Page 1 ABB general purpose drives Hardware manual ACS580-01 drives (0.75 to 250 kW, 1.0 to 350 hp)
Page 2: List Of Related Manuals
List of related manuals Drive manuals and guides Code (English) ACS580 standard control program firmware manual 3AXD50000016097 ACS580-01 (0.75 to 250 kW, 1.0 to 350 hp) hardware 3AXD50000044794 manual ACS580-01 quick installation and start-up guide for 3AXD50000044838 frames R1 to R5...
Page 3 Hardware manual ACS580-01 drives (0.75 to 250 kW, 1.0 to 350 hp) Table of contents 1. Safety instructions 4. Mechanical installation 6. Electrical installation  2017 ABB Oy. All Rights Reserved. 3AXD50000044794 Rev A EFFECTIVE: 2017-05-31...
Page 5: Table Of Contents
Table of contents 5 Table of contents List of related manuals ............2 1.
Page 6 6 Table of contents Unpacking and examining delivery, frames R1 and R2 ......47 Frames R1 and R2 cable box (IP21, UL Type 1) .
Page 7 Connecting the control cables ..........116 Default I/O connection diagram (ABB standard macro) ......117 Control cable connection procedure R1…R9 .
Page 8 8 Table of contents Checklist ..............139 8.
Page 9 Table of contents 9 Losses, cooling data and noise ..........176 Cooling air flow, heat dissipation and noise for stand-alone drives .
Page 10 10 Table of contents Frame R5, IP21 (UL Type 1) ..........212 Frame R5, IP55 (UL Type 12) .
Page 11 Providing feedback on ABB Drives manuals ........
Page 12 12 Table of contents...
Page 13: Safety Instructions
Safety instructions 13 Safety instructions Contents of this chapter This chapter contains the safety instructions which you must obey when you install and operate the drive and do maintenance on the drive. If you ignore the safety instructions, injury, death or damage can occur. Use of warnings and notes in this manual Warnings tell you about conditions which can cause injury or death, or damage to the equipment.
Page 14: General Safety In Installation, Start-Up And Maintenance
14 Safety instructions General safety in installation, start-up and maintenance These instructions are for all personnel that install the drive and do maintenance work on it. WARNING! Obey these instructions. If you ignore them, injury or death, or damage to the equipment can occur. •...
Page 15 Safety instructions 15 • 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.
Page 16: Electrical Safety In Installation, Start-Up And Maintenance
16 Safety instructions Electrical safety in installation, start-up and maintenance  Precautions before electrical work These warnings 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.
Page 17: Additional Instructions And Notes
Safety instructions 17  Additional instructions and notes WARNING! Obey these instructions. If you ignore them, injury or death, or damage to the equipment can occur. • If you install the drive on an IT system (an ungrounded power system or a high- resistance-grounded [over 30 ohms] power system), disconnect the ground-to- phase varistor;...
Page 18: Grounding
18 Safety instructions WARNING! Use a grounding wrist band when you handle the printed circuit boards. Do not touch the boards unnecessarily. The boards contain components sensitive to electrostatic discharge.  Grounding These instructions are for all personnel who are responsible for the electrical installation, including the grounding of the drive.
Page 19: Additional Instructions For Permanent Magnet Motor Drives
Safety instructions 19 Additional instructions for permanent magnet motor drives  Safety in installation, start-up and 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 and damage to the equipment can occur.
Page 20: General Safety In Operation
20 Safety instructions 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. • Do not control the motor with the disconnector at the drive power supply; instead, use the control panel start and stop keys or commands through the I/O terminals of the drive.
Page 21: Introduction To The Manual
Note: The manual does not apply to R0…R3 frames with type codes ACS580-01-: 02A6-4, 03A3-4, 04A0-4, 05A6-4, 07A2-4, 09A-4, 12A6-4, 017A-4, 025A-4, 032A-4, 038A-4, 045A-4. For these types, see ACS580-01 (0.75 to 250 kW, 1.0 to 350 hp) hardware manual (3AXD50000018826 [English]).
Page 22: Contents Of This Manual
22 Introduction to the manual Contents of this manual The manual consists of the following chapters: • Safety instructions (page 13) gives safety instructions you must obey when installing, commissioning, operating and servicing the drive. • Introduction to the manual (this chapter, page 21) describes applicability, target audience, purpose and contents of this manual.
Page 23: Related Documents
(inside of the front cover). Categorization by frame (size) The ACS580-01 is manufactured in frames (frame sizes) R1…R9. Some instructions and other information which only concern certain frames are marked with the symbol of the frame (R1…R9). The frame is marked on the type designation label attached to...
Page 24: Quick Installation And Commissioning Flowchart
24 Introduction to the manual Quick installation and commissioning flowchart Task Identify the frame of your drive: R1…R9. Operation principle and hardware description: Type designation key on page Plan the installation: select the cables, etc. Planning the electrical installation on page Check the ambient conditions, ratings and Technical data on page...
Page 25 Introduction to the manual 25 Terms and abbreviations Term/abbreviation Explanation ACS-BP-S Basic control panel, basic operator keypad for communication with the drive. The ACS580 supports ACS-BP-S basic control panel. ACS-AP-x Assistant control panel, advanced operator keypad for communication with the drive. The ACS580 supports types ACS-AP-I and ACS-AP-S, as well as ACS- AP-W, which has a Bluetooth interface.
Page 26 26 Introduction to the manual Term/abbreviation Explanation Frame (size) Refers to drive physical size, for example R1 and R2. The type designation label attached to the drive shows the frame of the drive, see section Type designation key on page 40. FSCA-01 Optional EIA-485 adapter module Input/Output...
Page 27: Operation Principle And Hardware Description
Operation principle and hardware description 27 Operation principle and hardware description Contents of this chapter This chapter briefly describes the operation principle, layout, type designation label and type designation information. It also shows a general diagram of power connections and control interfaces.
Page 28: Operation Principle
28 Operation principle and hardware description Operation principle The ACS580-01 is a drive for controlling asynchronous AC induction motors permanent magnet motors and synchronous reluctance motors (SynRM). The figure below shows the simplified main circuit diagram of the drive. ACS580-01...
Page 29: Layout
Operation principle and hardware description 29 Layout Frames R1…R2 The layout of a frame R1 drive is presented below. The main structure of frame R2 is similar to R1. IP55 frames are also slightly different from IP21 frames, for example, IP21 front cover has two parts while IP55 front cover only has one part.
Page 30 30 Operation principle and hardware description Frame R3 R3 IP21 20 21 Mounting points (4 pieces) 11 Input power connection (L1, L2, L3), motor connection (T1/U, T2/V, T3/W) and Cover brake connection (R-, R+) Cover screw 12 PE connection (power line) Control panel 13 Grounding connection (motor) Control panel connection...
Page 31 Operation principle and hardware description 31 Frame R4 R4 IP21 Mounting points (4 pieces) 10 Two EMC filter grounding screws (EMC). Checking the compatibility with IT Cover (ungrounded) and corner-grounded TN Cover screw systems on page 91. Control panel 11 Input power connection (L1, L2, L3), Control panel connection motor connection (T1/U, T2/V, T3/W) and brake connection (R-, R+)
Page 32 32 Operation principle and hardware description Frame R5 R5 IP21 PE 13 Mounting points (6 pieces: 2 at the top, 2 11 Two EMC filter grounding screws (EMC). at the bottom of the main part of the Checking the compatibility with IT frame, 2 at the top of the cable box) (ungrounded) and corner-grounded TN systems...
Page 33 Operation principle and hardware description 33 Frames R6…R9 The layout of a frame R6 drive is presented below. The constructions of frames R6…R9 differ to some extent. R6 IP21 Mounting points (6 pieces: 2 at the top, 2 13 Varistor grounding screw (VAR), under at the bottom of the main part of the the control panel platform frame, 2 at the top of the cable box)
Page 34: Overview Of Power And Control Connections
34 Operation principle and hardware description Overview of power and control connections The logical diagram below shows the power connections and control interfaces of the drive. Panel port Slot 1 Slot 2 T1/U T2/V T3/W UDC+ UDC- Option slot 1 for optional fieldbus adapter modules Option slot 2 for optional I/O extension modules Panel port.
Page 35: External Control Connection Terminals, Frames R1
Operation principle and hardware description 35  External control connection terminals, frames R …R5 The layout of the external control connection terminals of the R1 frame is shown below. Layout of the external control connection terminals is identical in frames R1…R5 but the location of the control board with the terminals is different in frames R3…R5.
Page 36: External Control Connection Terminals, Frames R6
36 Operation principle and hardware description  External control connection terminals, frames R6…R9 The layout of the external control connection terminals of frames R6…R9 is shown below. R6…R9 Description Analog inputs and outputs Aux. voltage output Digital inputs Safe torque off connection Connection to embedded EIA- 485 fieldbus adapter module Relay output 3...
Page 37: Control Panel
Operation principle and hardware description 37 Control panel To remove the control panel, press the retaining clip at the top (1a) and pull it forward from the top edge (1b). To reinstall the control panel, put the bottom of the container in position (1a), press the retaining clip at the top (1b) and push the control panel in at the top edge (1c).
Page 38: Control Panel Door Mounting Kits
