R1
09A4-4 3×2.5 + 2.5 14 R1
12A6-4 3×2.5 + 2.5 14 R2
17A0-4 3×6 + 6 10 R3
25A0-4 3×6 + 6 10 R3
033A-4 3×10 + 10 8 R3
032A-4 3×10 + 10 8 R4
038A-4 3×16 + 16 6 R4
045A-4 3×25 + 16 4 R4
050A-4 3×25 + 16 4 R4
1) Symmetrical, shielded, three-phase copper cable.

Terminal data for the power cables

The first table shows the terminal data in SI units. The second table shows the
terminal data in imperial units.
 Technical data 163

Type L1, L2, L3, T1/U, T2/V, T3/W, R-, R+/ PE

ACS380- UDC+
04xx-…
Minimum Maximum Tightening Minimum Maximum Tightening
(sol- (sol- torque (sol- (sol- torque
id/stran- id/stran- id/stran- id/stran-
ded) ded) ded) ded)

mm2 mm2 N·m mm2 mm2 N·m

1-phase Un = 230 V
02A4-1 0.5/0.5 4/2.5 0.5…0.6 4/2.5 6/4 1.2
03A7-1 0.5/0.5 4/2.5 0.5…0.6 4/2.5 6/4 1.2
04A8-1 0.5/0.5 4/2.5 0.5…0.6 4/2.5 6/4 1.2
06A9-1 0.5/0.5 4/2.5 0.5…0.6 4/2.5 6/4 1.2
07A8-1 0.5/0.5 4/2.5 0.5…0.6 4/2.5 6/4 1.2
09A8-1 0.5/0.5 4/2.5 0.5…0.6 4/2.5 6/4 1.2
12A2-1 0.5/0.5 4/2.5 0.5…0.6 4/2.5 6/4 1.2
3-phase Un = 230 V
02A4-2 0.5/0.5 4/2.5 0.5…0.6 4/2.5 6/4 1.2
03A7-2 0.5/0.5 4/2.5 0.5…0.6 4/2.5 6/4 1.2
04A8-2 0.5/0.5 4/2.5 0.5…0.6 4/2.5 6/4 1.2
06A9-2 0.5/0.5 4/2.5 0.5…0.6 4/2.5 6/4 1.2
07A8-2 0.5/0.5 4/2.5 0.5…0.6 4/2.5 6/4 1.2
09A8-2 0.5/0.5 4/2.5 0.5…0.6 4/2.5 6/4 1.2
12A2-2 0.5/0.5 4/2.5 0.5…0.6 4/2.5 6/4 1.2
17A5-2 0.5/0.5 10/6 1.2…1.5 4/2.5 6/4 1.2
25A0-2 0.5/0.5 10/6 1.2…1.5 4/2.5 6/4 1.2
033A-2 0.5/0.5 10/6 1.2…1.5 4/2.5 6/4 1.2
032A-2 0.5/0.5 25/16 2.5…3.7 10/6 25/16 2.9
048A-2 0.5/0.5 25/16 2.5…3.7 10/6 25/16 2.9
055A-2 0.5/0.5 25/16 2.5…3.7 10/6 25/16 2.9
3-phase Un = 400 V
01A8-4 0.5/0.5 4/2.5 0.5…0.6 4/2.5 6/4 1.2
02A6-4 0.5/0.5 4/2.5 0.5…0.6 4/2.5 6/4 1.2
03A3-4 0.5/0.5 4/2.5 0.5…0.6 4/2.5 6/4 1.2
04A0-4 0.5/0.5 4/2.5 0.5…0.6 4/2.5 6/4 1.2
164 Technical data

Type L1, L2, L3, T1/U, T2/V, T3/W, R-, R+/ PE

ACS380- UDC+
04xx-…
Minimum Maximum Tightening Minimum Maximum Tightening
(sol- (sol- torque (sol- (sol- torque
id/stran- id/stran- id/stran- id/stran-
ded) ded) ded) ded)

mm2 mm2 N·m mm2 mm2 N·m

05A6-4 0.5/0.5 4/2.5 0.5…0.6 4/2.5 6/4 1.2

07A2-4 0.5/0.5 4/2.5 0.5…0.6 4/2.5 6/4 1.2
09A4-4 0.5/0.5 4/2.5 0.5…0.6 4/2.5 6/4 1.2
12A6-4 0.5/0.5 4/2.5 0.5…0.6 4/2.5 6/4 1.2
17A0-4 0.5/0.5 10/6 1.2…1.5 4/2.5 6/4 1.2
25A0-4 0.5/0.5 10/6 1.2…1.5 4/2.5 6/4 1.2
033A-4 0.5/0.5 10/6 1.2…1.5 4/2.5 6/4 1.2
032A-4 0.5/0.5 25/16 2.5…3.7 10/6 25/16 2.9
038A-4 0.5/0.5 25/16 2.5…3.7 10/6 25/16 2.9
045A-4 0.5/0.5 25/16 2.5…3.7 10/6 25/16 2.9
050A-4 0.5/0.5 25/16 2.5…3.7 10/6 25/16 2.9

Type L1, L2, L3, T1/U, T2/V, T3/W, R-, R+/ PE

ACS380- UDC+
04xx-…
Minimum Maximum Tightening Minimum Maximum Tightening
torque torque

AWG AWG lbf·in AWG AWG lbf·in

1-phase Un = 230 V
02A4-1 18 10 5 12 10 10.6
03A7-1 18 10 5 12 10 10.6
04A8-1 18 10 5 12 10 10.6
06A9-1 18 10 5 12 10 10.6
07A8-1 18 10 5 12 10 10.6
09A8-1 18 10 5 12 10 10.6
12A2-1 18 10 5 12 10 10.6
3-phase Un = 230 V
02A4-2 18 10 5 12 10 10.6
 Technical data 165

Type L1, L2, L3, T1/U, T2/V, T3/W, R-, R+/ PE

ACS380- UDC+
04xx-…
Minimum Maximum Tightening Minimum Maximum Tightening
torque torque

AWG AWG lbf·in AWG AWG lbf·in

03A7-2 18 10 5 12 10 10.6
04A8-2 18 10 5 12 10 10.6
06A9-2 18 10 5 12 10 10.6
07A8-2 18 10 5 12 10 10.6
09A8-2 18 10 5 12 10 10.6
12A2-2 18 10 5 12 10 10.6
17A5-2 18 6 11…13 12 10 10.6
25A0-2 18 6 11…13 12 10 10.6
033A-2 18 6 11…13 12 10 10.6
032A-2 18 2 22…32 8 4 25.7
048A-2 18 2 22…32 8 4 25.7
055A-2 18 2 22…32 8 4 25.7
3-phase Un = 480 V
01A8-4 18 10 5 12 10 10.6
02A6-4 18 10 5 12 10 10.6
03A3-4 18 10 5 12 10 10.6
04A0-4 18 10 5 12 10 10.6
05A6-4 18 10 5 12 10 10.6
07A2-4 18 10 5 12 10 10.6
09A4-4 18 10 5 12 10 10.6
12A6-4 18 10 5 12 10 10.6
17A0-4 18 6 11…13 12 10 10.6
25A0-4 18 6 11…13 12 10 10.6
033A-4 18 6 11…13 12 10 10.6
032A-4 18 2 22…32 8 4 25.7
038A-4 18 2 22…32 8 4 25.7
045A-4 18 2 22…32 8 4 25.7
050A-4 18 2 22…32 8 4 25.7
166 Technical data

Note:
• 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.

Terminal data for the control cables

This table shows the control cable terminal data of the standard drive variant, that
is, the base unit with BMIO-01 I/O & Modbus module.

Wire size Torque

mm2 AWG N·m lbf·in

0.14…1.5 26…16 0.5…0.6 4.4…5.3

Electrical power network specification

Voltage (U1) Input voltage range:
ACS380-04xx-xxxx-1 drives: 1-phase 200 … 240 V AC -15% … +10%
ACS380-04xx-xxxx-2 drives: 3-phase 200 … 240 V AC -15% … +10%
ACS380-04xx-xxxx-4 drives: 3-phase 380 … 480 V AC -15% … +10%
Network type Public low voltage networks. Symmetrically grounded TN-S system,
IT (ungrounded), corner-grounded delta. Consult ABB before con-
necting to other systems (for example, TT, or midpoint grounded
delta).
Rated conditional 65 kA when protected by fuses given in the fuse tables.
short-circuit current
Icc(IEC 61800-5-1)
Maximum prospect- US and Canada: The drive is suitable for use on a circuit capable of
ive short-circuit cur- delivering not more than 100 kA symmetrical amperes (rms) at 480 V
rent rating (SCCR) maximum when protected by fuses given in the fuse table.
(UL 61800-5-1,
CSA C22.2 No. 274-13)
Harmonic current Refer to Compliance with the harmonic current limits in a public
limits in public net- network (IEC/EN 61000 3-2, IEC/EN 61000-3-12) (page 177).
work
(IEC/EN 61000-3-2,
IEC/EN 61000-3-12)
 Technical data 167

Input choke Refer to Input chokes (page 217) for general guidelines on the use of
the choke.
Use an input choke, if the short-circuit capacity of the network at
the drive terminals is more than specified in this table:
Input voltage R0, R1, R2 R3, R4

1-phase 200 … 240 V >1.5 kA -

3-phase 200 … 240 V >5.0 kA >7.5 kA
3-phase 380 … 480 V >5.0 kA >10 kA

You can use one choke for several drives if the short-circuit capacity
at the drive terminals is decreased to the value in the table.
Frequency (f1) 47 … 63 Hz, maximum rate of change 2%/s
Imbalance Max. ±3% of nominal phase to phase input voltage
Fundamental power 0.98 (at nominal load)
factor (cos phi)

Motor connection data

Motor type Asynchronous AC induction motors, permanent magnet synchronous
motors or ABB synchronous reluctance motors (SynRM motors)
Voltage (U2) 0 … U1, 3-phase symmetrical
Short-circuit protec- The motor output is short-circuit proof by IEC 61800-5-1 and UL
tion (IEC 61800-5-1, 61800-5-1.
UL 61800-5-1)
Frequency (f2) 0 … 599 Hz
Frequency resolution 0.01 Hz
Current See the electrical ratings given in this manual.
Switching frequency 2, 4, 8, or 12 kHz

￭ Motor cable length

Operational functionality and motor cable length
The drive is designed to operate with optimum performance with these maximum
motor cable lengths. The values are valid for 4 kHz switching frequency.
Note: Conducted and radiated emissions of these motor cable lengths do not
comply with the EMC requirements of IEC/EN 61800-3.
168 Technical data

Frame Maximum motor cable length

m ft

Standard drive, without external options

R0…R4 100 328

Note: In multimotor systems, the calculated sum of all motor cable lengths must
not exceed the maximum motor cable length given in the table.

EMC compatibility and motor cable length

To comply with the EMC requirements of IEC/EN 61800-3, do not exceed these
maximum motor cable lengths. The values are valid for 4 kHz switching frequency.

Frame Maximum motor cable length, 4 kHz

C1 1) C2 C3

m ft m ft m ft

With internal EMC filter

1-phase 200 … 240 V (ACS380-042x)
R0 - - 10 33 10 33
R1 - - 10 33 10 33
R2 - - 10 33 10 33
3-phase 380 … 480 V (C2: ACS380-042x, C3: ACS380-040x)
R0 - - 10 33 30 98
R1 - - 10 33 30 98
R2 - - 10 33 20 66
R3 - - 10 33 30 98
R4 - - 10 33 30 98
With optional external EMC filter
1-phase 200 … 240 V (ACS380-040x)
R0 10 33 10 33 10 33
R1 10 33 10 33 10 33
R2 - - - - - -
3-phase 200 … 240 V (ACS380-040x)
R1 - - 20 66 20 66
R2 - - 20 66 20 66
 Technical data 169

Frame Maximum motor cable length, 4 kHz

C1 1) C2 C3

m ft m ft m ft

R3 - - 20 66 20 66
R4 - - 20 66 20 66
3-phase 380 … 480 V (ACS380-040x)
R0 30 98 30 98 30 98
R1 40 131 40 131 40 131
R2 40 131 40 131 40 131
R3 40 131 40 131 40 131
R4 30 98 30 98 30 98
1) Category C1 with conducted emissions only. Radiated emissions are not compatible when measured
with the standard emission measurement setup and must be measured on cabinet and machine
installations for each case.

Note: Radiated emissions are according to C2 with ACS380-042x drives. For

ACS380-040x drives, use a metal enclosure to fulfill radiated emissions C2 limits
with an external EMC filter.

Control connection data

Analog inputs (AI1, Voltage signal, single- 0 … 10 V DC (10% overrange, 11 V DC max.)
AI2) ended Rin = 221.6 kohm
Current signal, single- 0 … 20 mA (10% overrange, 22 mA max.)
ended Rin = 137 ohm
Inaccuracy ≤ 1.0%, of full scale
Overvoltage protec- up to 30 V DC
tion
Potentiometer refer- 10 V DC ±1%, max. load current 10 mA
ence value

Analog output (AO) 1) Current output mode 0 … 20 mA (10% overrange, 22 mA max.) into
500 ohm load
Voltage output mode 0 … 10 V DC (10% overrange, 11 V DC max.)
into 200 kohm minimum load (resistive)
Inaccuracy ≤ 1.0%, of full scale
Auxiliary voltage out- As output +24 V DC ±10%, max. 250 mA
put/optional input
As input (optional) +24 V DC ±10%, max. 1000 mA (incl internal
(+24V)
fan load)
170 Technical data

Digital inputs Voltage 12 … 24 V DC (int. or ext. supply) Max. 30 V

(DI1…DI5) DC.
Type PNP and NPN
Input impedance Rin = 2 kohm

Programmable digital As inputs

I/O (DIO1, DIO2)1) Voltage 12 … 24 V DC with internal or external supply.
Max. 30 V DC.
Type PNP and NPN
Input impedance Rin = 2 kohm
As outputs
Type Transistor output PNP
Max. switching 30 V DC
voltage
Max. switching cur- 70 mA / 30 DC, short-circuit protected
rent
Frequency 10 Hz … 16 kHz
Resolution 1 Hz
Relay output (RA, RB, Type 1 From C (NO + NC)
RC)
Max. switching 250 V AC / 30 V DC
voltage
Max. switching cur- 2A
rent
Frequency input (FI) 10 Hz … 16 kHz
DI3 and DI4 can be used as digital or frequency inputs.
Frequency output DIO1 and DIO2 can be used as digital or frequency outputs.
(FO)
Safe torque off (STO) Refer to The Safe torque off function (page 233)
interface (SGND, S+,
S1, S2)
EIA-485 embedded Connector pitch 5 mm, maximum wire size 2.5 mm2 (14 AWG)
fieldbus (A+, B-, Physical layer: RS-485
BGND)
Cable type: Shielded twisted pair cable with twisted pair for data
and a wire or pair for signal ground, nominal impedance
100 … 165 ohm, for example Belden 9842
Transmission rate: 9.6 … 115.2 kbit/s
Termination by jumper
Control panel - drive EIA-485, male RJ-45 connector, cable type CAT 5e or better, maximum
connection cable length 100 m (328 ft)
 Technical data 171

Control panel - PC USB Type A – Type Mini-B cable, maximum cable length 3 m (9.8 ft)
connection
1) For information about BMIO-01 output behavior in certain conditions, refer to the default I/O connection
diagram in the control cable connection instructions.