38 Operation principle and hardware description  Control panel door mounting kits Door mounting kits for the control panel are available. For more information see DPMP-01 mounting platform for control panels (3AUA0000100140 [English]) or DPMP-02/03 mounting platform for control panels (3AUA0000136205 [English]. Type designation label The type designation label includes IEC and NEMA ratings, appropriate markings and the type designation and serial number, which allow identification of each drive.
Page 39: Locations Of The Labels On The Drive
Operation principle and hardware description 39  Locations of the labels on the drive...
Page 40: Type Designation Key
You find the type designation on the type designation label attached to the drive. The first digits from the left express the basic configuration, for example, ACS580-01-12A7-4. The optional selections are given after that, separated by plus signs, for example, +L501. The main selections are described below. Not all selections are available for all types.
Page 41 Operation principle and hardware description 41 CODE DESCRIPTION Fieldbus adapters K454 FPBA-01 PROFIBUS DP K457 FCAN-01 CANopen K451 FDNA-01 DeviceNet™ K473 FENA-11 Ethernet (EtherNet/IP™, Modbus/TCP, PROFINET) K469 FECA-01 EtherCAT K458 FSCA-01 Modbus/RTU K470 FEPL-02 Ethernet POWERLINK K462 FCNA-01 ControlNet™ K475 FENA-21 2-port Ethernet (EtherNet/IP™, Modbus/TCP, PROFINET) Embedded fieldbus CEIA-01 Embedded Modbus RTU adapter, EIA-485 (as standard)
Page 42 42 Operation principle and hardware description...
Page 43: Mechanical Installation
Mechanical installation 43 Mechanical installation Contents of this chapter The chapter tells how to check the installation site, unpack, check the delivery and install the drive mechanically. Safety WARNING! Frames R5…R9: Lift the drive with a lifting device. Use the lifting eyes of the drive.
Page 44: Checking The Installation Site
44 Mechanical installation Checking the installation site The drive must be installed on the wall. There are three alternative ways to install it: • vertically alone. Do not install the drive upside down. Frame Vertical installation - size Free space Above (a) Below (b) Beside...
Page 45 Mechanical installation 45 • vertically side by side Frame Vertical installation side by side - c = 0 size Free space Above (a) Below (b) Between (c) 11.8 11.8 11.8 11.8 11.8 3AXD00000586715.xls J Free space below is measured from the frame, not from the cable box used in frames R1…R2 and R5…R9.
Page 46: Required Tools
46 Mechanical installation Check the installation site according to the requirements below: • The installation site is sufficiently ventilated or cooled to transfer away the drive losses. See section Losses, cooling data and noise on page 176. • The operation conditions of the drive meet the specifications given in section Ambient conditions on page 192.
Page 47: Unpacking And Examining Delivery, Frames R1 And R2
Mechanical installation 47 Unpacking and examining delivery, frames R1 and R2 The figure below shows the layout of the transport package. Examine that all items are present and there are no signs of damage. Read the data on the type designation label of the drive to make sure that the drive is of the correct type.
Page 48: Frames R1 And R2 Cable Box (Ip21, Ul Type 1)
48 Mechanical installation To unpack: • Cut the straps (7). • Remove the upper tray (8a) and option tray (3). • Remove the cardboard box (5). • Remove the plastic bag (2). • Lift the drive.  Frames R1 and R2 cable box (IP21, UL Type 1) This illustration shows the contents of the cable box package.
Page 49: Unpacking And Examining Delivery, Frames R3
Mechanical installation 49 Unpacking and examining delivery, frames R3…R4 The figure below shows the drive package with its contents. Examine that all items are present and there are no signs of damage. Read the data on the type designation label of the drive to make sure that the drive is of the correct type. See section Type designation label on page 38.
Page 50: Unpacking And Examining Delivery, Frame R5
50 Mechanical installation Unpacking and examining delivery, frame R5 The figure below shows the layout of the transport package. Examine that all items are present and there are no signs of damage. Read the data on the type designation label of the drive to make sure that the drive is of the correct type. See section Type designation label on page 38.
Page 51: Frame R5 Cable Box (Ip21, Ul Type 1)
Mechanical installation 51 To unpack: • Cut the straps (7). • Remove the cardboard box (4) and option box (3). • Remove the cover protecting film (6). • Lift the drive.  Frame R5 cable box (IP21, UL Type 1) This illustration shows the contents of the cable box package.
Page 52: Unpacking And Examining Delivery, Frames R6
52 Mechanical installation Unpacking and examining delivery, frames R6…R9 The figure below shows the layout of the transport package. Examine that all items are present and there are no signs of damage. Read the data on the type designation label of the drive to make sure that the drive is of the correct type. See section Type designation label on page 38.
Page 53: Frame R6 Cable Box (Ip21, Ul Type 1)
Mechanical installation 53 To unpack: • Cut the straps (4). • Remove the cardboard box (3) and option tray (8). • Remove the VCI bag (5). • Attach lifting hooks to the lifting eyes of the drive (see the figure on page 43). Lift the drive with a hoist.
Page 54: Frame R7 Cable Box (Ip21, Ul Type 1)
54 Mechanical installation  Frame R7 cable box (IP21, UL Type 1) The figure below shows the contents of the cable box package. The package also includes an assembly drawing which shows how to install cable box to the drive frame.
Page 55: Frame R8 Cable Box (Ip21, Ul Type 1)
Mechanical installation 55  Frame R8 cable box (IP21, UL Type 1) The figure below shows the contents of the cable box package. The package also includes an assembly drawing which shows how to install the cable box to the drive frame.
Page 56: Frame R9 Cable Box (Ip21, Ul Type 1)
56 Mechanical installation  Frame R9 cable box (IP21, UL Type 1) The figure below shows the contents of the cable box package. The package also includes an assembly drawing which shows how to install the cable box to the drive frame.
Page 57: Installing The Drive
Mechanical installation 57 Installing the drive  Installing the drive vertically, frames R1…R4 The figures show frame R3 as an example. 1. Mark the hole locations using the mounting template included in the package. Do not leave the mounting template under the drive. The drive dimensions and hole locations are also shown in the drawings in chapter Dimension drawings on page...
Page 58: Install The Cable Box, Frames R1
58 Mechanical installation 4. Position the drive onto the bolts on the wall. 5. Tighten the bolts in the wall securely. ×4  Install the cable box, frames R1…R2 6. Remove the screw (6a) and lift the cover off (6b) from the separate cable box. 7.
Page 59: Installing The Drive Vertically, Frame R5
Mechanical installation 59  Installing the drive vertically, frame 1. Mark the hole locations using the mounting template included in the package. Do not leave the mounting template under the drive. The drive dimensions and hole locations are also shown in the drawings in chapter Dimension drawings on page 203.
Page 60 60 Mechanical installation IP21 (UL Type 1) 4. Remove the front cover: Remove the fastening screws (4a) and lift the cover from the bottom upwards (4b) and then to the top side (4c). 5. Attach the cable box to the drive frame. 6.
Page 61 Mechanical installation 61 IP21 (UL Type 1), IP55 (UL Type 12) 9. Position the drive onto the four bolts on the wall. Lift the drive with another person or with a lifting device as it is heavy. Tighten the bolts in the wall securely. 10.
Page 62: Installing The Drive Vertically, Frames R6
62 Mechanical installation  Installing the drive vertically, frames R6…R9 1. Mark the hole locations for the six mounting holes using the mounting template included in the package. Do not leave the mounting template under the drive. The drive dimensions and hole locations are also shown in the drawings in chapter Dimension drawings on page 203.
Page 63: Installing The Drive Vertically Side By Side
Mechanical installation 63 IP21 (UL Type 1) 6. Remove the front cover: Remove the fastening screws (a), move the cover to the top side (b) and then up (c). 7. Attach the cable box to the drive frame. 8. Tighten the box screws: two at the top and four at the bottom. M8×6 IP55 (UL Type 12) 9.
Page 64: Flange Mounting
64 Mechanical installation Flange mounting Instructions for flange mounting are delivered with the flange mounting kit: Flange mounting kit quick installation guide for ACX580-01 frames R0 to R5 (3AXD50000036610 [English]) or Flange mounting kit quick installation guide for ACS880-01 and ACX580-01 frames R6 to R9 (3AXD50000019099 [English]). For more information on flange mounting, see Flange mounting kit installation supplement (3AXD50000019100 [English]).
Page 65: Planning The Electrical Installation
Planning the electrical installation 65 Planning the electrical installation Contents of this chapter This chapter contains instructions for planning the electrical installation of the drive, for example, for checking the compatibility of the motor and drive, selecting cables, protections and cable routing. Limitation of liability The installation must always be designed and made according to applicable local laws and regulations.
Page 66: European Union
66 Planning the electrical installation  European Union To meet the European Union Directives, according to standard EN 60204-1, Safety of Machinery, the disconnecting device must be one of the following types: • switch-disconnector of utilization category AC-23B (EN 60947-3) •...
Page 67: Checking The Compatibility Of The Motor And Drive
Planning the electrical installation 67 Checking the compatibility of the motor and drive Use an asynchronous AC induction motor permanent magnet motor or synchronous reluctance motor with the drive. Several induction motors can be connected to the drive at a time but only one permanent magnet motor can be connected to the drive at a time.