Brake resistor connection data

Short-circuit protec- The brake resistor output is conditionally short-circuit proof by
tion (IEC 61800-5-1, IEC/EN 61800-5-1 and UL 61800-5-1.
IEC 60439-1, Rated conditional short-circuit current is as defined in IEC 60439-1.
UL 61800-5-1)

Energy efficiency data (ecodesign)

Energy efficiency data according to IEC 61800-9-2 is available from the ecodesign
tool (https://ecodesign.drivesmotors.abb.com/).

Energy efficiency data is not provided for the 1~230 V drives. The drives with one
phase input are not in the scope of the EU ecodesign requirements (Regulation
EU/2019/1781) or the UK ecodesign requirements (Regulation SI 2021 No. 745).

Protection classes
Degree of protection IP20. The drive must be installed in a cabinet to fulfill the require-
(IEC/EN 60529) ments for shielding from contact.
Enclosure types UL open type. For indoor use only. UL Type 1 kit is available as an
(UL 61800-5-1) option.

Note: UL Type 1 kits are not applicable with BRES-01 resolver inter-
face module.
Overvoltage category lll
(IEC 60664-1)
Protective classes l
(IEC/EN 61800-5-1)
172 Technical data

Ambient conditions
Environmental limits for the drive are given below. The drive must be used in a
heated indoor controlled environment.

Requirement Operation installed Storage in the pro- Transportation in the

for stationary use tective package protective package

Installation site alti- 230 V drives: - -

tude 0 … 2000 m
(0 … 6562 ft) above
sea level (with output
derating above
1000 m [3281 ft])
400/480 V drives:
0 … 4000 m
(0 … 13123 ft) above
sea level (with output
derating above
1000 m [3281 ft])
See Output derat-
ing (page 140).
Surrounding air tem- -10 … +60 °C -40 … +70 °C ±2% -40 … +70 °C ±2%
perature (14 … 140 °F). For (-40 … +158 °F ±2%) (-40 … +158 °F ±2%)
frame R0,
-10 … +50 °C
(14 … 122 °F).
If the temperature is
more than 50 °C
(122 °F), output derat-
ing is necessary. See
Output derat-
ing (page 140).
No frost permitted.
Relative humidity 5 … 95% Max. 95% Max. 95%
No condensation permitted. Maximum permitted relative humidity
is 60% in the presence of corrosive gases.
Contamination levels IEC 60721-3-3: 2002 IEC 60721-3-1: 1997 IEC 60721-3-2: 1997
(IEC 60721-3-x)
- Chemical gases Class 3C2 Class 1C2 Class 2C2
- Solid particles Class 3S2. No conduct- Class 1S3. (packing Class 2S2
ive dust permitted. must support this,
otherwise 1S2)
Pollution degree Pollution degree 2 - -
(IEC/EN 61800-5-1)
 Technical data 173

Requirement Operation installed Storage in the pro- Transportation in the

for stationary use tective package protective package

Sinusoidal vibration frequency - -

(IEC 60068-2-6, Test 10 … 150 Hz;
Fc 2007-12) amplitude ±0.075 mm
(0.003 in),
10 … 57,56 Hz;
constant peak acceler-
ation 10 m/s2
(33 ft/s2), 57,56 … 150
Hz; sweep: 1 oct/min;
10 sweep cycles in
each axis with STO
active;
uncertainty ±5.0%;
normal mounting
Shock/(IEC 60068-2- Not permitted According to ISTA 1A. According to ISTA 1A.
27, ISTA 1A) Max. 100 m/s2 Max. 100 m/s2
(330 ft/s2), 11 ms. (330 ft/s2), 11 ms.
Free fall - 76 cm (30 in) 76 cm (30 in)

Storage conditions
Store the drive in humidity controlled enclosed environments. Keep the drive in
its package.

Color
NCS 1502-Y (RAL 9002 / PMS 420 C)

Materials
￭ Drive
Refer to ACS380 drives recycling instructions and environmental information
(3AXD50000049465 [English]).

￭ Drive package
• Cardboard
• Molded pulp
• PE (suspension film package, plastic bag).
174 Technical data

￭ Package materials for options, accessories and spare parts

• Cardboard
• Kraft paper
• PP (straps)
• PE (film, bubble wrap)
• Plywood, wood (only for heavy components).
Materials vary according to the item type, size and shape. Typical package consists
of a cardboard box with paper filling or bubble wrap. ESD-safe packing materials
are used for printed circuit boards and similar items.

￭ Materials of manuals
Printed product manuals are made of recyclable paper. Product manuals are
available on the Internet.

Disposal
The main parts of the drive can be recycled to preserve natural resources and
energy. Product parts and materials should be dismantled and separated.
Generally all metals, such as steel, aluminum, copper and its alloys, and precious
metals can be recycled as material. Plastics, rubber, cardboard and other packaging
material can be used in energy recovery.
Printed circuit boards and DC capacitors need selective treatment according to
IEC 62635 guidelines.
To aid recycling, most plastic parts are marked with an appropriate identification
code. In addition, components containing substances of very high concern (SVHCs)
are listed in European Chemicals Agency's SCIP database. SCIP is the database for
information on Substances of Concern In articles as such or in complex objects
(Products) established under the Waste Framework Directive (2008/98/EC). For
further information, contact your local ABB distributor or consult European
Chemicals Agency's SCIP database to find out which SVHCs are used in the drive,
and to find out where those components are located.
Contact your local ABB distributor for further information on environmental
aspects. End of life treatment must follow international and national regulations.
For more information on ABB end of life services, refer to
new.abb.com/service/end-of-life-services.
 Technical data 175

Applicable standards
The drive complies with the following standards:

EN ISO 13849-1:2015 Safety of machinery – Safety related parts of the control systems –
Part 1: general principles for design
EN ISO 13849-2:2012 Safety of machinery – Safety-related parts of the control systems –
Part 2: Validation
EN 60204-1:2006 + Safety of machinery. Electrical equipment of machines. Part 1: Gen-
A1:2009 + AC:2010 eral requirements. Provisions for compliance: The final assembler
of the machine is responsible for installing
• an emergency-stop device
• a supply disconnecting device
EN 62061:2005 + Safety of machinery – Functional safety of safety-related electrical,
AC:2010 + A1:2013 + electronic and programmable electronic control systems
A2:2015
EN 61800-3:2004 + Adjustable speed electrical power drive systems. Part 3: EMC require-
A1:2012 ments and specific test methods
IEC 61800-3:2004 +
A1:2011
IEC/EN 61800-5- Adjustable speed electrical power drive systems – Part 5-1: Safety
1:2007+AMD1:2016 requirements – Electrical, thermal and energy
EN 61800-5-
1:2007+A1:2017+A11:2021
IEC 61800-9-2:2017 Adjustable speed electrical power drive systems – Part 9-2: Ecodesign
for power drive systems, motor starters, power electronics and their
driven applications – Energy efficiency indicators for power drive
systems and motor starters
ANSI/UL 61800-5- UL Standard for adjustable speed electrical power drive systems –
1:2015 Part 5-1: Safety requirements – Electrical, thermal and energy
CSA C22.2 No. 274-17 Adjustable speed drives

Markings
CE mark
Product complies with the applicable European Union legislation. For fulfilling
the EMC requirements, see the additional information concerning the drive EMC
compliance (IEC/EN 61800-3).

UKCA (UK Conformity Assessed) mark

Product complies with the applicable United Kingdom’s legislation (Statutory In-
struments). Marking is required for products being placed on the market in Great
Britain (England, Wales and Scotland).
176 Technical data

TÜV Safety Approved mark (functional safety)

Product contains Safe torque off and possibly other (optional) safety functions
which are certified by TÜV according to the relevant functional safety standards.
Applicable to drives and inverters; not applicable to supply, brake or DC/DC con-
verter units or modules.

UL Listed mark for USA and Canada

Product has been tested and evaluated against the relevant North American
standards by the Underwriters Laboratories. Valid with rated voltages up to 600 V.

RCM mark
Product complies with Australian and New Zealand requirements specific to EMC,
telecommunications and electrical safety. For fulfilling the EMC requirements,
see the additional information concerning the drive EMC compliance
(IEC/EN 61800-3).

CMIM mark
Product complies with Morocco's safety standard for marketing of toys and
electrical products.

EAC (Eurasian Conformity) mark

Product complies with the technical regulations of the Eurasian Customs Union.
EAC mark is required in Russia, Belarus and Kazakhstan.

Electronic Information Products (EIP) symbol including an Environment Friendly

Use Period (EFUP).
Product is compliant with the People’s Republic of China Electronic Industry
Standard (SJ/T 11364-2014) about hazardous substances. The EFUP is 20 years.
China RoHS II Declaration of Conformity is available from https://library.abb.com.

WEEE mark
At the end of life the product should enter the recycling system at an appropriate
collection point and not placed in the normal waste stream.

KC mark
Product complies with Korean Registration of Broadcasting and Communications
Equipment Clause 3, Article 58-2 of Radio Waves Act.
 Technical data 177

Compliance with the harmonic current limits in a public

network (IEC/EN 61000 3-2, IEC/EN 61000-3-12)
￭ 3-phase 230 V, 400 V or 480 V drive with the input choke
The drive complies with IEC 61000-3-12 provided that the short-circuit ratio Rsce
is greater than or equal to value 350 at the interface point between the user's
supply and the public system. It is the responsibility of the installer or user of the
equipment to ensure, by consultation with the distribution network operator if
necessary, that the short-circuit ratio Rsce is greater than or equal to 350.
The Rsce value meets the requirement if the short-circuit power at the interface
point between the user's supply and the public system is equal or bigger than the
value Scs calculated as follows:

where:

Scs Minimum short-circuit power limit

Rsce Short-circuit ratio
Seq Equipment (drive) input power
I1n Drive nominal input current with the input choke
U1 Drive input voltage

￭ 3-phase 230 V, 400 V or 480 V drive without the input choke

Refer to 1-phase 230 V drive with or without the input choke (page 177).

￭ 1-phase 230 V drive with or without the input choke

Do a harmonic current assessment for the whole system that the drive is part of,
and make sure that the harmonic current limits are not exceeded at the interface
point between the user's supply and the public system. Based on results, consider
the use of the input choke with the drive. If the assessment is not possible, you
can connect the drive to the public network if you have a permission from the
network operator.
Always use the input choke if the short circuit capacity of the network at the drive
input terminals exceeds the limit specified for the drive. Refer to Input
choke (page 167) in section Electrical power network specification (page 166).
178 Technical data

EMC compliance (IEC/EN 61800-3:2004 + A1:2012)

￭ Definitions
EMC stands for Electromagnetic Compatibility. It is the ability of
electrical/electronic equipment to operate without problems within an
electromagnetic environment. Likewise, the equipment must not disturb or
interfere with any other product or system within its locality.
First environment includes establishments connected to a low-voltage network
which supplies buildings used for domestic purposes.
Second environment includes establishments connected to a network not supplying
domestic premises.
Drive of category C1: drive of rated voltage less than 1000 V and intended for use
in the first environment.
Drive of category C2: drive of rated voltage less than 1000 V and intended to be
installed and started up only by a professional when used in the first environment.
Note: A professional is a person or organization having necessary skills in installing
and/or starting up power drive systems, including their EMC aspects.

Drive of category C3: drive of rated voltage less than 1000 V and intended for use
in the second environment and not intended for use in the first environment.
Drive of category C4: drive of rated voltage equal to or above 1000 V, or rated
current equal to or above 400 A, or intended for use in complex systems in the
second environment.

￭ Category C1
The drive complies with the conducted emission limits of the standard with the
following provisions:
1. The optional EMC filter is selected according to External EMC filters (page 223),
and the filter is installed as specified in the EMC filter manual.
2. The motor and control cables are selected as specified in this manual. The EMC
recommendations are obeyed.
3. The maximum motor cable length does not exceed the specified maximum
value. See EMC compatibility and motor cable length (page 168)
4. The drive is installed according to the instructions given in this manual.
This product can cause radio-frequency inference. In a residential or domestic
environment, supplementary mitigation measures may be required in addition to
the requirements listed above for the CE compliance.
 Technical data 179

￭ Category C2
This is applicable to drives with an internal EMC C2 filter.
The drive complies with the standard with the following provisions:
1. The motor and control cables are selected as specified in this manual. The EMC
recommendations are obeyed.
2. The maximum motor cable length does not exceed the specified maximum.
See EMC compatibility and motor cable length (page 168)
3. The drive is installed according to the instructions given in this manual.
This product can cause radio-frequency inference. In a residential or domestic
environment, supplementary mitigation measures may be required in addition to
the requirements listed above for the CE compliance.

WARNING!
Do not install a drive with the internal EMC filter connected to a grounding
system that the EMC filter is not compatible with (for example, an IT system).
The supply network becomes connected to ground potential through the
internal EMC filter capacitors, which can cause danger or damage to the
drive.

WARNING!
To prevent radio-frequency interference, do not use a category C2 drive on
a low-voltage public network that supplies domestic premises.

￭ Category C3
This is applicable to drives with an internal EMC C3 filter.
The drive complies with the standard with the following provisions:
1. The motor and control cables are selected as specified in this manual. The EMC
recommendations are obeyed.
2. The maximum motor cable length does not exceed the specified maximum
value. See EMC compatibility and motor cable length (page 168)
3. The drive is installed according to the instructions given in this manual.

WARNING!
Do not install a drive with the internal EMC filter connected to a grounding
system that the EMC filter is not compatible with (for example, an IT system).
The supply network becomes connected to ground potential through the
internal EMC filter capacitors, which can cause danger or damage to the
drive.
180 Technical data

WARNING!
To prevent radio-frequency interference, do not use a category C3 drive on
a low-voltage public network that supplies domestic premises.

￭ Category C4
If the provisions in category 1, 2 or 3 are not met, the requirements of the standard
can be met as follows:
1. It is ensured that no excessive emission is propagated to neighboring
low-voltage networks. In some cases, the inherent suppression in transformers
and cables is sufficient. If in doubt, the supply transformer with static screening
between the primary and secondary windings can be used.

1
7

2 8

4 4
5 9

6 6

1 Medium voltage network

2 Neighboring network
3 Point of measurement
4 Low voltage
5 Equipment (victim)
6 Equipment
7 Supply transformer
8 Static screen
9 Drive

2. An EMC plan for preventing disturbances is drawn up for the installation. A

template is available in Technical guide No. 3 EMC compliant installation and
configuration for a power drive system (3AFE61348280 [English]).
3. The motor and control cables are selected as specified in this manual. For the
best EMC performance, the EMC recommendations are obeyed.
 Technical data 181

4. The drive is installed according to the instructions given in this manual.

WARNING!
Do not install a drive with the internal EMC filter connected to a grounding
system that the EMC filter is not compatible with (for example, an IT system).
The supply network becomes connected to ground potential through the
internal EMC filter capacitors, which can cause danger or damage to the
drive.

WARNING!
To prevent radio-frequency interference, do not use a category C4 drive on
a low-voltage public network that supplies domestic premises.

UL checklist
WARNING!
Operation of this drive requires detailed installation and operation
instructions provided in the hardware and software manuals. The manuals
are provided in electronic format in the drive package or on the Internet.
Keep the manuals with the drive at all times. Hard copies of the manuals can
be ordered through the manufacturer.

• Make sure that the drive type designation label includes the applicable marking.
• DANGER - Risk of electric shock. After disconnecting the input power, always
wait for 5 minutes to let the intermediate circuit capacitors discharge before
you start working on the drive, motor or motor cable.
• The drive is to be used in a heated, indoor controlled environment. The drive
must be installed in clean air according to the enclosure classification. Cooling
air must be clean, free from corrosive materials and electrically conductive
dust.
• The maximum surrounding air temperature is 50 °C at rated output current.
The output current is derated for 50…60 °C in drives with frame size R1…R4.
• The drive is suitable for use in a circuit capable of delivering not more than
100000 rms symmetrical amperes, 480 V maximum (480 V drive types) or 240 V
maximum (240 V drive types) when protected by the UL fuses given elsewhere
in this chapter. The ampere ratings of the protections are based on fault tests
done according to the appropriate UL standard.
• The drive is suitable for use on a circuit capable of delivering not more than
65000 rms symmetrical amperes, 480Y/277 V maximum (480 V drive types),
when protected by a Type E combination motor controller specified by ABB.
182 Technical data

• The cables located within the motor circuit must be rated for at least 75 °C in
UL-compliant installations.
• The input cable must be protected with UL-rated fuses, or the ABB Type E
manual motor protectors (MMP) listed in this manual. The fuses or the manual
motor protectors provide branch circuit protection in accordance with the
National Electrical Code (NEC) and Canadian Electrical Code. Obey also any
other applicable local or provincial codes.

WARNING!
The opening of the branch-circuit protective device may be an indication
that a fault current has been interrupted. To reduce the risk of fire or
electric shock, current-carrying parts and other components of the device
should be examined and replaced if damaged.

• The integral solid state short circuit protection of the drive does not provide
branch circuit protection. Branch circuit protection must be provided in
accordance with the National Electrical Code and any additional local codes.
• The drive provides motor overload protection. For adjustments, see the
firmware manual.
• The drive overvoltage category according to IEC 60664-1 is III.

Disclaimers
￭ Generic disclaimer
The manufacturer shall have no obligation with respect to any product which (i)
has been improperly repaired or altered; (ii) has been subjected to misuse,
negligence or accident; (iii) has been used in a manner contrary to the
manufacturer’s instructions; or (iv) has failed as a result of ordinary wear and tear.

￭ Cyber security disclaimer

This product is designed to be connected to and to communicate information and
data via a network interface. It is Customer's sole responsibility to provide and
continuously ensure a secure connection between the product and Customer
network or any other network (as the case may be). Customer shall establish and
maintain any appropriate measures (such as but not limited to the installation of
firewalls, application of authentication measures, encryption of data, installation
of anti-virus programs, etc.) to protect the product, the network, its system and
the interface against any kind of security breaches, unauthorized access,
interference, intrusion, leakage and/or theft of data or information.
ABB and its affiliates are not liable for damages and/or losses related to such
security breaches, any unauthorized access, interference, intrusion, leakage and/or
theft of data or information.
 Dimension drawings 183

11
Dimension drawings

Contents of this chapter

The chapter contains the dimension drawings of the drive. The dimensions are in
millimeters and inches.
Note: Drives with the BIO-01 I/O extension module (option +L515) are supplied
with a high cover part that increases the depth of the drive by 15 mm (0.6 in).
184 Dimension drawings

Frame R0
￭ Frame R0, 1-phase 230 V, IP20
 Dimension drawings 185

￭ Frame R0, 1-phase 230 V, IP20, with side option

186 Dimension drawings

￭ Frame R0, 1-phase 230 V, UL Type 1

 Dimension drawings 187

￭ Frame R0, 1-phase 230 V, UL Type 1, with side option

188 Dimension drawings

￭ Frame R0, 3-phase 400/480 V, IP20

 Dimension drawings 189

￭ Frame R0, 3-phase 400/480 V, IP20, with side option

190 Dimension drawings

￭ Frame R0, 3-phase 400/480 V, UL Type 1

 Dimension drawings 191

￭ Frame R0, 3-phase 400/480 V, UL Type 1, with side option

192 Dimension drawings

Frame R1
￭ Frame R1, 1-phase 230 V, IP20
 Dimension drawings 193

￭ Frame R1, 1-phase 230 V, IP20, with side option

194 Dimension drawings

￭ Frame R1, 1-phase 230 V, UL Type 1

 Dimension drawings 195

￭ Frame R1, 1-phase 230 V, UL Type 1, with side option

196 Dimension drawings

￭ Frame R1, 3-phase 230 V and 400/480 V, IP20

 Dimension drawings 197

￭ Frame R1, 3-phase 230 V and 400/480 V, IP20, with side option
198 Dimension drawings

￭ Frame R1, 3-phase 230 V and 400/480 V, UL Type 1

 Dimension drawings 199

￭ Frame R1, 3-phase 230 V and 400/480 V, UL Type 1, with side option
200 Dimension drawings

Frame R2
￭ Frame R2, 1-phase 230 V, IP20
 Dimension drawings 201

￭ Frame R2, 1-phase 230 V, IP20, with side option

202 Dimension drawings

￭ Frame R2, 1-phase 230 V, UL Type 1

 Dimension drawings 203

￭ Frame R2, 1-phase 230 V, UL Type 1, with side option

204 Dimension drawings

￭ Frame R2, 3-phase 230 V and 400/480 V, IP20

 Dimension drawings 205

￭ Frame R2, 3-phase 230 V and 400/480 V, IP20, with side option
206 Dimension drawings

￭ Frame R2, 3-phase 230 V and 400/480 V, UL Type 1

 Dimension drawings 207

￭ Frame R2, 3-phase 230 V and 400/480 V, UL Type 1, with side option
208 Dimension drawings

Frame R3
￭ Frame R3, 3-phase 230 V and 400/480 V, IP20
 Dimension drawings 209

￭ Frame R3, 3-phase 230 V and 400/480 V, IP20, with side option
210 Dimension drawings

￭ Frame R3, 3-phase 230 V and 400/480 V, UL Type 1

 Dimension drawings 211

￭ Frame R3, 3-phase 230 V and 400/480 V, UL Type 1, with side option
212 Dimension drawings

Frame R4
￭ Frame R4, 3-phase 230 V and 400/480 V, IP20
 Dimension drawings 213

￭ Frame R4, 3-phase 230 V and 400/480 V, IP20, with side option
214 Dimension drawings

￭ Frame R4, 3-phase 230 V and 400/480 V, UL Type 1

 Dimension drawings 215

￭ Frame R4, 3-phase 230 V and 400/480 V, UL Type 1, with side option
216
 Input chokes 217

12
Input chokes

Contents of this chapter

This chapter describes how to select and install input chokes for the drive. The
chapter also contains the technical data of the input chokes.

When is an input choke necessary?

Determine the need for an external input choke at the drive power input on a
case-by-case basis. The input chokes are used:
• to protect the drive in networks with high short-circuit capacity. Refer to Input
choke (page 167) in sectionElectrical power network specification (page 166).
• to reduce harmonic current emissions. Refer to Compliance with the harmonic
current limits in a public network (IEC/EN 61000 3-2, IEC/EN
61000-3-12) (page 177).
• to reduce the rms value of input current. Refer to Maximum input
current (page 217).
• to reduce supply disturbance and low-frequency interference
• in common DC configurations.

Maximum input current

Input current (I1) of the drive depends on these items:
• motor actual shaft power and efficiency
218 Input chokes

• power output (or input) via DC connection to other drives in the common DC
setup
• network impedance (short circuit capacity) effect on total harmonics content
of the input current. Refer to Electrical power network specification (page 166)
for more information.
Below are the maximum continuous input current values (rms) allowed for different
drive types. If the actual continuous input current is higher (eg, due to very low
efficiency of the motor), it is possible to use an input choke to reduce the input
current rms value.

1-phase 3-phase 3-phase 400 V 480 V

200…240 V AC 200…240 V AC 380…480 V AC

I1 I1 I1 I1
ACS380-04xx-… ACS380-04xx-… ACS380-04xx-…
A A A A

02A4-1 5.5 02A4-2 3.5 01A8-4 2.8 2.2

03A7-1 7.4 03A7-2 4.8 02A6-4 3.5 2.7
04A8-1 9.1 04A8-2 5.8 03A3-4 4.8 3.9
06A9-1 12.6 06A9-2 8.4 04A0-4 6.1 4.5
07A8-1 14.9 07A8-2 9.4 05A6-4 8.5 6.6
09A8-1 21.0 09A8-2 12.8 07A2-4 10.1 6.2
12A2-1 25.6 12A2-2 16.0 09A4-4 12.9 9.8
- - 17A5-2 21.0 12A6-4 16.5 13.9
- - 25A0-2 30.5 17A0-4 23.4 18.8
- - 033A-2 37.5 25A0-4 31.8 26.6
- - 032A-2 37.4 033A-4 40.9 33.9
- - 048A-2 53.2 032A-4 40.7 33.7
- - 055A-2 60.0 038A-4 49.0 41.3
- - - - 045A-4 55.7 46.9
- - - - 050A-4 55.7 46.9

Selecting an input choke

Select the input choke according to the drive type.
 Input chokes 219

Type Frame Input choke type

ACS380-
04xx-…

CHK-04

CHK-06
CHK-D1

CHK-05
CHK-C1

CHK-02

CHK-03
CHK-A1

CHK-07
CHK-B1

CHK-01
1-phase Un = 230 V
02A4-1 R0 x
03A7-1 R0 x
04A8-1 R1 x
06A9-1 R1 x
07A8-1 R1 x
09A8-1 R2 x
12A2-1 R2 x
3-phase Un = 230 V
02A4-2 R1 x
03A7-2 R1 x
04A8-2 R1 x
06A9-2 R1 x
07A8-2 R1 x
09A8-2 R1 x
12A2-2 R2 x
17A5-2 R3 x
25A0-2 R3 x
033A-2 R3 x
032A-2 R4 x
048A-2 R4 x
055A-2 R4 x
3-phase Un = 400 V
01A8-4 R0 x
02A6-4 R1 x
03A3-4 R1 x
04A0-4 R1 x
220 Input chokes

Type Frame Input choke type

ACS380-
04xx-…

CHK-04

CHK-06
CHK-D1

CHK-05
CHK-C1

CHK-02

CHK-03
CHK-A1

CHK-07
CHK-B1

CHK-01
05A6-4 R1 x
07A2-4 R1 x
09A4-4 R1 x
12A6-4 R2 x
17A0-4 R3 x
25A0-4 R3 x
033A-4 R3 x
032A-4 R4 x
038A-4 R4 x
045A-4 R4 x
050A-4 R4 x

The degree of protection of an input choke is IP20. Refer to Dimensions (page 221)
for dimensions, wire sizes and tightening torques.

Guidelines for installing an input choke

Obey these guidelines when you install the input choke:
• If an external EMC filter is also installed, connect the input choke between the
supply and the filter.
• For optimal operation of the choke, fasten the drive and the choke on the same
conductive surface.
• Make sure that the choke does not prevent the airflow through the drive
module, and that the hot air rising from the choke cannot enter the air inlet of
the drive module.
• Keep the cable between the drive and the choke as short as possible.

WARNING!
The input choke is hot when in use and for some time after the use.
 Input chokes 221

￭ Connection diagram
1
L1 L2 L3 PE

U V W PE
2

X Y Z

U1 V1 W1 PE
4

1 AC supply
2 Input choke
3 External EMC filter (if present)
4 Drive

Dimensions
222 Input chokes

Input choke type

CHK-01 CHK-02 CHK-03 CHK-04 CHK-05 CHK-06 CHK-07 CHK-08
Dim A mm (in.) 120 150 150 150 207 207 249 249
(4.72) (5.91) (5.91) (5.91) (8.15) (8.15) (9.80) (9.80)
Dim B mm (in.) 146 175 175 175 272 326 326 346
(5.75) (6.89) (6.89) (6.89) (10.71) (12.83) (12.83) (13.62)
Dim C mm (in.) 86 100 100 154 154 167 167
79 (3.11)
(3.39) (3.94) (3.94) (6.06) (6.06) (6.57) (6.57)
Dim D mm (in.) 77 105 105 105 193 193 235 235
(3.03) (4.13) (4.13) (4.13) (7.60) (7.60) (9.25) (9.25)
Dim E mm (in.) 114 148 148 148 118 169 125 147
(4.49) (5.83) (5.83) (5.83) (4.65) (6.65) (4.92) (5.79)
F screw size M5 M5 M5 M5 M6 M6 M6 M6
Weight kg (lbs) 1.8 3.8 5.4 5.2 10 12 14 16
(4.0) (8.4) (11.9) (11.5) (22) (26.5) (31) (35)
Wire size
0.5…10 0.5…10 0.5…10 0.5…10 1.5…35 1.5…35 25…50 25…50
Main terminals
(20…6) (20…6) (20…6) (20…6) (16…0) (16…0) (6…0) (6…0)
mm2 (AWG)
Tightening
torque 1.5 1.5 1.5 1.5 3.2 3.2 6 6
Main terminals (13) (13) (13) (13) (28) (28) (53) (53)
N·m (lbf·in)
PE/Chassis ter-
M4 M5 M5 M5 M6 M6 M6 M8
minals
Tightening
torque
3 4 4 4 8 8 8 15
PE/Chassis ter-
(26) (35) (35) (35) (70) (70) (70) (135)
minals
N·m (lbf·in)
 External EMC filters 223

13
External EMC filters

Contents of this chapter

This chapter describes how to select external EMC filters for the drive.