Page 68: Requirements Table
Motor Nominal AC supply Requirement for type voltage Motor ABB du/dt and common mode filters, insulation insulated N-end motor bearings system < 100 kW 100 kW < P < 350 kW and frame size <...
Page 69 Motor nominal power du/dt du/dt filter at the output of the drive. Available from ABB as an optional add-on kit. Common mode filter. Depending on the drive type, CMF is available from ABB as an optional add-on kit. N-end bearing: insulated motor non-drive end bearing n.a.
Page 70 70 Planning the electrical installation Additional data for calculating the rise time and the peak line-to-line voltage If you need to calculate the actual peak voltage and voltage rise time considering the actual cable length, proceed as follows: • Peak line-to line voltage: Read the relative Û value from the appropriate diagram below and multiply it by the nominal supply voltage (U •...
Page 71 Planning the electrical installation 71 Û du/dt ------------ - (1/ s) l (m) du/dt ------------ - (1/s) Û l (m) Drive with du/dt filter Drive without du/dt filter Motor cable length Û Relative peak line-to-line voltage (du/dt)/U Relative du/dt value Note: ÛLL and du/dt values are approximately 20% higher with resistor braking.
Page 72: Selecting The Power Cables
72 Planning the electrical installation Selecting the power cables  General rules Select the input power and motor cables according to local regulations: • Select a cable capable of carrying the drive nominal current. See section Ratings (page 160) for the rated currents. •...
Page 73: Typical Power Cable Sizes
Planning the electrical installation 73  Typical power cable sizes The table below gives copper cable types with concentric copper shield for the drives with nominal current. The value separated by the plus sign means the diameter of the PE conductor. Frame North America...
Page 74: Alternative Power Cable Types
74 Planning the electrical installation  Alternative power cable types The recommended and the not allowed power cable types to be used with the drive are presented below. Recommended power cable types Symmetrical shielded cable with three phase conductors and a concentric PE conductor as the shield.
Page 75: Additional Us Requirements
Planning the electrical installation 75 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. Insulation jacket Helix of copper tape or copper wire Copper wire screen Inner insulation Cable core...
Page 76: Selecting The Control Cables
76 Planning the electrical installation Shielded power cables are available from the following suppliers: • Belden • LAPPKABEL (ÖLFLEX) • Pirelli. Selecting the control cables  Shielding All control cables must be shielded. Use a double-shielded twisted pair cable (figure a below) for analog signals. Employ one individually shielded pair for each signal.
Page 77: Drive Composer Pc Tool Cable
Planning the electrical installation 77 The cable type tested and approved by the manufacturer is used in control panel option kits. Suitable cables are CAT 5e unshielded or shielded twisted pair cables.  Drive composer PC tool cable Connect the Drive composer PC tool to the drive through the USB port of the control panel.
Page 78: Routing The Cables
78 Planning the electrical installation Routing the cables  General rules Route the motor cable away from other cable routes. Motor cables of several drives can be run in parallel installed next to each other. The motor cable, input power cable and control cables should be installed on separate trays.
Page 79: Separate Control Cable Ducts
Planning the electrical installation 79  Separate control cable ducts Lead 24 V and 230 V (120 V) control cables in separate ducts unless the 24 V cable is insulated for 230 V (120 V) or insulated with an insulation sleeving for 230 V (120 V).
Page 80: Implementing Thermal Overload And Short-Circuit Protection
The protective characteristics of 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.
Page 81: Protecting The Drive And The Input Power And Motor Cables Against Thermal Overload
Planning the electrical installation 81  Protecting the drive and the input power and motor cables against thermal overload The drive protects itself and the input and motor cables against thermal overload when the cables are sized according to the nominal current of the drive. No additional thermal protection devices are needed.
Page 82: Implementing The Emergency Stop Function
82 Planning the electrical installation 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 relevant standards. Note: Pressing the stop key on the control panel of the drive does not generate an emergency stop of the motor or separate the drive from dangerous potential.
Page 83: Implementing A Bypass Connection
Planning the electrical installation 83 WARNING! When the Vector control mode is in use, never open the output contactor while the drive controls the motor. The vector control operate extremely fast, much faster than it takes for the contactor to open its contacts. When the contactor starts opening while the drive controls the motor, the vector control will try to maintain the load current by immediately increasing the drive output voltage to the maximum.
Page 84: Example Bypass Connection
84 Planning the electrical installation  Example bypass connection An example bypass connection is shown below. Main switch for the drive Drive main contactor on/off control Bypass circuit breaker Motor power supply selection (drive or direct-on-line) Drive main contactor Start when the motor is connected direct- on-line Bypass contactor Stop when the motor is connected direct-...
Page 85: Protecting The Contacts Of Relay Outputs
Planning the electrical installation 85 Switching the motor power supply from drive to direct-on-line 1. Stop the drive and the motor with the drive control panel (drive in local control mode) or with the external stop signal (drive in remote control mode). 2.
Page 86: Limiting Relay Output Maximum Voltages At High Installation Altitudes
86 Planning the electrical installation 230 V AC 230 V AC + 24 V DC Relay outputs Varistor RC filter Diode Limiting relay output maximum voltages at high installation altitudes See sections Isolation areas, R1…R5 on page Isolation areas, R6…R9 page 189.
Page 87: Implementing A Motor Temperature Sensor Connection
Planning the electrical installation 87 Implementing a motor temperature sensor connection WARNING! IEC 60664 requires double or reinforced insulation between live parts and the surface of accessible parts of electrical equipment which are either non-conductive or conductive but not connected to the protective earth.. To connect a motor temperature sensor and other similar components to the drive, you have four alternatives: If there is double or reinforced insulation between the sensor and the live parts...
Page 88 88 Planning the electrical installation The table shows what temperature sensor types you can connect to the drive I/O extension modules as well as the insulation requirement for the sensor. Extension module Temperature sensor type Type Insulation Pt100, Pt1000 CMOD-02 Reinforced insulation between the motor thermistor connector and the other CPTC-02...
Page 89: Electrical Installation
Electrical installation 89 Electrical installation Contents of this chapter The chapter describes how to check the insulation of the assembly and the compatibility with IT (ungrounded) and corner-grounded TN systems. It then shows how to connect the power and control cables, install optional modules and connect a Warnings WARNING! Obey the instructions in chapter Safety instructions...
Page 90: Checking The Insulation Of The Assembly
90 Electrical installation Checking the insulation of the assembly  Drive Do not make any voltage tolerance or insulation resistance tests on any part of the drive as testing can damage the drive. Every drive has been tested for insulation between the main circuit and the chassis at the factory.
Page 91: Brake Resistor Assembly For R1
Electrical installation 91  Brake resistor assembly for R1…R3 Check the insulation of the brake resistor assembly (if present) as follows: 1. Check that the resistor cable is connected to the resistor, and disconnected from the drive output terminals R+ and R-. 2.
Page 92: Ground-To-Phase Varistor
92 Electrical installation  Ground-to-phase varistor The ground-to-phase varistor is not suitable for use on an IT (ungrounded) system. Disconnect the ground-to-phase varistor before connecting the drive to the supply network. Check the table on page 92. WARNING! Do not install the drive with the ground-to-phase varistor connected on an IT system (an ungrounded power system or a high- resistance-grounded [over 30 ohms] power system), otherwise the varistor circuit can be damaged.
Page 93: Frames R1
Electrical installation 93  Frames R1…R3 To disconnect the internal EMC filter or ground-to-phase varistor, if needed, do as follows: 1. Switch off the power from the drive. 2. Open the front cover, if not already opened, see page 97. 3.
Page 94: Frames R4
94 Electrical installation  Frames R4…R9 To disconnect the internal EMC filter or ground-to-phase varistor, if needed, do as follows: 1. Switch off the power from the drive. 2. Open the cover, if not already opened. Frame R4: see page 97, frame R5: see page 105, frames R6…R9: see page 63.
Page 95 Electrical installation 95 R6…R9...
Page 96: Connecting The Power Cables
96 Electrical installation Connecting the power cables  Connection diagram ACS580-01 UDC+ T1/U T2/V T3/W 3 ~ M (PE) (PE) For alternatives, see section Selecting the supply disconnecting device on page Use a separate grounding PE cable (2a) or a cable with a separate PE conductor (2b) if the conductivity of the shield does not meet the requirements for the PE conductor (see page 72).
Page 97: Connection Procedure, Frames R1
Electrical installation 97  Connection procedure, frames R1…R4 1. Remove the front cover: Loosen the retaining screw with a screwdriver (1a) and lift the cover from the bottom outwards (1b) and then up (1c). IP21 (UL Type 1), IP21 (UL Type 12), IP55 (UL Type 12), IP55 (UL Type 12), R1…R2...