Selecting the external EMC filter

If you use an external EMC filter, you must disconnect the internal EMC filter. Refer
to the electrical installation instructions.
Select the external EMC filter according to the drive type:

Type EMC filter type

ACS380-
04xx-… ABB order code Schaffner order code

1-phase UN = 230 V
02A4-1 RFI-11 FS 21754-6.1-07
03A7-1 RFI-12 FS 21754-16.1-07
04A8-1 RFI-12 FS 21754-16.1-07
06A9-1 RFI-12 FS 21754-16.1-07
07A8-1 RFI-12 FS 21754-16.1-07
3-phase UN = 230 V
02A4-2 RFI-32 FN 3258-16-44
03A7-2 RFI-32 FN 3258-16-44
04A8-2 RFI-32 FN 3258-16-44
224 External EMC filters

Type EMC filter type

ACS380-
04xx-… ABB order code Schaffner order code

06A9-2 RFI-32 FN 3258-16-44

07A8-2 RFI-32 FN 3258-16-44
09A8-2 RFI-32 FN 3258-16-44
12A2-2 RFI-33 FN 3258-30-33
17A5-2 RFI-33 FN 3258-30-33
25A0-2 RFI-33 FN 3258-30-33
033A-2 RFI-34 FN 3258-100-35
032A-2 RFI-34 FN 3258-100-35
048A-2 RFI-34 FN 3258-100-35
055A-2 RFI-34 FN 3258-100-35
3-phase UN = 400 V
01A8-4 RFI-32 FN 3258-16-44
02A6-4 RFI-32 FN 3258-16-44
03A3-4 RFI-32 FN 3258-16-44
04A0-4 RFI-32 FN 3258-16-44
05A6-4 RFI-32 FN 3258-16-44
07A2-4 RFI-32 FN 3258-16-44
09A4-4 RFI-32 FN 3258-16-44
12A6-4 RFI-33 FN 3258-30-33
17A0-4 RFI-33 FN 3258-30-33
25A0-4 RFI-33 FN 3258-30-33
033A-4 RFI-34 FN 3258-100-35
032A-4 RFI-34 FN 3258-100-35
038A-4 RFI-34 FN 3258-100-35
045A-4 RFI-34 FN 3258-100-35
050A-4 RFI-34 FN 3258-100-35

See also EMC compatibility and motor cable length and EMC compliance
(IEC/EN 61800-3:2004 + A1:2012) (page 178). For compliance information, refer to
Category C1 (page 178).
 Resistor braking 225

14
Resistor braking

Contents of this chapter

The chapter describes how to select the brake resistor and cables, protect the
system, connect the brake resistor and enable resistor braking.

Safety
WARNING!
Do not do work on the brake resistor or the resistor cable when the drive is
energized. A dangerous voltage is present in the resistor circuit, even when
the brake chopper is not operating, or when it is disabled by a parameter.

Operation principle
The brake chopper handles the extra energy generated by motor during a quick
deceleration. The extra energy increases the drive DC link voltage. The chopper
connects the brake resistor to the DC link whenever the voltage is greater than
the limit defined by the control program. Energy consumption by the resistor
losses lowers the voltage until the resistor can be disconnected.

Selecting the brake resistor

Drives have a built-in brake chopper as standard equipment. The brake resistor is
selected using the table and equations shown in this section.
1. Determine the required maximum braking power PRmax for the application.
PRmax must be smaller than PBRmax. Refer to Reference brake resistors (page 227).
226 Resistor braking

2. Calculate resistance R with Equation 1.

3. Calculate energy ERpulse with Equation 2.
4. Select the resistor so that the following conditions are met:
• The rated power of the resistor must be greater than or equal to PRmax.
• Resistance R must be between Rmin and Rmax given in the table for the used
drive type.
• The resistor must be able to dissipate energy ERpulse during the braking
cycle T.
Equations for selecting the resistor:
Equation 1
When the drive supply voltage is 200 ... 240 V:

When the drive supply voltage is 380 … 415 V:

When the drive supply voltage is 415 ... 480 V:

Equation 2

Equation 3

ton
PRmax
PRave
T

For conversion, use 1 hp = 746 W.

R Calculated brake resistor value (ohm). Make sure that: Rmin < R < Rmax
PRmax Maximum power during the braking cycle (W)
PRave Average power during the braking cycle (W)
ERpulse Energy conducted into the resistor during a single braking pulse (J)
ton Braking time (one cycle) (s)
T Braking cycle time (s)
 Resistor braking 227

WARNING!
Do not use a brake resistor with a resistance below the minimum value
specified for the particular drive. The drive and the internal chopper are not
able to handle the overcurrent caused by the low resistance.

￭ Reference brake resistors

Type Example resistor
Rmin Rmax PBRcont PBRmax
ACS380- types 1) 2)
04xx-…
ohm ohm kW hp kW hp Danotherm

1-phase UN = 230 V
02A4-1 32.5 468 0.25 0.33 0.38 0.50 CBH 360 C T 406 210R
03A7-1 32.5 316 0.37 0.50 0.56 0.74 or
CAR 200 D T 406 210R
04A8-1 32.5 213 0.55 0.75 0.83 1.10
06A9-1 32.5 145 0.75 1.00 1.10 1.50 CBR-V 330 D T 406
78R UL
07A8-1 32.5 96.5 1.10 1.50 1.70 2.20
09A8-1 32.5 69.9 1.50 2.00 2.30 3.00 CBR-V 560 D HT 406
39R UL
12A2-1 19.5 47.1 2.20 3.00 3.30 4.40
3-phase UN = 230 V
02A4-2 39 474 0.25 0.33 0.38 0.50 CBH 360 C T 406 210R
03A7-2 39 319 0.37 0.50 0.56 0.74 or
CAR 200 D T 406 210R
04A8-2 39 217 0.55 0.75 0.83 1.10
06A9-2 39 145 0.75 1.00 1.13 1.50 CBR-V 330 D T 406
78R UL
07A8-2 39 105 1.10 1.50 1.65 2.20
09A8-2 20 71 1.50 2.00 2.25 3.00 CBR-V 560 D HT 406
39R UL
12A2-2 20 52 2.20 2.00 3.30 4.40
17A5-2 16 38 3.00 3.00 4.50 6.00 CBT-H 560 D HT 406
19R
25A0-2 16 28 4.00 5.00 6.00 8.00
033A-2 8 17 5.50 7.50 8.25 11.00 CBT-H 560 D HT 406
15R
032A-2 3 20 5.50 7.50 8.25 11.00 CBT-V 760 G H T 282
8R
048A-2 3 14 7.50 10.00 11.25 15.00
055A-2 3 10 11.00 15.00 16.50 21.99
228 Resistor braking

Type Example resistor

Rmin Rmax PBRcont PBRmax
ACS380- types 1) 2)
04xx-…
ohm ohm kW hp kW hp Danotherm

3-phase UN = 400/480 V
01A8-4 99 933 0.37 0.50 0.56 0.74 CBH 360 C T 406 210R
02A6-4 99 628 0.55 0.75 0.83 1.10 or
CAR 200 D T 406 210R
03A3-4 99 428 0.75 1.00 1.13 1.50
04A0-4 99 285 1.10 1.50 1.65 2.20
05A6-4 99 206 1.50 2.00 2.25 3.00
07A2-4 53 139 2.20 2.00 3.30 4.40 CBR-V 330 D T 406
78R UL
09A4-4 53 102 3.00 3.00 4.50 6.00
12A6-4 32 76 4.00 5.00 6.00 8.00
17A0-4 32 54 5.50 7.50 8.25 11.00 CBT-H 560 D HT 406
39R
25A0-4 23 39 7.50 10.00 11.25 15.00
033A-4 16 33 11.00 15.00 17 22.00 CBT-H 560 D HT 406
19R
032A-4 6 29 11.00 15.00 17 22.00 CBT-H 560 D HT 406
19R
038A-4 6 24 15.00 20.00 23 30.00 CBT-H 760 D HT 406
16R
045A-4 6 20 18.50 25.00 28 37.00
050A-4 6 20 22.00 30.00 33 44.00
1) Braking cycle differs from that of the drive. Refer to brake resistor manufacturer’s documentation.
2) If brake resistors from other manufacturers are used, the characteristics must agree with the values
in the table.

Definitions
PBRmax The maximum braking capacity of the drive, when the length of the
braking pulse is at most 1 minute for each 10 minutes (PBRcont × 1.5).
Must be more than the desired braking power.
PBRcont The continuous braking capacity of the drive
Rmax The maximum resistance value of the brake resistor that can provide
PBRcont
Rmin The minimum permitted resistance value of the brake resistor

Selecting and routing the brake resistor cables

Use a shielded cable specified in the technical data.
 Resistor braking 229

￭ Minimizing electromagnetic interference

Make sure that the installation is compliant with the EMC requirements. Obey
these rules in order to minimize electromagnetic interference caused by the rapid
voltage and current changes in the resistor cables:
• Shield the brake resistor cable. Use shielded cable or a metallic enclosure. If
you use unshielded single-core cables, route them inside a cabinet that
efficiently suppresses the radiated emissions.
• Install the cables away from other cable routes.
• Avoid long parallel runs with other cables. The minimum parallel cabling
separation distance is 0.3 meters (1 ft).
• Cross the other cables at 90° angles.
• Keep the cable as short as possible in order to minimize the radiated emissions
and stress on the brake chopper. The longer the cable the greater the radiated
emissions, inductive load and voltage peaks over the IGBT semiconductors of
the brake chopper.

￭ Maximum cable length

The maximum length of the resistor cable(s) is 10 m (33 ft).

Selecting the installation location for the brake resistors

Protect the open (IP00) brake resistors against contact. Install the brake resistor
in a place where it cools effectively. Arrange the cooling of the resistor so that:
• no danger of overheating is caused to the resistor or nearby materials, and
• the temperature of the space that the resistor is in does not go above the
allowed maximum value.

WARNING!
The materials near the brake resistor must be non-flammable. The surface
temperature of the resistor is high. Air flowing from the resistor is of
hundreds of degrees Celsius. If the exhaust vents are connected to a
ventilation system, make sure that the material withstands high
temperatures. Protect the resistor against contact.

Protecting the system in brake circuit fault situations

￭ Protecting the system in cable and brake resistor short-circuit
situations
The drive input fuses will also protect the resistor cable when it is identical with
the input power cable.
230 Resistor braking

￭ Protecting the system against thermal overload

The drive has a brake thermal model which protects the brake resistor against
overload. ABB recommends to enable the thermal model at start up.
ABB recommends to equip the drive with a main contactor for safety reasons even
when you have enabled the resistor thermal model. Wire the contactor so that it
opens in case the resistor overheats. This is essential for safety since the drive
will not otherwise be able to interrupt the main supply if the chopper remains
conductive in a fault situation. An example wiring diagram is shown below. ABB
recommends that you use resistors equipped with a thermal switch (1) inside the
resistor assembly. The switch indicates overtemperature.
ABB recommends that you also wire the thermal switch to a digital input of the
drive, and configure the input to cause a fault trip at resistor overtemperature
indication.

3
1 L1 L2 L3

1
OFF
2

1 3 5
13 3

ON
2 4 6 14 4
5
Θ 4

L1 L2 L3 x +24V

2
x DIx
K1

1 Drive input power connection with a main contactor

2 Drive
3 Main contactor control circuit
4 Brake resistor thermal switch
5 Digital input. Monitors the brake resistor thermal switch.
 Resistor braking 231

Mechanical and electrical installation of brake resistor

WARNING!
Obey the safety instructions of the drive. 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, commissioning or
maintenance work.

WARNING!
Stop the drive and do the steps in section Electrical safety
precautions (page 20) before you start the work.

￭ Mechanical installation
Refer to the resistor manufacturer’s instructions.

￭ Electrical installation
Measuring the insulation
See the electrical installation instructions of the drive.

Connecting power cables

See the electrical installation instructions of the drive.

Connection the control cables

Connect the thermal switch of the brake resistor as described in Protecting the
system against thermal overload (page 230).

Start-up
Set the following parameters:
1. Disable the overvoltage control of the drive with parameter 30.30 Overvoltage
control.
2. Set the source of parameter 31.01 External event 1 source to point to the digital
input where the thermal switch of the brake resistor is wired.
3. Set parameter 31.02 External event 1 type to Fault.
4. Enable the brake chopper by parameter 43.06 Brake chopper enable. If Enabled
with thermal model is selected, set also the brake resistor overload protection
parameters 43.08 and 43.09 according to the application.
5. Check the resistance value of parameter 43.10 Brake resistance.
232 Resistor braking

With these parameter settings, the drive generates a fault and coasts to a stop
on brake resistor overtemperature.
 The Safe torque off function 233

15
The Safe torque off function

Contents of this chapter

This chapter describes the Safe torque off (STO) function of the drive and gives
instructions for its use.

Description
The Safe torque off function can be used, for example, as the final actuator device
of safety circuits (such as an emergency stop circuit) that stop the drive in case
of danger. Another typical application is a prevention of unexpected start-up
function that enables short-time maintenance operations like cleaning or work on
non-electrical parts of the machinery without switching off the power supply to
the drive.
When activated, the Safe torque off function disables the control voltage for the
power semiconductors of the drive output stage, thus preventing the drive from
generating the torque required to rotate the motor. If the motor is running when
Safe torque off is activated, it coasts to a stop.
The Safe torque off function has a redundant architecture, that is, both channels
must be used in the safety function implementation. The safety data given in this
manual is calculated for redundant use, and does not apply if both channels are
not used.
234 The Safe torque off function

The Safe torque off function complies with these standards:

Standard Name

IEC 60204-1:2021 Safety of machinery – Electrical equipment of machines –

EN 60204-1:2018 Part 1: General requirements

IEC 61000-6-7:2014 Electromagnetic compatibility (EMC) – Part 6-7: Generic

standards – Immunity requirements for equipment intended
to perform functions in a safety-related system (functional
safety) in industrial locations

IEC 61326-3-1:2017 Electrical equipment for measurement, control and laborat-

ory use – EMC requirements – Part 3-1: Immunity require-
ments for safety-related systems and for equipment inten-
ded to perform safety-related functions (functional safety)
– General industrial applications

IEC 61508-1:2010 Functional safety of electrical/electronic/programmable

electronic safety-related systems – Part 1: General require-
ments

IEC 61508-2:2010 Functional safety of electrical/electronic/programmable

electronic safety-related systems – Part 2: Requirements for
electrical/electronic/programmable electronic safety-related
systems

IEC 61511-1:2017 Functional safety – Safety instrumented systems for the

process industry sector

IEC 61800-5-2:2016 Adjustable speed electrical power drive systems – Part 5-2:
EN 61800-5-2:2007 Safety requirements – Functional

EN IEC 62061:2021 Safety of machinery – Functional safety of safety-related

control systems

EN ISO 13849-1:2015 Safety of machinery – Safety-related parts of control systems

– Part 1: General principles for design

EN ISO 13849-2:2012 Safety of machinery – Safety-related parts of control systems

– Part 2: Validation

The function also corresponds to Prevention of unexpected start-up as specified

by EN ISO 14118:2018 (ISO 14118:2017), and Uncontrolled stop (stop category 0)
as specified in EN/IEC 60204-1.

￭ Compliance with the European Machinery Directive and the UK Supply

of Machinery (Safety) Regulations
The Declarations of conformity are shown at the end of this chapter.
 The Safe torque off function 235

Wiring
For the electrical specifications of the STO connection, see the technical data of
the control unit.

￭ Connection principle
Single ACS380 drive, internal power supply

1
K 2

+ 24 V DC
S+
SGND
S1
S2 UDC+

3 4

UDC-

1 Drive
2 Control unit
3 Control logic
4 To motor
K Activation switch
236 The Safe torque off function

Single ACS380 drive, external power supply

24 V DC
- + 1
2

S+ + 24 V DC
SGND
S1
S2 UDC+

4
3

UDC-

1 Drive
2 Control unit
3 Control logic
4 To motor
K Activation switch
 The Safe torque off function 237

Single-channel connection of activation switch

1
2
K

S+
+ 24 V DC
SGND
S1

UDC+
S2

4
3

UDC-

1 Drive
2 Control unit
3 Control logic
4 To motor
K Activation switch

Note: A single-channel activation switch can limit the SIL/PL capability of the
safety function to a lower level than the SIL/PL capability of the STO function of
the drive.

Note:
• Both STO inputs (S1, S2) must be connected to the activation switch. Otherwise,
no SIL/PL classification is given.
• Pay special attention to avoiding any potential failure modes for the wiring.
For example, use a shielded cable. For measures for fault exclusion of wiring,
refer to EN ISO 13849-2:2012, table D.4.
238 The Safe torque off function

￭ Wiring examples
Single ACS380 drive, internal power supply

1 2

OUT
S+
13 23 31 Y1 Y2

SGND K

14 24 32 A1 A2
S1
S2 GND

1 Drive
2 Safety PLC
K Safety relay

Single ACS380 drive, external power supply

1 24 V DC 2
- +
OUT
S+
13 23 31 Y1 Y2

SGND K

14 24 32 A1 A2
S1
S2 GND

1 Drive
2 Safety PLC
K Safety relay
 The Safe torque off function 239

Multiple ACS380 drives, internal power supply

+24 V S+

SGND K

S1
2 S2

S+
SGND

S1
2 S2

S+
SGND

S1
2 S2

1 Drive
2 Control unit
K Activation switch
240 The Safe torque off function

Multiple ACS380 drives, external power supply

24 V DC
– +

+24 V S+
SGND

S1
2 S2

S+
SGND

S1
2 S2

S+
SGND

S1
2 S2

1 Drive
2 Control unit
K Activation switch

￭ Activation switch
In the wiring diagrams, the activation switch has the designation [K]. This
represents a component such as a manually operated switch, an emergency stop
push button switch, or the contacts of a safety relay or safety PLC.
 The Safe torque off function 241

• In case a manually operated activation switch is used, the switch must be of

a type that can be locked out to the open position.
• The contacts of the switch or relay must open/close within 200 ms of each
other.

￭ Cable types and lengths

• ABB recommends double-shielded twisted-pair cable.
• Maximum cable lengths:
• 300 m (1000 ft) between activation switch [K] and drive control unit
• 60 m (200 ft) between multiple drives
• 60 m (200 ft) between external power supply and first control unit

Note: A short-circuit in the wiring between the switch and an STO terminal causes
a dangerous fault. Therefore, it is recommended to use a safety relay (including
wiring diagnostics) or a wiring method (shield grounding, channel separation)
which reduces or eliminates the risk caused by the short-circuit.

Note: The voltage at the STO input terminals of the drive must be at least 13 V DC
to be interpreted as “1”.
The pulse tolerance of the input channels is 1 ms.

￭ Grounding of protective shields

• Ground the shield in the cabling between the activation switch and the control
unit at the control unit only.
• Ground the shield in the cabling between two control units at one control unit
only.
242 The Safe torque off function

Operation principle
1. The Safe torque off activates (the activation switch is opened, or safety relay
contacts open).
2. The STO inputs of the drive control unit de-energize.
3. The control unit cuts off the control voltage from the output IGBTs.
4. The control program generates an indication as defined by parameter 31.22
(see the firmware manual of the drive).
The parameter selects which indications are given when one or both STO
signals are switched off or lost. The indications also depend on whether the
drive is running or stopped when this occurs.
Note: This parameter does not affect the operation of the STO function itself.
The STO function will operate regardless of the setting of this parameter: a
running drive will stop upon removal of one or both STO signals, and will not
start until both STO signals are restored and all faults reset.

Note: The loss of only one STO signal always generates a fault as it is
interpreted as a malfunction of STO hardware or wiring.

5. The motor coasts to a stop (if running). The drive cannot restart while the
activation switch or safety relay contacts are open. After the contacts close,
a reset may be needed (depending on the setting of parameter 31.22). A new
start command is required to start the drive.
 The Safe torque off function 243

Start-up including validation test

To ensure the safe operation of a safety function, validation is required. The final
assembler of the machine must validate the function by performing a validation
test. The test must be performed
1. at initial start-up of the safety function
2. after any changes related to the safety function (circuit boards, wiring,
components, settings, replacement of inverter module, etc.)
3. after any maintenance work related to the safety function
4. after a drive firmware update
5. at the proof test of the safety function.

￭ Competence
The validation test of the safety function must be carried out by a competent
person with adequate expertise and knowledge of the safety function as well as
functional safety, as required by IEC 61508-1 clause 6. The test procedures and
report must be documented and signed by this person.

￭ Validation test reports

Signed validation test reports must be stored in the logbook of the machine. The
report shall include documentation of start-up activities and test results, references
to failure reports and resolution of failures. Any new validation tests performed
due to changes or maintenance shall be logged into the logbook.

￭ Validation test procedure

After wiring the Safe torque off function, validate its operation as follows.
If an FSPS-21 module is installed, refer to its documentation.

Action

WARNING!
Obey the safety instructions. If you ignore them, injury or death, or damage to
the equipment can occur.

Make sure that the motor can be run and stopped freely during start-up.

Stop the drive (if running), switch the input power off and isolate the drive from the
power line using a disconnector.

Check the STO circuit connections against the wiring diagram.

Close the disconnector and switch the power on.

244 The Safe torque off function

Action

Test the operation of the STO function when the motor is stopped.
•Give a stop command for the drive (if running) and wait until the motor shaft is
at a standstill.
Make sure that the drive operates as follows:
• Open the STO circuit. The drive generates an indication if one is defined for the
'stopped' state in parameter 31.22 (see the firmware manual).
• Give a start command to verify that the STO function blocks the drive's operation.
The motor should not start.
• Close the STO circuit.
• Reset any active faults. Restart the drive and check that the motor runs normally.

Test the operation of the STO function when the motor is running.
• Start the drive and make sure the motor is running.
• Open the STO circuit. The motor should stop. The drive generates an indication
if one is defined for the 'running' state in parameter 31.22 (see the firmware
manual).
• Reset any active faults and try to start the drive.
• Make sure that the motor stays at a standstill and the drive operates as described
above in testing the operation when the motor is stopped.
• Close the STO circuit.
• Reset any active faults. Restart the drive and check that the motor runs normally.

Test the operation of the failure detection of the drive. The motor can be stopped
or running.
• Open the 1st input channel of the STO circuit. If the motor was running, it should
coast to a stop. The drive generates an FA81 fault indication (see the firmware
manual).
• Give a start command to verify that the STO function blocks the drive's operation.
The motor should not start.
• Open the STO circuit (both channels).
• Give a reset command.
• Close the STO circuit (both channels).
• Reset any active faults. Restart the drive and check that the motor runs normally.
• Open the 2nd input channel of the STO circuit. If the motor was running, it should
coast to a stop. The drive generates an FA82 fault indication (see the firmware
manual).
• Give a start command to verify that the STO function blocks the drive's operation.
The motor should not start.
• Open the STO circuit (both channels).
• Give a reset command.
• Close the STO circuit (both channels).
• Reset any active faults. Restart the drive and check that the motor runs normally.

Document and sign the validation test report which verifies that the safety function
is safe and accepted for operation.
 The Safe torque off function 245

Use
1. Open the activation switch, or activate the safety functionality that is wired
to the STO connection.
2. The STO inputs on the drive control unit de-energize, and the control unit cuts
off the control voltage from the output IGBTs.
3. The control program generates an indication as defined by parameter 31.22
(see the firmware manual of the drive).
4. The motor coasts to a stop (if running). The drive will not restart while the
activation switch or safety relay contacts are open.
5. Deactivate the STO by closing the activation switch, or resetting the safety
functionality that is wired to the STO connection.
6. Reset any faults before restarting.

WARNING!
The Safe torque off function does not disconnect the voltage of the main
and auxiliary circuits from the drive. Therefore maintenance work on electrical
parts of the drive or the motor can only be carried out after isolating the
drive from the supply and all other voltage sources.

WARNING!
The drive cannot detect or memorize any changes in the STO circuitry when
the drive control unit is not powered or when the main power to the drive is
off. If both STO circuits are closed and a level-type start signal is active when
the power is restored, it is possible that the drive starts without a fresh start
command. Take this into account in the risk assessment of the system.
This is also valid when the drive is only powered by a BAPO-xx auxiliary power
extension module.

WARNING!
Permanent magnet or synchronous reluctance [SynRM] motors only:
In case of a multiple IGBT power semiconductor failure, the drive can produce
an alignment torque which maximally rotates the motor shaft by 180/p
degrees (with permanent magnet motors) or 180/2p degrees (with
synchronous reluctance [SynRM] motors) regardless of the activation of the
Safe torque off function. p denotes the number of pole pairs.

Notes:
• If a running drive is stopped by using the Safe torque off function, the drive
will cut off the motor supply voltage and the motor will coast to a stop. If this
246 The Safe torque off function

causes danger or is not otherwise acceptable, stop the drive and machinery
using the appropriate stop mode before activating the Safe torque off function.
• The Safe torque off function overrides all other functions of the drive.
• The Safe torque off function is ineffective against deliberate sabotage or
misuse.
• The Safe torque off function has been designed to reduce the recognized
hazardous conditions. In spite of this, it is not always possible to eliminate all
potential hazards. The assembler of the machine must inform the final user
about the residual risks.
 The Safe torque off function 247

Maintenance
After the operation of the circuit is validated at start-up, the STO function shall
be maintained by periodic proof testing. In high demand mode of operation, the
maximum proof test interval is 20 years. In low demand mode of operation, the
maximum proof test interval is 10 years; see section Safety data (page 249). It is
assumed that all dangerous failures of the STO circuit are detected by the proof
test. To perform the proof test, do the Validation test procedure (page 243).
Note: See also the Recommendation of Use CNB/M/11.050 (published by the
European co-ordination of Notified Bodies) concerning dual-channel safety-related
systems with electromechanical outputs:
• When the safety integrity requirement for the safety function is SIL 3 or PL e
(cat. 3 or 4), the proof test for the function must be performed at least every
month.
• When the safety integrity requirement for the safety function is SIL 2 (HFT =
1) or PL d (cat. 3), the proof test for the function must be performed at least
every 12 months.

The STO function of the drive does not contain any electromechanical components.
In addition to proof testing, it is a good practice to check the operation of the
function when other maintenance procedures are carried out on the machinery.
Include the Safe torque off operation test described above in the routine
maintenance program of the machinery that the drive runs.
If any wiring or component change is needed after start-up, or the parameters are
restored, do the test given in section Validation test procedure (page 243).
Use only spare parts approved by ABB.
Record all maintenance and proof test activities in the machine logbook.

￭ Competence
The maintenance and proof test activities of the safety function must be carried
out by a competent person with adequate expertise and knowledge of the safety
function as well as functional safety, as required by IEC 61508-1 clause 6.
248 The Safe torque off function

Fault tracing
The indications given during the normal operation of the Safe torque off function
are selected by drive control program parameter 31.22.
The diagnostics of the Safe torque off function cross-compare the status of the
two STO channels. In case the channels are not in the same state, a fault reaction
function is performed and the drive trips on an FA81 or FA82 fault. An attempt to
use the STO in a non-redundant manner, for example activating only one channel,
will trigger the same reaction.
See the firmware manual of the drive control program for the indications generated
by the drive, and for details on directing fault and warning indications to an output
on the control unit for external diagnostics.
Any failures of the Safe torque off function must be reported to ABB.
 The Safe torque off function 249

Safety data
The safety data for the Safe torque off function is given below.
Note: The safety data is calculated for redundant use, and applies only if both STO
channels are used.
 PFH
PFDavg PFDavg PFDavg
Frame SFF (T1 = 20 MTTFD DC TM PFHdiag λDiag_s λDiag_d
SIL SC PL (T1 = 2 (T1 = 5 (T1 = 10 Cat. HFT CCF
size (%) a) (a) (%) (a) (1/h) (1/h) (1/h)
a) a) a)
(1/h)

1-phase UN = 230 V
R0 3 3 e >99 8.52E-09 7.43E-05 1.86E-04 3.72E-04 1968 ≥90 3 1 80 20 6.29E-08 0.00E+00 9.51E-08
R1 3 3 e >99 8.52E-09 7.43E-05 1.86E-04 3.72E-04 1968 ≥90 3 1 80 20 6.29E-08 0.00E+00 9.51E-08
R2 3 3 e >99 8.52E-09 7.43E-05 1.86E-04 3.72E-04 1968 ≥90 3 1 80 20 6.29E-08 0.00E+00 9.51E-08
3-phase UN = 230 V
R1 3 3 e >99 7.65E-09 6.71E-05 1.68E-04 3.36E-04 2210 ≥90 3 1 80 20 6.29E-08 0.00E+00 9.51E-08
250 The Safe torque off function

R2 3 3 e >99 7.65E-09 6.71E-05 1.68E-04 3.36E-04 2209 ≥90 3 1 80 20 6.29E-08 0.00E+00 9.51E-08
R3 3 3 e >99 7.61E-09 6.68E-05 1.67E-04 3.34E-04 2569 ≥90 3 1 80 20 6.29E-08 0.00E+00 9.51E-08
R4 3 3 e >99 7.61E-09 6.68E-05 1.67E-04 3.34E-04 2568 ≥90 3 1 80 20 6.29E-08 0.00E+00 9.51E-08
3-phase UN = 400/480 V
R0 3 3 e >99 7.65E-09 6.71E-05 1.68E-04 3.36E-04 2210 ≥90 3 1 80 20 6.29E-08 0.00E+00 9.51E-08
R1 3 3 e >99 7.65E-09 6.71E-05 1.68E-04 3.36E-04 2210 ≥90 3 1 80 20 6.29E-08 0.00E+00 9.51E-08
R2 3 3 e >99 7.65E-09 6.71E-05 1.68E-04 3.36E-04 2209 ≥90 3 1 80 20 6.29E-08 0.00E+00 9.51E-08
R3 3 3 e >99 7.61E-09 6.68E-05 1.67E-04 3.34E-04 2569 ≥90 3 1 80 20 6.29E-08 0.00E+00 9.51E-08
R4 3 3 e >99 7.61E-09 6.68E-05 1.67E-04 3.34E-04 2568 ≥90 3 1 80 20 6.29E-08 0.00E+00 9.51E-08
3AXD10001401865 E
 The Safe torque off function 251

• The STO is a type A safety component as defined in IEC 61508-2.