Page 98 98 Electrical installation 3. Remove the rubber grommets from the cable entry if they point up. (The grommets may point up or down when you open the package, depending on the frame size.) R1…R3: The grommets point down and at this point you need to remove only the grommets for motor and input power cable, as well as brake resistor cable, if used.
Page 99 Electrical installation 99 Motor cable 4. Cut an adequate hole into the rubber grommet. Slide the grommet onto the cable. 5. Prepare the ends of the cable as illustrated in the figure. In frames R1 and R2 there are markings on the drive frame near the power cable terminals helping you to strip the wires to the correct length of 8 mm.
Page 100 100 Electrical installation 7. Connect the motor cable: • Ground the shield 360 degrees by tightening the clamp of the power cable grounding shelf onto the stripped part of the cable. (7a) • Connect the twisted shield of the cable to the grounding terminal. (7b) •...
Page 101 Electrical installation 101 10. Slide the cable through the hole in the cable entry and attach the grommet to the hole. 11. Connect the input power cable: • Ground the shield 360 degrees by tightening the clamp of the power cable grounding shelf onto the stripped part of the cable.
Page 102 102 Electrical installation Grounding shelf 12. Frames R1…R2, R4: Install the grounding shelf (included with the mounting screws in a plastic bag in the delivery). R1…R2 Brake resistor cable (if used) Frames R1…R3 only 13. Repeat steps 4…6 for the brake resistor cable. Cut off one phase conductor.
Page 103 Electrical installation 103 14. Connect the cable as the motor cable in step 7. Ground the shield 360 degrees (14a). Connect the twisted shield to the grounding terminal (14b) and the conductors to the R+ and R- terminals (14c) and tighten to the torque given below the figure.
Page 104 104 Electrical installation 16. Secure the cables outside the unit mechanically. 17. Ground the motor cable shield at the motor end. For minimum radio frequency interference, ground the motor cable shield 360 degrees at the cable entry of the motor terminal box.
Page 105: Connection Procedure, Frame R5
Electrical installation 105  Connection procedure, frame R5 IP21 (UL Type 1) 1. Remove the module cover: Loosen the retaining screws with a screwdriver (1a) and lift the cover from the bottom outwards (1b) and then up (1c). Remove the box cover: Loosen the retaining screws with a screwdriver (1d) and slide the cover downwards (1e).
Page 106 106 Electrical installation 2. Attach the residual voltage warning sticker in the local language next to the control board. 3. Remove the shroud on the power cable terminals by releasing the clips with a screwdriver (3a) and pulling the shroud out (3b).
Page 107 Electrical installation 107 Motor cable Use symmetrical shielded cable for motor cabling. If the cable shield is the sole PE conductor for drive or motor, make sure that is has sufficient conductivity for the PE. 4. Cut an adequate hole into the rubber grommet. Slide the grommet onto the cable. 5.
Page 108 108 Electrical installation 6. Slide the cable through the hole of the bottom plate and attach the grommet to the hole. 7. Connect the motor cable: • Ground the shield 360 degrees by tightening the clamp of the power cable grounding shelf onto the stripped part of the cable (7a).
Page 109 Electrical installation 109 Input power cable 8. Repeat steps 4…6 for the input power cable. 9. Connect the input power cable. Tighten the screws to the torque given in the figure. 10. Install the cable box plate. Position the plate and tighten the screw. Frame size L1, L2, L3 N·m...
Page 110 110 Electrical installation 11. Reinstall the shroud on the power terminals by putting the tabs at the top of the shroud in their counterparts on the drive frame and then pressing the shroud in place. Finalization 12. Secure the cables outside the unit mechanically. 13.
Page 111: Connection Procedure, Frames R6
Electrical installation 111  Connection procedure, frames R6…R9 WARNING! If the drive will be connected on an IT (ungrounded) system, make sure you have disconnected the EMC filter and ground-to-phase varistor. See page 91. If the drive will be connected on a corner-grounded TN system, make sure you have disconnected the EMC filter.
Page 112 112 Electrical installation Motor cable 6. Cut an adequate hole into the rubber grommet. Slide the grommet onto the cable. 7. Prepare the ends of the input power cable and motor cable as illustrated in the figure. If you use aluminum cables, put grease to the peeled aluminum cable before connecting it to the drive.
Page 113 Electrical installation 113 Input power cable 10. Connect the input power cable as in step 9. Use terminals L1, L2 and L3. M5×25/35 Frame size L1, L2, L3, T1/U, T2/V, T3/W N·m lbf·ft N·m N·m N·m lbf·ft 22.1 29.5 29.5 51.6 Terminals T1/U, T2/V and T3/W •...
Page 114 114 Electrical installation Terminals L1, L2 and L3 • Remove the combi screw that attaches the connector to its terminal post, and pull the connector off. • Put the conductor under the connector pressure plate and pre-tighten the conductor. • Put the connector back onto the terminal post.
Page 115: Dc Connection
Electrical installation 115 13. Reinstall the shroud on the power terminals. 14. Secure the cables outside the unit mechanically. 15. Ground the motor cable shield at the motor end. For minimum radio frequency interference, ground the motor cable shield 360 degrees at the cable entry of the motor terminal box.
Page 116: Connecting The Control Cables
See section Default I/O connection diagram (ABB standard macro) on page the default I/O connections of the ABB standard macro. For other macros, see ACS580 firmware manual (3AXD50000016097 [English]). Connect the cables as described under Control cable connection procedure R1…R9...
Page 117: Default I/O Connection Diagram (Abb Standard Macro)
Electrical installation 117  Default I/O connection diagram (ABB standard macro) R1…R5 Reference voltage and analog inputs and outputs Signal cable shield (screen) 1…10 kohm 1,3) Output frequency/speed reference: 0…10 V AGND Analog input circuit common +10V Reference voltage 10 V DC...
Page 118 118 Electrical installation R6…R9 Reference voltage and analog inputs and outputs Signal cable shield (screen) 1…10 kohm 1,3) Output frequency/speed reference: 0…10 V AGND Analog input circuit common +10V Reference voltage 10 V DC Not configured AGND Analog input circuit common max.
Page 119 Electrical installation 119 Notes: Current [0(4)…20 mA, R = 100 ohm] or voltage [ 0(2)…10 V, R > 200 kohm]. Change of setting requires changing the corresponding parameter. Total load capacity of the Auxiliary voltage output +24V (X2:10) is 6.0 W (250 mA / 24 V) minus the power taken by the option modules installed on the board.
Page 120 120 Electrical installation Switches Switch Description Position Modbus link termination. Must be set to the Bus not terminated terminated (ON) position when the drive is (default) (TERM) the first or last unit on the link. TERM Bus terminated TERM Switches on the biasing voltages to the Bias off (default) bus.
Page 121 Electrical installation 121 PNP configuration for digital inputs Internal and external +24 V power supply connections for PNP configuration are shown in the figure below. Internal +24 V power supply External +24 V power supply PNP connection (source) PNP connection (source) X2 &...
Page 122 122 Electrical installation Connection for obtaining 0…10 V from analog output 2 (AO2) To obtain 0…10 V from analog output AO2, connect a 500 ohm resistor (or two 1 kohm resistors in parallel) between the analog output 2 AO2 and analog common ground AGND.
Page 123 Electrical installation 123 Connection examples of two-wire and three-wire sensors Hand/Auto, Hand/PID, and PID macros (see ACS580 firmware manual (3AXD50000016097 [English])) use analog input 2 (AI2). The macro wiring diagrams on these pages use an externally powered sensor (connections not shown). The figures below give examples of connections using a two-wire or three-wire sensor/transmitter supplied by the drive auxiliary voltage output.
Page 124 124 Electrical installation DI5 as frequency input For setting the parameters for the digital frequency input, see ACS580 standard control program firmware manual (3AXD50000016097 [English]). DI6 as PTC input If DI6 is used as a PTC input, see ACS580 standard control program firmware manual (3AXD50000016097 [English]) for how to set parameters accordingly.
Page 125 Electrical installation 125 AI1 and AI2 as Pt100, Pt1000, Ni1000, KTY83 and KTY84 sensor inputs (X1) One, two or three Pt100 sensors; one, two or three Pt1000 sensors; or one Ni1000, KTY83 or KTY84 sensor for motor temperature measurement can be connected between an analog input and output as shown below.
Page 126: Control Cable Connection Procedure R1
126 Electrical installation  Control cable connection procedure R1…R9 WARNING! Obey the instructions in chapter Safety instructions on page 13. If you ignore them, injury or death, or damage to the equipment can occur. 1. Stop the drive and do the steps in section Precautions before electrical work page before you start the work.
Page 127 Electrical installation 127 9. Route the cable as shown in the figures on pages (R1…R2 and R3), (R4), (R5) or (R6…R9). 10. Connect the conductors to the appropriate terminals of the control board and tighten to 0.5…0.6 N·m (0.4 lbf·ft). 11.
Page 128 128 Electrical installation R1…R2 INPUT BREAKERS MOTOR T1/U T2/V T3/W UDC+ R3: 0.5…0.6 N·m (0.4 lbf·ft) …R2: 0.5…0.6 N·m (0.4 lbf·ft)
Page 129 Electrical installation 129 0.5...0.6 N·m (0.4 lbf·ft)
Page 130 130 Electrical installation 0.5...0.6 N·m (0.4 lbf·ft)
Page 131 Electrical installation 131 R6…R9 0.5...0.6 N·m (0.4 lbf·ft) 0.5...0.6 N·m (0.4 lbf·ft) M4×20...
Page 132: Installing Option Modules
132 Electrical installation Installing option modules Note: In US deliveries, options are already installed at the factory. Note: If you will install the FPBA 01 module, see section FPBA-01 PROFIBUS DP adapter module connectors on page for suitable connector types. ...
Page 133 Electrical installation 133 R1…R2 R3…R5...