• Relevant failure modes:
• The STO trips spuriously (safe failure)
• The STO does not activate when requested
• A fault exclusion on the failure mode “short circuit on printed circuit board”
has been made (EN 13849-2, table D.5). The analysis is based on an
assumption that one failure occurs at one time. No accumulated failures
have been analyzed.
• STO response times:
• STO reaction time (shortest detectable break): 1 ms
• STO response time: 5 ms (typical), 15 ms (maximum)
• Fault detection time: Channels in different states for longer than 200 ms
• Fault reaction time: Fault detection time + 10 ms.
• Indication delays:
• STO fault indication (parameter 31.22) delay: < 500 ms
• STO warning indication (parameter 31.22) delay: < 1000 ms.

￭ Terms and abbreviations

Term or Reference Description
abbreviation

Cat. EN ISO 13849-1 Classification of the safety-related parts of a control

system in respect of their resistance to faults and their
subsequent behavior in the fault condition, and which is
achieved by the structural arrangement of the parts, fault
detection and/or by their reliability. The categories are:
B, 1, 2, 3 and 4.

CCF EN ISO 13849-1 Common cause failure (%)

DC EN ISO 13849-1 Diagnostic coverage (%)

HFT IEC 61508 Hardware fault tolerance

MTTFD EN ISO 13849-1 Mean time to dangerous failure: (Total number of life
units) / (Number of dangerous, undetected failures)
during a particular measurement interval under stated
conditions

PFDavg IEC 61508 Average probability of dangerous failure on demand,

that is, mean unavailability of a safety-related system to
perform the specified safety function when a demand
occurs
252 The Safe torque off function

Term or Reference Description

abbreviation

PFH IEC 61508 Average frequency of dangerous failures per hour, that
is, average frequency of a dangerous failure of a safety
related system to perform the specified safety function
over a given period of time

PFHdiag IEC/EN 62061 Average frequency of dangerous failures per hour for the
diagnostic function of STO

PL EN ISO 13849-1 Performance level. Levels a…e correspond to SIL

Proof test IEC 61508, IEC Periodic test performed to detect failures in a
62061 safety-related system so that, if necessary, a repair can
restore the system to an "as new" condition or as close
as practical to this condition

SC IEC 61508 Systematic capability (1…3)

SFF IEC 61508 Safe failure fraction (%)

SIL IEC 61508 Safety integrity level (1…3)

STO IEC/EN 61800-5-2 Safe torque off

T1 IEC 61508-6 Proof test interval. T1 is a parameter used to define the

probabilistic failure rate (PFH or PFD) for the safety
function or subsystem. Performing a proof test at a
maximum interval of T1 is required to keep the SIL
capability valid. The same interval must be followed to
keep the PL capability (EN ISO 13849) valid.
See also section Maintenance.

TM EN ISO 13849-1 Mission time: the period of time covering the intended
use of the safety function/device. After the mission time
elapses, the safety device must be replaced. Note that
any TM values given cannot be regarded as a guarantee
or warranty.

λDiag_d IEC 61508-6 Dangerous failure rate (per hour) of the diagnostics
function of STO

λDiag_s IEC 61508-6 Safe failure rate (per hour) of the diagnostics function
of STO

￭ TÜV certificate
The TÜV certificate is available on the Internet.
 The Safe torque off function 253

￭ Declarations of conformity

ABB
EU Declaration of Conformity
Machinery Directive 2006/42/EC
xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx xxxxxxxxxxxxxxxxxxxxxxxxxxx
We
Manufacturer: ABB Oy
Address: Hiomotie 13, 00380 Helsinki, Finland.
Phone: +358 10 22 11
declare under our sole responsibility that the following product:

Frequency converter

ACS380-04

with regard to the safety functions

- Safe Torque Off

- Safe stop 1 (SS1-t, with FSPS-21 PROFIsafe module, +Q986)
is in conformity with all the relevant safety component requirements of EU Machinery Directive 2006/42/EC, when the listed safety function is
used for safety component functionality.

The following harmonized standards have been applied:

EN 61800-5-2:2007 Adjustable speed electrical power drive systems – Part 5-2: Safety requirements -
Functional
EN IEC 62061:2021 Safety of machinery – Functional safety of safety-related control systems

EN ISO 13849-1:2015 Safety of machinery – Safety-related parts of control systems. Part 1: General
requirements
EN ISO 13849-2:2012 Safety of machinery – Safety-related parts of the control systems. Part 2:
Validation
EN 60204-1:2018 Safety of machinery – Electrical equipment of machines – Part 1: General
requirements
The following other standards have been applied:

IEC 61508:2010, parts 1-2 Functional safety of electrical / electronic / programmable electronic safety-
related systems
IEC 61800-5-2:2016 Adjustable speed electrical power drive systems – Part 5-2: Safety requirements -
Functional

The product(s) referred in this Declaration of conformity fulfil(s) the relevant provisions of other European Union Directives which are notified in
Single EU Declaration of conformity 3AXD10000495941.

Authorized to compile the technical file: ABB Oy, Hiomotie 13, 00380 Helsinki, Finland.

Helsinki, August 31, 2022

Signed for and on behalf of:

Mika Vartiainen Mikko Korpinen

Local Division Manager Product Unit Manager
ABB Oy ABB Oy

Document number 3AXD10000462189

Page 1 of 1
254 The Safe torque off function

ABB
Declaration of Conformity
Supply of Machinery (Safety) Regulations 2008
xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx xxxxxxxxxxxxxxxxxxxxxxxxxxx
We
Manufacturer: ABB Oy
Address: Hiomotie 13, 00380 Helsinki, Finland.
Phone: +358 10 22 11
declare under our sole responsibility that the following product:

Frequency converter
ACS380-04

with regard to the safety functions

- Safe Torque Off

- 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 designated standards have been applied:

EN 61800-5-2:2007 Adjustable speed electrical power drive systems – Part 5-2: Safety requirements -
Functional
EN IEC 62061:2021 Safety of machinery – Functional safety of safety-related control systems

EN ISO 13849-1:2015 Safety of machinery – Safety-related parts of control systems. Part 1: General
requirements
EN ISO 13849-2:2012 Safety of machinery – Safety-related parts of the control systems. Part 2:
Validation
EN 60204-1:2018 Safety of machinery – Electrical equipment of machines – Part 1: General
requirements
The following other standards have been applied:
EN 61508:2010, parts 1-2 Functional safety of electrical / electronic / programmable electronic safety-
related systems
EN 61800-5-2:2017 Adjustable speed electrical power drive systems – Part 5-2: Safety requirements -
Functional

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.

Authorized to compile the technical file: ABB Limited, Daresbury Park, Cheshire, United Kingdom, WA4 4BT.

Helsinki, August 31, 2022

Signed for and on behalf of:

Mika Vartiainen Mikko Korpinen

Local Division Manager Product Unit Manager
ABB Oy ABB Oy

Document number 3AXD10001329530

Page 1 of 1
 BTAC-02 pulse encoder interface module 255

16
BTAC-02 pulse encoder
interface module

Contents of this chapter

This chapter contains a description and technical data of the optional BTAC-02
pulse encoder interface module and describes how to start up the module.

Safety instructions
WARNING!
Obey the safety instructions of the drive. If you ignore them, injury or
death, or damage to the equipment can occur.

Hardware description
￭ Product overview
The BTAC pulse encoder interface module (option +L535) adds a digital pulse
encoder interface to the drive. Use a pulse encoder, if you need accurate speed or
position (angle) feedback from the motor shaft. The BTAC module supplies power
to the encoder.
The BTAC module has the features of the BAPO-01 auxiliary power extension
module. It provides back-up power to the drive.
256 BTAC-02 pulse encoder interface module

￭ Layout
1. BTAC module
2. Locking screw hole
3. X103 connector
4. X104 connector

7 5. X105 connector
6. X106 connector
7. Internal X100 connector
1
8. Internal X102 connector
9. Grounding rail
3
10. Grounding screw

6
8

10

Mechanical installation
Refer to Installing options (page 92) and BAPO, BREL, BRES, and BTAC modules
quick installation guide (3AXD50000837946 [English]).

Electrical installation
￭ Wiring – General
Connect the pulse encoder to the BTAC module with cables as specified in this
table.
 BTAC-02 pulse encoder interface module 257

Cable Maximum con- Maximum cable

nector size length

4 × (2+1) double-shielded twisted pair cable with indi- 2.5 mm2 12 AWG 100 m 1) 328 ft
vidual and overall shields
1) If the encoder supply voltage is less than 10 V, the maximum cable length is 50 m (164 ft).

Terminal designations
The encoder user interface of the BTAC module consists of four 1×3-pin terminal
blocks.
Use this table for reference when you wire the BTAC module and encoder terminals.

Identification
Description
BTAC Encoder

X103
VIN Vcc/PWR External power supply input
VOUT Vcc/PWR Power supply output for the encoder
GND 0 V / GND External power and encoder ground
X104
A 1 A A+ Encoder signal A + terminal
A- 1- A- A- Encoder signal A - terminal
GND - - - Encoder ground
X105
B 2 B B+ Encoder signal B + terminal
B- 2- B- B- Encoder signal B - terminal
GND - - - Encoder ground
X106
Z 3 Z Z+ Encoder signal Z + terminal
Z- 3- Z- Z- Encoder signal Z - terminal
GND - - - Encoder ground
258 BTAC-02 pulse encoder interface module

Channels
Description
BTAC Encoder

A 1 A A+ • Maximum signal frequency: 200 kHz

• Signal levels:
A- 1- A- A-
B 2 B B+ Encoder supply Logic “1” Logic “0”
voltage
B- 2- B- B-
5V >2.5 V <1.9 V
Z 3 Z Z+
15 V >7.5 V <5.3 V
Z- 3- Z- Z-
24 V >12.1 V <8.3 V

• Decision levels are automatically defined based on the daisy

chained power supply voltage level.
• Input channels are isolated from the logic and ground.
• When the drive runs in the Forward direction, channel A should
lead channel B by 90° (electrical).
• Channel Z: One pulse per revolution (used in positioning ap-
plications only).

￭ Wiring – Encoder power supply interface

Connect the encoder power supply through the BTAC module. The same power
supply feeds power to the signal interface of the BTAC module.

0V Vcc Vin
Vout Vcc
GND 0V

1 Encoder
2 BTAC module
3 Encoder power supply
 BTAC-02 pulse encoder interface module 259

When using a 24 V encoder, it is possible to supply power to the encoder and BTAC
module from the 24 V DC auxiliary power output of the drive. If you supply power
from the auxiliary power output, make sure that you do not exceed the maximum
load capacity.
Use the following table to determine if you can use the auxiliary power output.
Add the missing values and calculate the sum. The sum must be less than (or equal
to) the maximum output current of the auxiliary power output. For the maximum
output current, see the drive technical data.

Loads with the drive 24 V DC auxiliary voltage output mA

Number of digital inputs used × 15 mA each
BTAC-02 50 mA
Encoder current requirement
Requirements for other user connection(s) to drive 24 V DC auxiliary voltage
output
Total

￭ Wiring – Encoder
1. Remove the connector cover.
2. Determine the encoder wiring configuration:
• Refer to Phasing (page 259) to determine if the encoder has a normal pulse
order – encoder channel A pulse leads channel B pulse.
• Refer to Encoder output types (page 260) to determine the encoder output
type.
• For push-pull types, refer to the manufacturer’s recommendation for the
connection. You can use single-ended or differential output.
3. Refer to Wiring diagrams – Push-pull type encoder output (page 261), Wiring
diagrams – Open collector (sinking) encoder output (page 263) or Wiring
diagrams – Open emitter (sourcing) encoder output (page 264) to select the
applicable diagram, and wire the encoder.
Obey these guidelines:
• Normally, ground the cable shield only at the drive end.
• Do not route the encoder cables in parallel to power cables (for example,
motor cables).
4. Make sure that the encoder phasing is correct. Refer to Phasing (page 259).

Phasing
When the encoder is connected correctly, running the drive in the Forward (positive
speed reference) direction should produce a positive encoder speed feedback.
Option A: Oscilloscope test. On incremental encoders, the two output channels,
typically A and B or 1 and 2, are 90° (in phase) apart from each other. When rotated
260 BTAC-02 pulse encoder interface module

clockwise, in most encoders channel A leads channel B. To determine the leading

channel, refer to the encoder documentation or use an oscilloscope.

90° The diagram shows normal phasing:

Pulse A leads (rises earlier than)
pulse B.
A or 1
A or 1
B or 2
B or 2

Connect the encoder output channel that leads when the drive runs Forward to
BTAC terminal A. Connect the output channel that trails to BTAC terminal B.
Option B: Functional test
For this test:
• Temporarily, switch the drive to the scalar mode. Set parameter 99.04 Motor
ctrl mode to 1 (SCALAR).
• Run the drive in the forward direction.
• Make sure that the value of parameter 90.13 Enc1 revol extension increases.
• If the value of parameter 90.13 Enc1 revol extension decreases, switch the A+/A-
(or 1+/1-) connections.

Encoder output types

Push-pull Open collector (sinking) Open emitter (sourcing)

VCC VCC VCC

RL
OUT
OUT
OUT
RL

VCC = Encoder input power supply voltage

RL = Load resistor at encoder output channel
 BTAC-02 pulse encoder interface module 261

Wiring diagrams – Push-pull type encoder output

Diagram assumes normal pulse order in Forward rotation: Pulse A leads

A
B
For encoders with pulse B leading, change the diagram:
• Wire encoder A and B to BTAC terminals B and A, respectively.
• Wire encoder A- and B- (if present) to BTAC terminals B- and A-, respectively.

Differential connection

2 3

Vin
1
Vout
GND
1 A
1 A
GND
2 B

2 B
GND

0 Z

0 Z
SCR 0V VCC
GND

1)

1 Encoder
2 BTAC module
3 Encoder power supply
262 BTAC-02 pulse encoder interface module

Single-ended connection

2 3

Vin
1
Vout
GND
1 A
A
GND
2 B
B
GND
Z
0
SCR 0V VCC Z
GND

1)

1 Encoder
2 BTAC module
3 Encoder power supply
 BTAC-02 pulse encoder interface module 263

Wiring diagrams – Open collector (sinking) encoder output

Diagram assumes normal pulse order in Forward rotation: Pulse A leads.

A
B
For encoders with pulse B leading, change the diagram: Wire encoder A and B to
BTAC terminals B and A, respectively.

2 3

Vin
1
2) Vout
RL
GND
1 A
A
GND
2 B
B
GND
Z
0
SCR 0V VCC Z
GND

1)

1 Encoder
2 BTAC module
3 Encoder power supply
4 Three identical resistors

The resistor size depends on the encoder power supply Vin = VOUT:

Vin= 30 V RL = 2.7…3.0 kohm, 0.5 W

Vin= 24 V RL = 1.8…2.2 kohm, 0.5 W
Vin= 15 V RL = 1.0…1.5 kohm, 0.5 W
Vin= 5 V RL = 390…470 kohm, 0.125 W
264 BTAC-02 pulse encoder interface module

Wiring diagrams – Open emitter (sourcing) encoder output

Diagram assumes normal pulse order in Forward rotation: Pulse A leads.

A
B
For encoders with pulse B leading, change the diagram: Wire encoder A and B to
BTAC terminals B and A, respectively.

2 3

Vin
1
Vout
GND
2)RL
A
1
A
GND
2 B
B
GND
Z
0
SCR 0V VCC Z
GND

1)

1 Encoder
2 BTAC module
3 Encoder power supply
4 Three identical resistors

The resistor size depends on the encoder power supply Vin = VOUT:

Vin= 30 V RL = 2.7…3.0 kohm, 0.5 W

Vin= 24 V RL = 1.8…2.2 kohm, 0.5 W
Vin= 15 V RL = 1.0…1.5 kohm, 0.5 W
Vin= 5 V RL = 390…470 kohm, 0.125 W
 BTAC-02 pulse encoder interface module 265

Apply power
1. Turn on the input power to the drive.
2. Continue with Start-up.

Start-up
To configure the operation of the BTAC module:
1. Power up the drive.
2. Set parameters in groups 90 Feedback selection, 91 Encoder adapter settings
and 92 Encoder 1 configuration. These parameters display the configuration
of the encoder interface modules.

￭ Feedback selection
Use these parameters to select feedback or display feedback from the encoder.

No. Name/Value Description Def/FbEq16/32

90 Feedback selection
90.01 Motor speed Displays the estimated or measured motor speed -
for control that is used for motor control, ie. final motor
speed feedback selected by parameter 90.41 Mo-
tor feedback selection and filtered by 90.42 Motor
speed filter time.
This parameter is read-only.
-32768…32767 Motor speed used for control. 1=1 rpm/100=1
rpm
90.02 Motor posi- Displays the motor position (within one revolu-
tion tion) received from the source selected by para-
meter 90.41 Motor feedback selection.
0 … 1 rev Motor position. 32767=1
rev/100000000=1
rev
90.10 Enc1 speed Displays encoder 1 speed in rpm. -
This parameter is read-only.
-32768…32767 Encoder 1 speed. 1=1 rpm/100=1
rpm
90.11 Enc1 posi- Displays the actual position of encoder 1 within -
tion one revolution.
This parameter is read-only.
0 … 1 rev Encoder 1 position within one revolution. 32767=1
rev/100000000=1
rev
266 BTAC-02 pulse encoder interface module

No. Name/Value Description Def/FbEq16/32

90.13 Enc1 revol Displays the revolution counter extension. na/1=1

extension The counter is incremented when encoder position
wraps around in the positive direction, and
decremented in the negative direction.
The parameter is effective only if the position is
absolute.The parameter value is updated for both
singleturn and multiturn encoders.
This parameter is read-only.
90.41 Motor feed- Selects the source of motor speed and motor po- estimate
back sel sition used as feedbacks for speed control and
motor model.
estimate A calculated speed estimate 0
Encoder 1 Actual speed measured by encoder 1. 1
90.42 Motor speed Defines a filter time for motor speed feedback 3 ms
filt time used for control.
0 … 10000 Motor speed filter time. 1=1 ms/1=1 ms
ms
90.45 Motor feed- Selects how the drive reacts to loss of measured Fault
back fault motor feedback.
Fault Drive trips on a 7301 Motor speed feedback fault. 0
Warning Drive generates a A7B0 Motor speed feedback 1
warning and continues operation using estimated
feedbacks.

Note: Before using this setting, test the stability

of the speed control loop with estimated feed-
back by running the drive on estimated feedback
(see 90.41 Motor feedback sel).
90.46 Force open Defines the speed feedback used for motor con- No
loop trol.
No The motor model uses the feedback selected by 0
90.41 Motor feedback sel.
Yes The motor model uses the calculated speed estim- 1
ate (regardless of the setting of 90.41 Motor
feedback sel, which in this case only selects the
source of feedback for the speed controller).
90.47 Enable mo- Enables motor encoder drift detection. Yes
tor encoder
drift detec-
tion
 BTAC-02 pulse encoder interface module 267

No. Name/Value Description Def/FbEq16/32

No Does not generate an error if encoder drift is de- 0

tected.
Yes Generates fault 7301 Motor speed feedback if en- 1
coder drift is detected.

￭ Encoder adapter settings

These parameters display the configuration of the encoder interface modules.

No. Name/Value Description Def/FbEq16/32

91 Enc adapter settings

91.10 Enc par re- Validates any changed encoder interface module Done
fresh parameters. This is needed for any parameter
changes in groups 90…92 to take effect. After
refreshing, the value reverts automatically to
Done.

Note: The parameter cannot be changed while

the drive is running.
Done Refreshing done. 0
Configure Refreshing. 1

Encoder configuration
This parameter group selects the settings for the encoder

No. Name/Value Description Def/FbEq16/32

92 Encoder 1 configuration
92.10 Pulses/rev Defines the TTL or HTL pulse number per revolu- 32
tion.
0…65535 1=1

Diagnostics
With parameter 90.45 Motor feedback fault, you can select how the drive reacts
when it detects that the encoder signal is lost.
• 90.45 = 0 (Fault) – The drive generates a fault (7301 Motor speed feedback),
and the motor coasts to a stop.
• 90.45 = 1 (Warning) – The drive generates a warning (A7B0 Motor speed
feedback) and continues operation using estimated feedbacks.
If the drive generates this fault or warning:
268 BTAC-02 pulse encoder interface module

Code Fault/Warning Cause

(hex)

7301 Motor speed feedback No motor speed feedback is received

4 Drift detected.
Check for slippage between encoder and motor.
3FC Incorrect motor feedback configuration
3FD Incorrect motor speed
A7B0 Motor speed feedback No motor speed feedback is received
4 Encoder drift detected.
Check for slippage between encoder and motor.
3FC Incorrect motor feedback configuration
3FD Incorrect motor speed

Technical data
￭ Encoder interface
The encoder user interface is isolated with reinforced insulation from the DC
potential.

Encoder type
• Incremental, TTL/HTL encoders
• Differential, single-ended, open collector, and open emitter encoder outputs
(refer to Encoder output types (page 260))
• Three channels A, B and Z
• Maximum pulse frequency: 200 kHz
• Encoder power supply range: 5…30 V

Encoder interface connectors

Four 3-pin (1×3) spring-clamp type terminal blocks, tin plated, 2.5 mm2 wire size
(14 AWG), pitch 5.0 mm.

Cable
The maximum permitted cable length is 100 m (328 ft).

Encoder and BTAC module power supply

• 50 mA (BTAC) + encoder current consumption (refer to the encoder data sheet)
• Voltage: 5…30 V DC (Depends on the encoder. Refer to the encoder data sheet.)
 BTAC-02 pulse encoder interface module 269

￭ Back-up power supply for the drive

Refer to electrical installation instructions.

￭ Internal connectors
Connector X102 provides encoder interface signals to the drive control board.
Connector X102 data: 1×8 pin header, pitch 2.54 mm, height 33.53 mm.
Connector X100 serves as power supply interface between the BTAC module and
the drive’s control board. It provides back-up power supply in main power loss
situations.
Connector X100 data: 2×4 pin header, pitch 2.54 mm, height 15.75 mm.

￭ Dimensions
270
 BRES-01 resolver interface module 271

17
BRES-01 resolver interface
module

Contents of this chapter

This chapter contains a description and technical data of the optional BRES-01
resolver interface module and describes how to connect and start up the module.

Safety instructions
WARNING!
Obey the safety instructions of the drive. If you ignore them, injury or
death, or damage to the equipment can occur.

Hardware description
￭ Product overview
BRES-01 resolver interface module (option +L516) adds a resolver interface to the
drive. Resolver can be used, if a more accurate speed or position (angle) feedback
is needed from the motor shaft.
BRES-01 has the features of the BAPO-01 auxiliary power extension module. It
provides back-up power to the drive (with the external 24 VDC supply) to keep the
control unit and communication operational without mains supply to the drive.
272 BRES-01 resolver interface module

￭ Functional description
BRES-01 feeds the excitation signal to the resolver and reads from the resolver
analog sine and cosine signals. Based on the sine and cosine signals, the resolver
position (angle) and speed can be defined. Position (absolute) of resolver is read
at start and then updated based on the speed signal. The speed signal (Encoder
1 speed) is based on the pulses (counts) from the BRES-01 module.
The following figure shows the SIN and COS outputs and the excitation signal.

Excitation

SIN

Carrier in phase with excitation Carrier in anti-phase with excitation

COS

Carrier in phase Carrier in anti-phase with excitation Carrier in phase

with excitation with excitation

90° 180° 270°

Zero position Zero position
 BRES-01 resolver interface module 273

￭ Layout
1. BRES-01 module
2. Locking screw hole
3. X103 connector (D con-
nector for resolver feed-
back)
7
4. X104 terminal for resolv-
er feedback
5. X105 terminal for extern-
al 24 VDC supply
1
3 6. Connectors for X104 and
X105
7. Internal X100 connector
4 8. Internal X102 connector
6 2
9. Grounding rail
10. Grounding screw

9
10

Mechanical installation
Refer to Installing options (page 92) and BAPO, BREL, BRES, and BTAC modules
quick installation guide (3AXD50000837946 [English]).

Electrical installation
￭ Terminal designations
The resolver user interface of the BRES-01 module has two connectors for resolver
feedback and one connector for external power supply. Resolver feedback can be
connected with D-connector (X103) or screw terminal block (X104).
274 BRES-01 resolver interface module

Resolver input (X103, X104)

X103

EXCITATION+ PTC/KTY_0V PTC/KTY COS- SIN-

5 4 3 2 1

EXCITATION- COM_B GND COS+ SIN+

10 9 8 7 6

GND GND COM_B COM_B GND

15 14 13 12 11

D-con- Signal Description

nector
(X103)
1 SIN- Inverted SIN signal
2 COS- Inverted COS signal
3 PTC/KTY Not connected
4 PTC/KTY_0V Not connected
5 EXCITATION+ Excitation signal +
6 SIN+ SIN signal
7 COS+ COS signal
8 GND Ground for shield (SHLD) connection
9 COM_B Not connected
10 EXCITATION- Excitation signal -
11 GND Ground for shield (SHLD) connection
12 COM_B Not connected
13 COM_B Not connected
14 GND Ground for shield (SHLD) connection
15 GND Ground for shield (SHLD) connection
 BRES-01 resolver interface module 275

X104

Terminal Signal Description

block
(X104)
1 EXC+ Excitation signal +
2 EXC- Excitation signal -
3 COS+ COS signal
4 COS- Inverted COS signal
5 SIN+ SIN signal
6 SIN- Inverted SIN signal
7 SHLD Ground for shield (SHLD) connection

External power supply (X105)

Usually, BRES-01 module is powered by the drive internal power supply. BRES-01
can also be supplied from the external 24 VDC power supply via terminal X105,
when the capacity of internal power supply in the drive is limited due to other
options in use.
Use the following table to determine if you can use the auxiliary power output.
Add the missing values and calculate the sum. The sum must be less than (or equal
to) the maximum output current of the auxiliary power output. For the maximum
output current, see the drive technical data.

Loads with the drive 24 V DC auxiliary voltage output mA

Number of digital inputs used × 15 mA each
BRES-01 50 mA
Encoder current requirement
276 BRES-01 resolver interface module

Requirements for other user connection(s) to drive 24 V DC auxiliary voltage

output
Total

￭ Connecting the resolver cable

1. Do not route the resolver cable in parallel to power cables (for example, motor
cables). Refer to Routing the cables (page 63) for more information.
2. Use the recommended cable type. Refer to Resolver cable (page 277). Make sure
that the cable has 3 twisted pairs.
3. Connect the resolver signals to correct terminal pins via D-connector (X103)
or terminal block (X104). Refer to Terminal designations (page 273).
• Additional GND pins with the D-connector (X103) are reserved for
connecting cable shields. Connection of the shields to GND (chassis) can
also be made through the D-connector hood cable clamping.
• With terminal block (X104), connect the shields via pin 7 (SHLD).
4. Ground the cable shields under a grounding clamp (usually only at the drive
end).
5. Mechanically attach the cables on the outside of the drive.

Start-up
To configure the operation of the BRES-01 module:
1. Power up the drive.
2. Set parameters in groups 15 I/O Extension module, 90 Feedback selection, 91
Encoder module settings and 92 Encoder 1 configuration. Refer to ACS380
machinery control program firmware manual (3AXD50000029275 [English]).
3. Make sure that the resolver rotation direction is correct before using it as
feedback for the speed control. This can be done by comparing estimated
speed with encoder 1 speed. If these are opposite, then can invert the direction
by parameter, or change resolver signal wiring.

Technical data
￭ Resolver interface
The resolver interface is isolated with reinforced insulation from the DC potential.

Resolver type
• 1 pole pair
• Excitation frequency: 3…12 kHz (adjustable with 1 kHz step by drive parameter)
 BRES-01 resolver interface module 277

• Excitation voltage: 5/7/12 Vrms (adjustable by drive parameter)

• Excitation current: 75 mA max.
• Transformation ratio: 0,5
• Maximum speed: 10000 rpm.
Contact ABB for resolvers that do not match the above ratings.

Resolver interface connectors (X103, X104)

• D connector: 15-pin high density D-sub, female.
• 7-pin screw terminal block:

Wire size and type 1) Cable size

With ferrule, without plastic sleeve 0.25 mm2…1.5 mm2 (28…16 AWG)
With ferrule and plastic sleeve 0.25 mm2…0.5 mm2 (28…20 AWG), pitch
3.5 mm
Conductor cross section rigid / single 0.14 mm2…1.5 mm2 (26…16 AWG)
strand
Conductor cross section flexible / multi- 0.14 mm2…1.5 mm2 (26…16 AWG)
strand
1) ABB recommends to use ferrule.

Resolver cable
• Recommended cable type: shielded twisted pair cable with 3 pairs.
• The maximum permitted cable length: 100 m (328 ft).

Power supply connection (X105)

• Input voltage: 24 V +/-10%
• Input current: max. 65 mA at 24 V. For resolvers that consume power more
than 65 mA at 24 V, use the external power supply only when the resolver
excitation current exceeds 65 mA.

￭ Back-up power supply for the drive

Refer to BAPO-01 auxiliary power extension module (page 285).