Page 134: Wiring The Modules
134 Electrical installation R6…R9  Wiring the modules See the appropriate option module manual for specific installation and wiring instructions.
Page 135: Reinstalling Covers
Electrical installation 135 Reinstalling covers  Reinstalling cover, frames R1…R4 1. Reinstall the cover: Put the tabs on the cover top in their counterparts on the housing (1a) and the press the cover (1b). 2. Tighten the retaining screw at the bottom with a screwdriver. IP21 (UL Type 1) R1…R2 IP21 (UL Type 1) R3…R4 IP55 (UL Type 12) R1…R3...
Page 136: Reinstalling Covers, Frame R5
136 Electrical installation  Reinstalling covers, frame R5 IP21 (UL Type 1) 1. Reinstall the box cover: Slide the cover upwards (1a) and tighten the retaining screws (1b). 2. Reinstall the module cover: Press the cover at the bottom (2a) and tighten the retaining screws (2b).
Page 137: Reinstalling Side Plates And Covers, Frames R6
Electrical installation 137  Reinstalling side plates and covers, frames R6…R9 IP21 (UL Type 1) 1. Reinstall the side plates of the cable box. Tighten the retaining screws with a screwdriver. 2. Slide the cover of the cable box on the module from below until the cover snaps into place.
Page 138: Connecting A Pc
138 Electrical installation Connecting a PC To be able to connect a PC to the drive, you need an assistant control panel (ACS- AP-I, ACS-AP-S or ACS-AP-W). It is also possible to use CCA-01 configuration adapter. Connect a PC to the drive with a USB data cable (USB Type A <-> USB Type Mini-B) as follows: 1.
Page 139: Installation Checklist
Installation checklist 139 Installation checklist Contents of this chapter This chapter contains an installation checklist which you must complete before you start up the drive. Warnings WARNING! Obey the instructions in chapter Safety instructions on page 13. If you ignore them, injury or death, or damage to the equipment can occur. Checklist Do the steps in section Precautions before electrical work...
Page 140 140 Installation checklist Check that … If the drive has not been powered (either in storage or unused) over one year: The electrolytic DC capacitors in the DC link of the drive have been reformed. See section Replacing the auxiliary cooling fan, IP55 (UL Type 12) frames R1…R2 on page 150.
Page 141: Maintenance And Hardware Diagnostics
(www.abb.com/drivesservices). For more information, consult your local ABB Service representative (www.abb.com/searchchannels). 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.
Page 142: Description Of Symbols
Second auxiliary cooling fan (LONGLIFE) R8 and R9: page Aging Control panel battery: page 4FPS10000309652.xlsx H Valid for ACS580-01 type codes listed in this manual. For other type codes, see ACS580-01 (0.75 to 250 kW, 1.0 to 350 hp) hardware manual (3AXD50000018826 [English]).
Page 143: Heatsink
Maintenance and hardware diagnostics 143 Heatsink The drive heatsink fins pick up dust from the cooling air. The drive can run into overtemperature warnings and faults if the heatsink is not clean. When necessary, clean the heatsink as follows. WARNING! Obey the instructions in chapter Safety instructions on page 13.
Page 144: Fans
144 Maintenance and hardware diagnostics Fans See section Maintenance intervals on page for the fan replacement interval in average operation conditions. In a speed-controlled fan, the speed of the fan matches the cooling needs. This increases the life span of the fan. Main fans are speed controlled.
Page 145: Replacing The Main Cooling Fan, Ip21 And Ip55 (Ul Type 1 And Ul Type 12) Frames R1
Maintenance and hardware diagnostics 145  Replacing the main cooling fan, IP21 and IP55 (UL Type 1 and UL Type 12) frames R1…R4 WARNING! Obey the instructions in chapter Safety instructions on page 13. Ignoring the instructions can cause physical injury or death, or damage to the equipment.
Page 146 146 Maintenance and hardware diagnostics 2. Lever the fan assembly off the drive frame with for example a screwdriver (2a) and pull out the fan assembly (2b). 3. Install the fan assembly in reverse order.
Page 147: Replacing The Main Cooling Fan, Ip21 And Ip55 (Ul Type 1 And Ul Type 12) Frames R5
Maintenance and hardware diagnostics 147  Replacing the main cooling fan, IP21 and IP55 (UL Type 1 and UL Type 12) frames R5…R8 WARNING! Obey the instructions in chapter Safety instructions on page 13. Ignoring the instructions can cause physical injury or death, or damage to the equipment.
Page 148: Frame R9
148 Maintenance and hardware diagnostics  Replacing the main cooling fans, IP21 and IP55 (UL Type 1 and UL Type 12) frame R9 WARNING! Obey the instructions in chapter Safety instructions on page 13. Ignoring the instructions can cause physical injury or death, or damage to the equipment.
Page 149: Replacing The Auxiliary Cooling Fan, Ip21 And Ip55 (Ul Type 1 And Ul Type 12) Frames R5
Maintenance and hardware diagnostics 149  Replacing the auxiliary cooling fan, IP21 and IP55 (UL Type 1 and UL Type 12) frames R5…R9 WARNING! Obey the instructions in chapter Safety instructions on page 13. Ignoring the instructions can cause physical injury or death, or damage to the equipment.
Page 150: Replacing The Auxiliary Cooling Fan, Ip55 (Ul Type 12) Frames R1
150 Maintenance and hardware diagnostics  Replacing the auxiliary cooling fan, IP55 (UL Type 12) frames R1…R2 WARNING! Obey the instructions in chapter Safety instructions on page 13. Ignoring the instructions can cause physical injury or death, or damage to the equipment.
Page 151: Replacing The Auxiliary Cooling Fan, Ip55 (Ul Type 12) Frame R3
Maintenance and hardware diagnostics 151  Replacing the auxiliary cooling fan, IP55 (UL Type 12) frame R3 WARNING! Obey the instructions in chapter Safety instructions on page 13. Ignoring the instructions can cause physical injury or death, or damage to the equipment.
Page 152: Replacing The Auxiliary Cooling Fan, Ip55 (Ul Type 12) Frame R4
152 Maintenance and hardware diagnostics  Replacing the auxiliary cooling fan, IP55 (UL Type 12) frame R4 WARNING! Obey the instructions in chapter Safety instructions on page 13. Ignoring the instructions can cause physical injury or death, or damage to the equipment.
Page 153: Replacing The Second Auxiliary Cooling Fan, Ip55 (Ul Type 12) Frames R8
Maintenance and hardware diagnostics 153  Replacing the second auxiliary cooling fan, IP55 (UL Type 12) frames R8…R9 WARNING! Obey the instructions in chapter Safety instructions on page 13. Ignoring the instructions can cause physical injury or death, or damage to the equipment.
Page 154: Capacitors
For information on reforming the capacitors, see Converter module capacitor reforming instructions (3BFE64059629 [English]), available on the Internet (go to http://www.abb.com and enter the document code in the Search field).
Page 155: Control Panel
Maintenance and hardware diagnostics 155 Control panel  Cleaning the control panel Use a soft damp cloth to clean the control panel. Avoid harsh cleaners which could scratch the display window.  Replacing the battery in the control panel A battery is used in all control panels, except the basic control panel that does not support the clock function, to keep the clock operating in memory during power interruptions.
Page 156: Leds
156 Maintenance and hardware diagnostics LEDs  Drive LEDs There is a green POWER and a red FAULT LED on the front of the drive. They are visible through the panel cover but invisible if a control panel is attached to the drive. The table below describes the drive LED indications.
Page 157: Control Panel Leds
Maintenance and hardware diagnostics 157  Control panel LEDs The assistant control panel has one LED. The table below describes the control panel LED indications. For more information see ACS-AP-x assistant control panels user’s manual (3AUA0000085685 [English]). Control panel LED, at the left edge of the control panel LED off LED lit and steady LED blinking/flickering...
Page 158 158 Maintenance and hardware diagnostics...
Page 159: Technical Data
Technical data 159 Technical data Contents of this chapter The chapter contains the technical specifications of the drive, for example ratings, sizes and technical requirements as well as provisions for fulfilling the requirements for CE, UL and other approval marks.
Page 160: Ratings
160 Technical data Ratings  IEC ratings Type Input Max. Output ratings Max. Frame rating current losses size ACS580 Nominal use Light-duty use Heavy-duty use -01- 3-phase U = 400 V (380…415 V) 02A7-4 0.75 0.75 0.55 03A4-4 0.75 04A1-4 05A7-4 07A3-4 10.1...
Page 161: Nema Ratings
Technical data 161  NEMA ratings Type Input Max. Output ratings Max. Frame North rating current losses flow size ACS580 American Nominal use Heavy-duty use -01- type ACS580 -01- /min 3-phase U = 480 V (440…480 V) 02A7-4 0.75 02A1-4 03A4-4 03A0-4 04A1-4...
Page 162: Sizing
Note: The ratings apply at ambient temperature of 40 °C (104 °F) for I . Above theses temperatures derating is required. Note: The DriveSize dimensioning PC tool available from ABB (http://new.abb.com/drives/software-tools/drivesize) is recommended for selecting the drive, motor and gear combination.
Page 163: Derating
Example 1: How to calculate the derated current The IP21 drive type is ACS580-01-062A-4, which has motor current 62 A. Calculate the derated motor current ( ) at 4kHz switching frequency, at 1500 m altitude and at 50 °C ambient...
Page 164: Ambient Temperature Derating, Ip21 (Ul Type 1)
164 Technical data  Ambient temperature derating, IP21 (UL Type 1) In the temperature range +40…50 °C (+104…122 °F), the rated output current is derated by 1% for every added 1 °C (1.8 °F). The output current can be calculated by multiplying the current given in the rating table by the derating factor (k, in the diagram below).
Page 165 Technical data 165 (1.8 °F). The output current can be calculated by multiplying the current given in the rating table by the derating factor (k): 1.00 0.95 0.90 0.85 0.825 0.80 0.75 … -15 °C +40 °C +45 °C +50 °C -59 °F +104 °F +113 °F...
Page 166: Altitude Derating
166 Technical data  Altitude derating In altitudes 1000…4000 m (3300…13120 ft) above sea level, the derating is 1% for every 100 m (330 ft). The output current is calculated by multiplying the current given in the rating table by the derating factor k, which for x meters (1000 m <= x <= 4000 m) is: .
Page 167: Switching Frequency Derating
Technical data 167 The altitude derating can be reduced if the temperature is below +40 °C, for example, if the temperature is 30 °C, the derating factor is 1 - 1.5% 10 = 0.85. You can reduce · the output current by 35% instead of 40% at 4000 meter above the see level. Note: Check the supply network compatibility restrictions above 2000 m (6562 ft), Installation site altitude on page 192.
Page 168: Fuses (Iec)
168 Technical data Fuses (IEC) gG as well as uR or aR fuses for protection against short-circuit in the input power cable or drive are listed below. Either fuse type can be used for frames R1…R9 if it operates rapidly enough. The operating time depends on the supply network impedance and the cross-sectional area and length of the supply cable.
Page 169: Gg Fuses
0.5 seconds. Obey the local regulations. Type Min. Input gG (IEC 60269) North short- current American ACS580 Nominal Voltage ABB type circuit -01- type current rating 60269 current ACS580 size -01- 3-phase U = 400 or 480 V (380…415 V, 440…480 V)
Page 170: Ur And Ar Fuses
170 Technical data  uR and aR fuses Type Min. short- Input uR or aR circuit current ACS580 Nominal Voltage Bussmann IEC 60269 current -01- current rating type size 3-phase U = 400 or 480 V (380…415 V, 440…480 V) 02A7-4 170M1561 03A4-4...
Page 171: Fuses (Ul)
Technical data 171 Fuses (UL) UL class T fuses for branch circuit protection per NEC are listed below. Fast acting class T or faster fuses are recommended in the USA. Check on the fuse time- current curve to ensure the operating time of the fuse is below 0.5 seconds. Obey the local regulations.
Page 172: Circuit Breakers
172 Technical data Circuit breakers The table below lists MCB and MCCB circuit breakers that can be used with the drive. Not allowed for US installation. Type MCBs and MCCBs ACS580 ABB type Max. Tmax Tmax Electronic SACE ordering -01-...
Page 173: Dimensions, Weights And Free Space Requirements
Technical data 173 Dimensions, weights and free space requirements Frame Dimensions and weights Dimensions and weights size IP21 UL Type 1 Weight H1 Weight mm mm mm mm mm mm 332 301 355 332 125 223 13.08 11.85 13.96 13.08 4.92 8.78 10.59 432 395 449 432 125 229 17.02 15.55 17.67 17.02 4.92 9.00...
Page 174 174 Technical data Frame Dimensions and weights size IP55 UL Type 12 Weight Weight mm mm mm mm 387 332 125 233 15.23 13.08 4.92 9.17 11.25 2.56 5.09 481 432 125 239 18.93 17.02 4.92 9.41 14.80 2.56 5.10 456 490 203 237 13.0 17.94 19.29 7.99...
Page 175 Technical data 175 Frame Free space, IP21 (UL Type 1) and IP55 (UL Type 12) size Vertical mounting Vertical mounting stand alone side by side Above Below Beside Above Below Between 7.87 1.18 5.91 7.87 7.87 7.87 1.18 5.91 7.87 7.87 7.87 7.87...
Page 176: Losses, Cooling Data And Noise
176 Technical data Losses, cooling data and noise The air flow direction is from bottom to top.  Cooling air flow, heat dissipation and noise for stand-alone drives The table below specifies the heat dissipation in the main circuit at nominal load and in the control circuit with minimum load (I/O, options and panel not in use) and maximum load (all digital inputs and relays in the ON state, and the panel, fieldbus and fan in use).
Page 177: Cooling Air Flow And Heat Dissipation For Flange Mounting (Option +C135)
Technical data 177  Cooling air flow and heat dissipation for flange mounting (option +C135) Type Heat dissipation Air flow Frame (option +135) (option +135) ACS580 size -01- Heatsink Front Heatsink Front /min /min 3-phase U = 400 or 480 V (380…415 V, 440…480 V) 145A-4 1251 169A-4...
Page 178: Terminal And Lead-Through Data For The Power Cables
178 Technical data Terminal and lead-through data for the power cables  Input, motor, resistor and DC cable lead-throughs, maximum wire sizes (per phase) and terminal screw sizes and tightening torques (T) are given below. Frame Cable lead- L1, L2, L3, T1/U, T2/V, T3/W terminals Grounding terminals throughs size...
Page 179 Technical data 179 Frame Cable lead- R+, R-, UDC+ and UDC- terminals throughs size Per cable Ø Min wire size Max wire size T (Wire screw) type (solid/ (solid/ stranded) stranded) M… N·m 0.20/0.25 1.2…1.5 0.5/0.5 16/16 1.2…1.5 0.5/0.5 35/25 2.5…4.5 0.5/0.5 2×50...
Page 180 180 Technical data  Input, motor, resistor and DC cable lead-throughs, maximum wire sizes (per phase) and terminal screw sizes and tightening torques (T) are given below. Frame Cable lead- L1, L2, L3, T1/U, T2/V, T3/W terminals Grounding terminals throughs size Ø...
Page 181 Technical data 181 Frame Cable lead- R+, R-, UDC+ and UDC- terminals throughs size Per cable Ø Min wire size Max wire size T (Wire screw) type (solid/ (solid/ stranded) stranded) M… lbf·ft 0.906 0.906 0.906 1.54 1.54 2/10 1.77 300 MCM 22.1 2.13...
Page 182: Terminal And Lead-Through Data For The Control Cables
182 Technical data Terminal and lead-through data for the control cables  Control cable lead-throughs, wire sizes and tightening torques (T) are given below. Frame Cable lead- Control cable entries and terminal sizes throughs size Holes +24V, DCOM, DGND, EXT. 24V DI, AI/O, AGND, RO, STO cable terminals...
Page 183: Electrical Power Network Specification
Technical data 183 Electrical power network specification Voltage (U Input voltage range 3~ 380…480 V AC. This is indicated in the type designation label as typical input voltage levels 3~ 400/480 V AC. Network type Public low voltage networks. TN (grounded), IT (ungrounded) and corner-grounded TN systems.
Page 184 184 Technical data Maximum recommended motor Operational functionality and motor cable length cable length The drive is designed to operate with optimum performance with the following maximum motor cable lengths. Note: Conducted and radiated emissions of these motor cable lengths do not comply with EMC requirements. Frame Maximum motor cable length, 4 kHz size...
Page 185: Brake Resistor Connection Data For Frames R1
Technical data 185 EMC compatibility and motor cable length To comply with the European EMC Directive (standard EN 61800-3), use the following maximum motor cable lengths at 4 kHz switching frequency. See the table below. Frame Maximum motor cable length, 4 kHz size EMC limits for Category C2 Standard drive with an internal EMC filter.
Page 186: Control Connection Data
186 Technical data Control connection data External power supply Maximum power: Frames R1…R5: 25 W, 1.04 A at 24 V AC/DC ±10% with an option module Frames R6…R9: 36 W, 1.50 A at 24 V AC/DC ±10% as standard Supplied from an external power supply through option module CMOD-01 or CMOD-02 with frames R1…R5.
Page 187 Technical data 187 Relay outputs RO1…RO3 250 V AC / 30 V DC, 2 A (Term. 19…27) Terminal size: Frames R1…R5: 0.14…1.5 mm Frames R6…R9: 0.14…2.5 mm See sections Isolation areas, R1…R5 on page Isolation areas, R6…R9 on page 189. Analog inputs AI1 and AI2 Current/voltage input mode selected with a parameter.
Page 188 188 Technical data Isolation areas, R1…R5 Panel port AI/AO Power unit connection 24 V SLOT1 SLOT2 I/O extension Symbol Description Reinforced insulation (IEC/EN 61800-5-1:2007) Functional insulation (IEC/EN 61800-5-1:2007) Below altitudes 4000 m (6562 ft): The terminals on the control board fulfill the Protective Extra Low Voltage (PELV) requirements (EN 50178): There is adequate insulation between the user terminals which only accept ELV voltages and terminals that accept higher voltages (relay...
Page 189 Technical data 189 Isolation areas, R6…R9 SLOT1 X1:1…3 X1:4…6 X1:7…8 Power unit connection 24 V X3:1…3 X3:4…6 Ext. 24 V SLOT2 I/O extension Panel port Symbol Description Reinforced insulation (IEC/EN 61800-5-1:2007) Functional insulation (IEC/EN 61800-5-1:2007) The terminals on the control board fulfill the Protective Extra Low Voltage (PELV) requirements (EN 50178): There is reinforced insulation between the user terminals which only accept ELV voltages and terminals that accept higher voltages (relay outputs).
Page 190 190 Technical data Grounding of frames R1…R5 Slot 1 Slot 2 AGND +10V AGND AGND X2 & X3 +24V DGND DCOM X6, X7, X8 RO1C RO1A RO1B RO2C RO2A RO2B RO3C RO3A RO3B DGND OUT1 OUT2 SGND Ground Jumper installed at factory...
Page 191 Technical data 191 Grounding of frames R6…R9 Slot 1 Slot 2 AGND +10V AGND AGND X2 & X3 +24V DGND DCOM X6, X7, X8 RO1C RO1A RO1B RO2C RO2A RO2B RO3C RO3A RO3B DGND OUT1 OUT2 SGND 24VAC/DC+in 24VAC/DC-in Ground Jumper installed at factory...
Page 192: Efficiency
192 Technical data Auxiliary circuit power consumption Maximum external power supply: Frames R1…R5: 25 W, 1.04 A at 24 V AC/DC (with option modules CMOD-01, CMOD-02) Frames R6…R9: 36 W, 1.50 A at 24 V AC/DC (as standard, terminals 40…41) Efficiency Approximately 98% at nominal power level Degree of protection...
Page 193 Technical data 193 Relative humidity 5 to 95% Max. 95% Max. 95% No condensation allowed. Maximum allowed relative humidity is 60% in the presence of corrosive gases. Contamination levels IEC 60721-3-3: IEC 60721-3-1: IEC 60721-3-2: (IEC 60721-3-x) 2002: 1997 1997 Classification of environmental conditions - Part...
Page 194: Materials
194 Technical data Shock/Drop (ISTA) Not allowed R1…R4 (ISTA 1A): Drop, 6 faces, 3 edges and 1 corner Weight range 0…10 kg (0…22 lb) 29.9 10…19 kg (22…42 lb) 24.0 19…28 kg (42…62 lb) 18.1 28…41 kg (62…90 lb) 13.4 R5…R9 (ISTA 3E): Shock, incline impact: 1.1 m/s (3.61 ft/s) Shock, rotational edge drop: 200 mm...
Page 195 Technical data 195 EN 60204-1:2006 + AC:2010 Safety of machinery. Electrical equipment of machines. Part 1: General requirements. Provisions for compliance: The final assembler of the machine is responsible for installing - emergency-stop device - supply disconnecting device. IEC/EN 60529:1992 + A2: 2013 Degrees of protection provided by enclosures (IP code) EN 61000-3-12:2011 Electromagnetic compatibility (EMC) - Part 3-12: Limits -...
Page 196: Ce Marking