￭ Internal connectors
Connector X102 provides encoder interface signals to the drive control unit.
Connector X102 data: 1×8 pin header, pitch 2.54 mm, height 33.53 mm.
278 BRES-01 resolver interface module

Connector X100 serves as power supply interface between the BRES-01 module
and the drive’s control unit. It provides back-up power supply in main power loss
situations. Connector X100 data: 2×4 pin header, pitch 2.54 mm, height 15.75 mm.

￭ Dimensions
 BREL-01 relay output extension module 279

18
BREL-01 relay output
extension module

Contents of this chapter

This chapter contains a description and technical data of the optional BREL-01
relay output extension module.

Safety instructions
WARNING!
Obey the safety instructions of the drive. If you ignore them, injury or
death, or damage to the equipment can occur.

Hardware description
￭ Product overview
BREL-01 relay output extension module (option +L511) adds four relay outputs to
the drive.
280 BREL-01 relay output extension module

￭ Layout
1. BREL-01 module
2. Locking screw hole
3. X103 connector
4. X104 connector
5. X105 connector
7
6. X106 connector
7. Internal X100 connector
1
8. Internal X102 connector
9. Grounding rail
3 10. Grounding screw

6
8

10

Mechanical installation
Refer to Installing options (page 92) and BAPO, BREL, BRES, and BTAC modules
quick installation guide (3AXD50000837946 [English]).

Electrical installation
Use 0.5 … 2.5 mm2 (20 … 14 AWG) cable with a sufficient voltage rating.
If you connect an inductive load (relay or contactor coil, motor) protect the relay
contacts with a varistor, RC filter (AC) or diode (DC). Install the protective
component as close to the inductive load as possible. Do not install protective
components at the relay output terminals.
 BREL-01 relay output extension module 281

Identification Description

X103 4 Relay outputs RO4…RO7:

1 COM Common Max. switching voltage: 250 V AC / 30 V DC
Max. switching current: 2 A
2 NC Normally closed
Galvanically isolated.
3 NO Normally open
X104 5
1 COM Common
2 NC Normally closed
3 NO Normally open
X105 6
1 COM Common
2 NC Normally closed
3 NO Normally open
X106 7
1 COM Common
2 NC Normally closed
3 NO Normally open

Start-up
To configure the operation of the relays added with the BREL-01 module:
1. Power up the drive.
2. Set the parameter 15.01 Extension module type to 5 (BREL).
3. Use the control panel on the drive and set the parameters for relay outputs
RO4…RO7 in 15 I/O extension module. Refer to the ACS380 Firmware manual
(3AXD50000029275 [English]) for parameter descriptions.

Configuration parameters
The configuration parameters of the BREL-01 module are in group 15 I/O extension
module.

No. Name/Value Description Def /

FbEq16/32

15 I/O extension module

15.01 Extension Activates (and specifies the type of) I/O extension None
module type module.
282 BREL-01 relay output extension module

No. Name/Value Description Def /

FbEq16/32

BREL External relay option BREL-01. 5

15.02 Detected I/O extension module detected on the drive. None
extension
module
BREL External relay option BREL-01. 5
15.04 RO status Displays the status of the relay outputs. This 1=1
parameter is read-only.
Bit 0 RO4 1 = Relay output 4 is ON. -
Bit 1 RO5 1 = Relay output 5 is ON. -
Bit 2 RO6 1 = Relay output 6 is ON. -
Bit 3 RO7 1 = Relay output 7 is ON. -
15.05 RO force The electrical statuses of the relay/digital outputs 1 = 1
selection can be overridden for e.g. testing purposes. A bit in
parameter 15.06 RO forced data is provided for each
relay or digital output, and its value is applied
whenever the corresponding bit in this parameter
is 1.
Bit 0 RO4 1 = Force relay output 4 to value of bit 0 of -
parameter 15.06 RO forced data.
Bit 1 RO5 1 = Force relay output 5 to value of bit 0 of -
parameter 15.06 RO forced data.
Bit 2 RO6 1 = Force relay output 6 to value of bit 0 of -
parameter 15.06 RO forced data.
Bit 3 RO7 1 = Force relay output 7 to value of bit 0 of -
parameter 15.06 RO forced data.
15.06 RO forced data Allows the data value of a forced relay or digital 1=1
output to be changed from 0 to 3.
Bit 0 RO4 Force the value of this bit to RO4, if so defined in -
parameter 15.05 RO force selection.
Bit 1 RO5 Force the value of this bit to RO5, if so defined in -
parameter 15.05 RO force selection.
Bit 2 RO6 Force the value of this bit to RO6, if so defined in -
parameter 15.05 RO force selection.
Bit 3 RO7 Force the value of this bit to RO7, if so defined in -
parameter 15.05 RO force selection.
15.07 RO4 source Selects a drive signal to be connected to relay Not
output RO4. energized
 BREL-01 relay output extension module 283

No. Name/Value Description Def /

FbEq16/32

Not energized Output is not energized. 0

Energized Output is energized. 1
For the complete parameter list, refer to the drive firmware manual. …
15.08 RO4 ON delay Defines the activation delay for relay output RO4. 0.0 s
0.0 … 3000.0 s Activation delay for RO4. 10 = 1 s
15.09 RO4 OFF delay Defines the deactivation delay for relay output RO4. 0.0 s
0.0 … 3000.0 s Deactivation delay for RO4. 10 = 1 s
15.10 RO5 source Selects a drive signal to be connected to relay Not
output RO5. energized
Not energized Output is not energized. 0
Energized Output is energized. 1
For the complete parameter list, refer to the drive firmware manual. …
15.11 RO5 ON delay Defines the activation delay for relay output RO5. 0.0 s
0.0 … 3000.0 s Activation delay for RO5. 10 = 1 s
15.12 RO5 OFF delay Defines the deactivation delay for relay output RO5. 0.0 s
0.0 … 3000.0 s Deactivation delay for RO5. 10 = 1 s
15.13 RO6 source Selects a drive signal to be connected to relay Not
output RO6. energized
Not energized Output is not energized. 0
Energized Output is energized. 1
For the complete parameter list, refer to the drive firmware manual. …
15.14 RO6 ON delay Defines the activation delay for relay output RO6. 0.0 s
0.0 … 3000.0 s Activation delay for RO6. 10 = 1 s
15.15 RO6 OFF delay Defines the deactivation delay for relay output RO6. 0.0 s
0.0 … 3000.0 s Deactivation delay for RO6. 10 = 1 s
15.16 RO7 source Selects a drive signal to be connected to relay Not
output RO7. energized
Not energized Output is not energized. 0
Energized Output is energized. 1
For the complete parameter list, refer to the drive firmware manual. …
15.17 RO7 ON delay Sets the activation delay for relay output 7. 0.0 s
0.0…3000.0 s Activation delay for relay output 7. 10 = 1 s
284 BREL-01 relay output extension module

No. Name/Value Description Def /

FbEq16/32

15.18 RO7 OFF delay Sets the deactivation delay for relay output 7. 0.0 s
0.0…3000.0 s Deactivation delay for relay output 7. 10 = 1 s

Technical data
External connectors: Four 3-pin (1×3) spring-clamp type terminal blocks, tin plated,
2.5 mm2 (14 AWG) wire size, pitch 5.0 mm.
Internal connectors: Connector X102 provides relay control signals from the control
board: 1×8 pin header, pitch 2.54 mm, height 33.53 mm. Connector X100 is not in
use in BREL-01: 2×4 pin header, pitch 2.54 mm, height 15.75 mm.
Dimensions:
 BAPO-01 auxiliary power extension module 285

19
BAPO-01 auxiliary power
extension module

Contents of this chapter

This chapter contains a description and technical data of the optional BAPO-01
auxiliary power extension module.

Safety instructions
WARNING!
Obey the safety instructions of the drive. If you ignore them, injury or
death, or damage to the equipment can occur.

Hardware description
The BAPO-01 auxiliary power extension module (option +L534) lets you use an
external 24 V DC power supply with the drive. An external power supply is used to
keep the drive control board energized during a power outage.
The BAPO-01 module has internal connections to provide back-up power to the
control board (I/O, fieldbus). There is a DC to DC flyback converter power supply
inside the module. This power supply takes 24 V DC as input and outputs 5 V DC
to the control board to keep the processor and communication links on at all times.
286 BAPO-01 auxiliary power extension module

Note: The BAPO-01 is not a battery.

If you change drive parameters when the control board is energized by the BAPO-01
module, force parameter saving by setting the value of parameter 96.07 Parameter
save manually to (1) Save. Otherwise, changed data will not be saved.

￭ Layout

3
1

1 BAPO-01 module
2 Locking screw hole
3 Internal X100 connector
4 Internal X102 connector
5 Grounding rail
 BAPO-01 auxiliary power extension module 287

Mechanical installation
Refer to Installing options (page 92) and BAPO, BREL, BRES, and BTAC modules
quick installation guide (3AXD50000837946 [English]).

Electrical installation
Connect the external power supply to the +24 V and DGND terminals on the drive.
See the electrical installation instructions of the drive.
Do not chain an external 24 V DC power supply to several drives. Each drive must
be powered by a single 24 V DC power supply, or a separate 24 V DC output of one
auxiliary power source.

1 2

24VDC (+) +24V BAPO-01

GND (-) DGND

4 5

1 External power supply

2 Drive

3 +24 V internal

4 Main power supply

5 +5 V internal
288 BAPO-01 auxiliary power extension module

Start-up
To configure the BAPO-01 module:
1. Power up the drive.
2. Set the parameter 95.04 Control board supply to 1 (External 24V).

Technical data
Voltage and current rating for the auxiliary power supply: +24 V DC ±10%, max.
1000 mA (including internal fan load).
Power loss: Power losses with maximum load 4 W.
Dimensions:

26 [1.024]
11.3 [0.444]
16 [0.63] 86.1 [3.391]

171.6 [6.754]
181.3 [7.138]
6 [0.24]
4.5 [0.177]

2.5 [0.098]

52.5 [2.067 42.2 [1.662] 13.3 [0.524]

68.5 [2.697]
 BIO-01 I/O extension module 289

20
BIO-01 I/O extension module

Contents of this chapter

This chapter contains a description and technical data of the optional BIO-01 I/O
extension module.

Safety instructions
WARNING!
Obey the safety instructions of the drive. If you ignore them, injury or
death, or damage to the equipment can occur.

Hardware description
￭ Product overview
BIO-01 (option +L515) is an I/O extension module to be used with a fieldbus adapter
module. The BIO-01 module is installed between the drive and the fieldbus module.
BIO-01 has two digital inputs (DI4, DI5) and one analog input (A1). It also has two
terminals (S1, S2) that can be configured with the switches on the module. S1 can
be configured as analog output (AO1) or digital output (DO1). S2 can be configured
as digital output (DO1) or digital input (DI3).
290 BIO-01 I/O extension module

￭ Layout
1. Locking tab
1
2. Option module slot
2
3. Chassis screw
4. I/O connector

5 5. Switches for config-

uring terminals S1 and
S2

Mechanical installation
See the electrical installation instructions of the drive.
Before you install the BIO-01 option module, make sure that the chassis screw
slider is in the top position. After the option module is installed, tighten the chassis
screw and move the slider to the bottom position.
The BIO-01 option module kit comes with a higher cable clamp plate. Use this cable
clamp plate to ground the wires that connect to the BIO-01 option module.

Terminal configuration
You must configure terminals S1 and S2 before you install the fieldbus module.
Refer to the table that follows for the possible configurations:

Setting Result

Switch S1 Switch S2 Terminal S1 func- Terminal S2 func- Supported configur-

tions as tions as ation

DO1 (de- DI3 (default) Digital output DO1 Digital input DI3 Yes
fault)
AO1 DI3 (default) Analog output AO1 Digital input DI3 Yes
AO1 DO1 Analog output AO1 Digital output DO1 Yes
DO1 (de- DO1 - - No
fault)
 BIO-01 I/O extension module 291

If you change the switch configuration while the drive is powered on, the drive will
trip on a fault. Also, an unsupported configuration will cause the drive to trip on
a fault.

Electrical installation
The BIO-01 module has removable spring clamp terminals. Use ferrules on the
multistranded conductor ends.
The connection diagram below is applicable to drives with the BIO-01 I/O extension
module when the ABB standard macro is selected (parameter 96.04).

Connection Terminal Description 1)

+24 V Auxiliary voltage output +24 V DC, max. 250 mA ×

DGND Auxiliary voltage output common ×
DCOM Digital input common for all ×
+24 V
DGND DI1 Stop (0) / Start (1) ×
DCOM DI2 Forward (0) / Reverse (1) ×
DI1
DI2 S2 (DI3) Constant frequency/speed selection
DI3 DI4 Constant frequency/speed selection
DI4
DI5 Ramp set 1 (0) / Ramp set 2 (1)
DI5
DO1 S1 (DO1) Not configured (DIO1)
AI1 AI1 Output frequency/speed ref: 0 … 10 V DC
+10V
GND +10V Reference voltage +10 V DC (max. 10 mA)
SCR GND Analog circuit common / DO common
S+
SCR Signal cable shield
SGND
S1 S+ Safe torque off. Both S1 and S2 circuits must be ×
S2 closed for the drive to start. (Factory connection.)
SGND ×
S1 ×
S2 ×
1) × = on base unit, blank = on BIO-01 module.

Start-up
The BIO-01 module is automatically identified by the drive firmware. To configure
the inputs and outputs, refer to the drive firmware manual.
292 BIO-01 I/O extension module

Technical data
Control connection data: Spring type terminal blocks. Conductor size accepted
by the terminals: 0.2 … 1.5 mm2 (24 … 16 AWG). Exception: max. 0.75 mm2 (18 AWG)
for a multistranded conductor with a ferrule and plastic sleeve.
Internal connections of GND and SCR terminals
+24 V
DGND
DCOM
DI1
DI2
DI3
DI4
DI5
DIO1
AI1
+10V
GND
SCR
S+
SGND
S1
S2
 BIO-01 I/O extension module 293

Dimensions
Note: BIO-01 is supplied with a high cover part (part number 3AXD50000190188)
for the ACS380 drives. When used, it increases the drive depth by 15 mm (0.6 in).
294
—
Further information

Product and service inquiries

Address any inquiries about the product to your local ABB representative, quoting
the type designation and serial number of the unit in question. A listing of ABB
sales, support and service contacts can be found by navigating to
www.abb.com/contact-centers.

Product training
For information on ABB product training, navigate to
new.abb.com/service/training.

Providing feedback on ABB manuals

Your comments on our manuals are welcome. Navigate to
forms.abb.com/form-26567.

Document library on the Internet

You can find manuals and other product documents in PDF format on the Internet
at www.abb.com/drives/documents.

a4 (frozen)
PDF-A5
Created 2024-04-10, 10:56:38
www.abb.com/drives

3AXD50000029274G

3AXD50000029274 Rev G (EN)

2024-04-10

© Copyright 2024 ABB. All rights reserved.

Specifications subject to change without notice.