196 Technical data CE marking A CE mark is attached to the drive to verify that the drive follows the provisions of the European Low Voltage, EMC and RoHS Directives.The CE marking also verifies that the drive, in regard to its safety functions (such as Safe torque off), conforms with the Machinery Directive as a safety component.
Page 197: Compliance With The En 61800-3:2004 + A1:2012
Technical data 197 Compliance with the 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.
Page 198: Category C2
198 Technical data  Category C2 The emission limits are complied with the following provisions: 1. The motor and control cables are selected as specified in this manual. 2. The drive is installed according to the instructions given in this manual. 3.
Page 199: Category C4
Equipment 2. An EMC plan for preventing disturbances is drawn up for the installation. A template is available from the local ABB representative. 3. The motor and control cables are selected as specified in this manual. 4. The drive is installed according to the instructions given in this manual.
Page 200: Ul Marking
200 Technical data UL marking The drive is cULus Listed.  UL checklist • Make sure that the drive type designation label includes the cULus Listed marking. • CAUTION - 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.
Page 201: China Rohs Marking
Technical data 201 China RoHS marking The People’s Republic of China Electronic Industry Standard (SJ/T 11364-2014) specifies the marking requirements for hazardous substances in electronic and electrical products. The green mark is attached to the drive to verify that it does not contain toxic and hazardous substances or elements above the maximum concentration values, and that it is an environmentally-friendly product which can be recycled and reused.
Page 202 ABB and its affiliates are not liable for damages and/or losses related to such security breaches, any unauthorized access,...
Page 203: Dimension Drawings
Dimension drawings 203 Dimension drawings Contents of this chapter This chapter shows the dimension drawings of the ACS580-01. The dimensions are given in millimeters and [inches].
Page 204: Frame R1, Ip21 (Ul Type 1)
204 Dimension drawings Frame R1, IP21 (UL Type 1)
Page 205: Frame R1, Ip55 (Ul Type 12)
Dimension drawings 205 Frame R1, IP55 (UL Type 12)
Page 206: Frame R2, Ip21 (Ul Type 1)
206 Dimension drawings Frame R2, IP21 (UL Type 1)
Page 207: Frame R2, Ip55 (Ul Type 12)
Dimension drawings 207 Frame R2, IP55 (UL Type 12)
Page 208: Frame R3, Ip21 (Ul Type 1)
208 Dimension drawings Frame R3, IP21 (UL Type 1)
Page 209: Frame R3, Ip55 (Ul Type 12)
Dimension drawings 209 Frame R3, IP55 (UL Type 12)
Page 210: Frame R4, Ip21 (Ul Type 1)
210 Dimension drawings Frame R4, IP21 (UL Type 1)
Page 211: Frame R4, Ip55 (Ul Type 12)
Dimension drawings 211 Frame R4, IP55 (UL Type 12)
Page 212: Frame R5, Ip21 (Ul Type 1)
212 Dimension drawings Frame R5, IP21 (UL Type 1)
Page 213: Frame R5, Ip55 (Ul Type 12)
Dimension drawings 213 Frame R5, IP55 (UL Type 12)
Page 214: Frame R6, Ip21 (Ul Type 1)
214 Dimension drawings Frame R6, IP21 (UL Type 1)
Page 215: Frame R6, Ip55 (Ul Type 12)
Dimension drawings 215 Frame R6, IP55 (UL Type 12)
Page 216: Frame R7, Ip21 (Ul Type 1)
216 Dimension drawings Frame R7, IP21 (UL Type 1)
Page 217: Frame R7, Ip55 (Ul Type 12)
Dimension drawings 217 Frame R7, IP55 (UL Type 12)
Page 218: Frame R8, Ip21 (Ul Type 1)
218 Dimension drawings Frame R8, IP21 (UL Type 1)
Page 219: Frame R8, Ip55 (Ul Type 12)
Dimension drawings 219 Frame R8, IP55 (UL Type 12)
Page 220: Frame R9, Ip21 (Ul Type 1)
220 Dimension drawings Frame R9, IP21 (UL Type 1)
Page 221: Frame R9, Ip55 (Ul Type 12)
Dimension drawings 221 Frame R9, IP55 (UL Type 12)
Page 222 222 Dimension drawings...
Page 223: Resistor Braking
Resistor braking 223 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. Operation principle and hardware description The brake chopper handles the energy generated by a decelerating motor. The chopper connects the brake resistor to the intermediate DC circuit whenever the voltage in the circuit exceeds the limit defined by the control program.
Page 224: Resistor Braking, Frames R1
224 Resistor braking Resistor braking, frames R1…R3  Planning the braking system Selecting the brake resistor Frames R1…R3 have an built-in brake chopper as standard equipment. The brake resistor is selected using the table and equations presented in this section. 1.
Page 225 Resistor braking 225 The table shows reference resistor types for the maximum braking power. Type Reference resistor types BRmax ACS580 Danotherm -01- 3-phase U = 400 or 480 V (380…415 V, 440…480 V) 02A7-4 CBH 360 C T 406 210R 03A4-4 CBH 360 C T 406 210R 04A1-4...
Page 226 The maximum length of the resistor cable(s) is 10 m (33 ft). EMC compliance of the complete installation Note: ABB has not verified that the EMC requirements are fulfilled with external user- defined brake resistors and cabling. The EMC compliance of the complete installation...
Page 227 Resistor braking 227 Placing the brake resistor Install the resistors outside the drive in a place where they will cool. Arrange the cooling of the resistor in a way that: • no danger of overheating is caused to the resistor or nearby materials •...
Page 228: Mechanical Installation
228 Resistor braking We recommend that you also wire the thermal switch to a digital input of the drive. L1 L2 L3  ACS580 ACS580 L1 L2 L3 +24V  Mechanical installation All brake resistors must be installed outside the drive. Follow the resistor manufacturer’s instructions.
Page 229: Start-Up
Resistor braking 229  Start-up Note: Protective oil on the brake resistors will burn off when the brake resistor is used for the first time. Make sure that the airflow is sufficient. Set the following parameters: 1. Disable the overvoltage control of the drive with parameter 30.30 Overvoltage control.
Page 230: Resistor Braking, Frames R4
For more information, see NBRA-6xx Braking Choppers Installation and start-up guide (3AFY58920541 [English]) and ACS-BRK Brake Units Installation and start-up guide (3AFY61514309 [English]). Type Brake Reference resistor types BRmax ACS580-01 chopper 3-phase U = 400 or 480 V (380…415 V, 440…480 V) 062A-4 ACS-BRK-D 18.1 40.2 Built in with the brake chopper...
Page 231: Safe Torque Off Function
Safe torque off function 231 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, to construct safety or supervision circuits that stop the drive in case of danger (such as an emergency stop circuit).
Page 232: Compliance With The European Machinery Directive
232 Safe torque off function The Safe torque off function of the drive complies with these standards: Standard Name EN 60204-1:2016 Safety of machinery – Electrical equipment of machines – Part 1: General requirements IEC 61326-3-1:2008 Electrical equipment for measurement, control and laboratory use – EMC requirements –...
Page 233: Connection Principle
Safe torque off function 233 Connection principle  Connection with internal +24 V DC power supply Drive Control board OUT1 + 24 V DC OUT2 + 24 V DC SGND UDC+ T1/U, Control logic T2/V, T3/W UDC-...
Page 234: Connection With Internal +24 V Dc Power Supply, Single Line
234 Safe torque off function  Connection with internal +24 V DC power supply, single line Drive Control board OUT1 + 24 V DC OUT2 + 24 V DC SGND UDC+ T1/U, Control logic T2/V, T3/W UDC- Notes: • Both STO inputs (IN1, IN2) must be connected to the activation switch. Otherwise, no SIL/PL classification is given.
Page 235: Connection With External +24 V Dc Power Supply
Safe torque off function 235  Connection with external +24 V DC power supply 24 V DC Drive Control board OUT1 + 24 V DC OUT2 + 24 V DC SGND UDC+ T1/U, Control logic T2/V, T3/W UDC- Wiring examples An example of a Safe torque off wiring with internal +24 V DC power supply is shown below.
Page 236: Activation Switch
236 Safe torque off function An example of a Safe torque off wiring with external +24 V DC power supply is shown below. +24 V DC external Drive Safety PLC power supply OUT1 OUT2 36 SGND Safety relay For information on the specifications of the STO input, see chapter Control connection data (page 186).
Page 237: Grounding Of Protective Shields
Safe torque off function 237  Grounding of protective shields • Ground the shield in the cabling between the activation switch and the control board at the control board. • Ground the shield in the cabling between two control boards at one control board only.
Page 238: Acceptance Test Reports
238 Safe torque off function functional safety, as required by IEC 61508-1 clause 6. The test procedures and report must be documented and signed by this person.  Acceptance test reports Signed acceptance 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.
Page 239: Acceptance Test Procedure
Safe torque off function 239  Acceptance test procedure After wiring the Safe torque off function, validate its operation as follows. If a CPTC-02 module is installed, see CPTC-02 ATEX-certified thermistor protection module, Ex II (2) GD (+L537+Q971) user's manual (3AXD50000030058 [English]). Action WARNING! Follow the Safety...
Page 240: Use
240 Safe torque off function Action Test the operation of the failure detection of the drive. The motor can be stopped or running. • Open the 1st channel of the STO circuit. If the motor was running, it should coast to a stop.
Page 241 Safe torque off function 241 WARNING! With permanent magnet motors or synchronous reluctance [SynRM] motors only: In case of a multiple IGBT power semiconductor failure, the drive system 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.
Page 242: Maintenance
If any wiring or component change is needed after start up, or the parameters are restored, follow the test given in section Acceptance test procedure (page 239). Use only spare parts approved by ABB. Record all maintenance and proof test activities in the machine logbook.  Competence...
Page 243 See the drive firmware manual for the indications generated by the drive, and for details on directing fault and warning indications to an output on the control board for external diagnostics. Any failures of the Safe torque off function must be reported to ABB.
Page 244: Safety Data
244 Safe torque off function Safety data The safety data for the Safe torque off function is given below. Note: The safety data is calculated for redundant use, and does not apply if both STO channels are not used. Frame IEC 61508 and IEC/EN 61800-5-2 size Lifetime...
Page 245 Safe torque off function 245 • 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).
Page 246: Abbreviations
246 Safe torque off function  Abbreviations Abbr. Reference Description Cat. EN ISO 13849-1:2015 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.
Page 247: Certificate
Safe torque off function 247  Certificate TÜV certificate (3AXD10000302787) is available on the Internet. See section Document library on the Internet on the inside of the back cover.
Page 248 248 Safe torque off function...
Page 249: Optional I/O Extension Modules
Optional I/O extension modules 249 Optional I/O extension modules Contents of this chapter This chapter describes how to install and start up the optional CHDI-01, CMOD-01 and CMOD-02 multifunction extension modules. The chapter also contains diagnostics and technical data. CHDI-01 115/230 V digital input extension module ...
Page 250: Mechanical Installation
250 Optional I/O extension modules Layout Item Description Additional information Grounding screw Hole for mounting screw 3-pin terminal blocks for relay outputs Page 3-pin terminal block for 115/230 V inputs Page Diagnostic LED Page  Mechanical installation Necessary tools and instructions •...
Page 251: Electrical Installation
Optional I/O extension modules 251 Installing the module See chapter Installing option modules on page 132.  Electrical installation Warnings WARNING! Obey the instructions in chapter Safety instructions on page 13. If you ignore them, injury or death, or damage to the equipment can occur. If you are not a qualified electrician, do not do electrical work.
Page 252 252 Optional I/O extension modules Marking Description HDI11 115/230 V input 5 HDI12 115/230 V input 6 Neutral point NEUTRAL Neutral points 72, 75 and 78 are connected. General cabling instructions Obey the instructions given in chapter Planning the electrical installation on page 65.
Page 253: Start-Up
Optional I/O extension modules 253  Start-up Setting the parameters 1. Power up the drive. 2. If no warning is shown, • make sure that the value of both parameter 15.02 Detected extension module and parameter 15.01 Extension module type is CHDI-01. If warning A7AB Extension I/O configuration failure is shown, •...
Page 254: Technical Data
254 Optional I/O extension modules  Technical data Dimension drawing: The dimensions are in millimeters and [inches]. Installation: Into an option slot on the drive control board Degree of protection: IP20 Ambient conditions: See the drive technical data. Package: Cardboard...
Page 255 Optional I/O extension modules 255 Isolation areas: CHDI-01 Plugged to drive SLOT2 Symbol Description Reinforced insulation (IEC 61800-5-1:2007) Functional insulation (IEC 61800-5-1:2007) Relay outputs (50…52, 53…55): • Wire size max. 1.5 mm • Minimum contact rating: 12 V / 10 mA •...
Page 256: Cmod-01 Multifunction Extension Module (External 24 V Ac/Dc And Digital I/O)
256 Optional I/O extension modules CMOD-01 multifunction extension module (external 24 V AC/DC and digital I/O)  Safety instructions WARNING! Obey the safety instructions for the drive. If you ignore the safety instructions, injury or death can occur.  Hardware description Product overview The CMOD-01 multifunction extension module (external 24 V AC/DC and digital I/O) expands the outputs of the drive control board.
Page 257: Mechanical Installation
Optional I/O extension modules 257 Layout Item Description Additional information Grounding screw Page Hole for mounting screw Page 3-pin terminal blocks for relay outputs Page 3-pin terminal block for transistor output Page 2-pin terminal block for external power supply Page Diagnostic LED Page ...
Page 258: Electrical Installation
258 Optional I/O extension modules Installing the module See chapter Installing option modules on page 132.  Electrical installation Warnings WARNING! Obey the instructions in chapter Safety instructions on page 13. If you ignore them, injury or death, or damage to the equipment can occur. If you are not a qualified electrician, do not do electrical work.
Page 259 Optional I/O extension modules 259 External power supply The external power supply is needed only if you want to connect an external back-up power supply for the drive control board. Note: Frames R1…R5 need CMOD-01 for connecting external power supply, frames R6…R9 have corresponding terminals 40 and 41 on the control board.
Page 260: Start-Up
260 Optional I/O extension modules Frequency output connection example DO1 SRC DO1 OUT DO1 SGND CMOD-01 An externally supplied frequency indicator which provides, for example: • a 40 mA / 12 V DC power supply for the sensor circuit (CMOD frequency output) •...
Page 261: Diagnostics
Optional I/O extension modules 261 Examples are given below. Parameter setting example for relay output This example shows how make relay output RO4 of the extension module indicate the reverse direction of rotation of the motor with a one-second delay. Parameter Setting 15.07 RO4 source...
Page 262: Technical Data
262 Optional I/O extension modules  Technical data Dimension drawing: The dimensions are in millimeters and [inches]. Installation: Into an option slot on the drive control board Degree of protection: IP20 Ambient conditions: See the drive technical data. Package: Cardboard...
Page 263 Optional I/O extension modules 263 Isolation areas: CMOD-01 Plugged to 24 V drive SLOT2 Symbol Description Reinforced insulation (IEC 61800-5-1:2007) Functional insulation (IEC 61800-5-1:2007) Relay outputs (50…52, 53…55): • Wire size max. 1.5 mm • Minimum contact rating: 12 V / 10 mA •...
Page 264: Cmod-02 Multifunction Extension Module
264 Optional I/O extension modules CMOD-02 multifunction extension module (external 24 V AC/DC and isolated PTC interface)  Safety instructions WARNING! Obey the safety instructions for the drive. If you ignore the safety instructions, injury or death can occur.  Hardware description Product overview The CMOD-02 multifunction extension module (external 24 V AC/DC and isolated...
Page 265: Mechanical Installation
Optional I/O extension modules 265 Layout Item Description Additional information Grounding screw Page Hole for mounting screw Page 2-pin terminal block for motor thermistor connection Page 2-pin terminal block for relay output Page 2-pin terminal block for external power supply Page Diagnostic LED Page...
Page 266: Electrical Installation
266 Optional I/O extension modules Unpacking and checking the delivery 1. Open the option package. 2. Make sure that the package contains: • CMOD-02 multifunction extension module • mounting screw 3. Make sure that there are no signs of damage. Installing the module See chapter Installing option modules...
Page 267 Optional I/O extension modules 267 External power supply The external power supply is needed only if you want to connect an external back-up power supply for the drive control board. Note: Frames R1…R5 need CMOD-01 for connecting external power supply, frames R6…R9 have corresponding terminals 40 and 41 on the control board.
Page 268: Start-Up
268 Optional I/O extension modules Relay output connection example CMOD-02 RO PTC C PTC B OUT1 OUT2 SGND Power supply connection example 24V AC/DC + in 24V AC/DC - in CMOD-02 External power supply, 24 V AC/DC WARNING! Do not connect the +24 V AC cable to the control board ground when the control board is powered using an external 24 V AC supply.
Page 269: Diagnostics
Optional I/O extension modules 269 You can now see the parameters of the extension module in parameter group 15 I/O extension module.  Diagnostics Faults and warning messages Warning A7AB Extension I/O configuration failure. LEDs The extension module has one diagnostic LED. Color Description Green...
Page 270: Technical Data
270 Optional I/O extension modules  Technical data Dimension drawing: The dimensions are in millimeters and [inches]. Installation: Into an option slot on the drive control board Degree of protection: IP20 Ambient conditions: See the drive technical data. Package: Cardboard...
Page 271 Optional I/O extension modules 271 Isolation areas: CMOD-02 Plugged to 24 V RO PTC drive SLOT2 Symbol Description Reinforced insulation (IEC 61800-5-1:2007) Functional insulation (IEC 61800-5-1:2007) Motor thermistor connection (60…61): • Wire size max. 1.5 mm • Supported standards: DIN 44081 and DIN 44082 •...
Page 272 272 Optional I/O extension modules...
Page 273: Common Mode And Du/Dt Filters
Checking the compatibility of the motor and drive, page 60. Common mode filter kits are available from ABB, see the table on page 274. A kit includes three wound cores. For installation instructions of the cores, see the instruction included in the core package.
Page 274: Common Mode Filter Types
274 Common mode and du/dt filters  Common mode filter types For du/dt filters for smaller types, contact your local representative. Type Common mode filters ACS580 -01- ABB drives 3-phase U = 400 V (380…415 V) 145A-4 3AXD50000017269 169A-4 3AXD50000017270 206A-4...
Page 275: Description, Installation And Technical Data Of The Foch Filters
Common mode and du/dt filters 275  Description, installation and technical data of the FOCH filters See FOCH du/dt filters hardware manual (3AFE68577519 [English]).  Description, installation and technical data of the NOCH filters See AOCH and NOCH du/dt filters hardware manual (3AFE58933368 [English]).
Page 276 276 Common mode and du/dt filters...
Page 278 3AXD50000044794 Rev A (EN) 2017-05-31...

ABB ACS580-01 Hardware Manual

1 Safety Instructions

2 Introduction to the Manual

3 Operation Principle and Hardware Description

4 Mechanical Installation

5 Planning the Electrical Installation

6 Electrical Installation

7 Installation Checklist

8 Maintenance and Hardware Diagnostics

9 Technical Data

10 Dimension Drawings

11 Resistor Braking

12 Safe Torque off Function

13 Optional I/O Extension Modules

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Summary of Contents for ABB ACS580-01