Page 1 — ABB DRIVES FOR HVAC ACH580-31 drives Hardware manual...
Page 2 —...
Page 3 ACH580-31 drives Hardware manual Table of contents 1. Safety instructions 4. Mechanical installation 6. Electrical installation – 7. Electrical installation – North America  2019 ABB Oy. All Rights Reserved. 3AXD50000037066 Rev E EFFECTIVE: 2019-08-28...
Page 5: Table Of Contents
Table of contents 1 Table of contents 1. Safety instructions Contents of this chapter ............11 Use of warnings and notes in this manual .
Page 6 Additional requirements for the regenerative and low harmonic drives ... 55 Additional requirements for ABB high-output and IP23 motors ....55 Additional requirements for non-ABB high-output and IP23 motors .
Page 7 Table of contents 3 Protecting the motor against thermal overload ....... . . 71 Implementing a ground fault detection function .
Page 8 4 Table of contents AI1 and AI2 as Pt100, Pt1000, Ni1000, KTY83 and KTY84 sensor inputs (X1) . . . 105 Safe torque off (X4) ..........105 Control cable connection procedure .
Page 9 Table of contents 5 Maintenance intervals ............141 Description of symbols .
Page 10 6 Table of contents US ..............176 Electrical power network specification .
Page 11 Table of contents 7 Competence ............212 Fault tracing .
Page 12 8 Table of contents Installing the module ..........227 Electrical installation .
Page 13 Table of contents 9 Faults and warning messages ......... 246 LEDs .
Page 14 10 Table of contents...
Page 15: Safety Instructions
Safety instructions 11 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 16: General Safety In Installation, Start-Up And Maintenance
12 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 17 Safety instructions 13 functions reset the drive automatically and continue operation after a fault or supply break. If these functions are activated, the installation must be clearly marked as defined in IEC/EN 61800-5-1, subclause 6.5.3, for example, "THIS MACHINE STARTS AUTOMATICALLY". •...
Page 18: Electrical Safety In Installation, Start-Up And Maintenance
14 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 19: Additional Instructions And Notes
Safety instructions 15  Additional instructions and notes WARNING! Obey these instructions. If you ignore them, injury or death, or damage to the equipment can occur. • A drive with the EMC filter connected can be installed to a symmetrically grounded TN-S system.
Page 20: Grounding
16 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 21 Safety instructions 17 • use a device which automatically disconnects the supply if the protective earth conductor breaks. If the protective earth conductor is separate (ie, it does not form part of the input power cable or the input power cable enclosure), the cross section must be at least: •...
Page 22: Additional Instructions For Permanent Magnet Motor Drives
18 Safety instructions 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 23: Introduction To The Manual
Introduction to the manual 19 Introduction to the manual Contents of this chapter The chapter describes applicability, target audience and purpose of this manual. It describes the contents of this manual and refers to a list of related manuals for more information.
Page 24: Quick Installation And Commissioning Flowchart
20 Introduction to the manual Quick installation and commissioning flowchart Task Identify the frame of your drive: R3, R6 or R8. See the type designation label of the drive. Plan the installation: select the cables, etc. Guidelines for planning the electrical installation on page Check the ambient conditions, ratings and...
Page 25 Introduction to the manual 21 Term/abbreviation Explanation ACX-AP-x Assistant control panel, advanced operator keypad for communication with the drive. The ACH580 offers limited support of ACS-AP-I and ACS-AP-W. The Start, Stop, Loc/Rem buttons on these panels act as Hand, Auto and Off buttons, respectively, when used with the ACH580.
Page 26 22 Introduction to the manual Term/abbreviation Explanation DPMP-EXT Door mounting kit for the panel. For one drive; contains both DPMP-02 and CDPI-01, which connects the DPMP-02 to the drive. Drive Frequency converter for controlling AC motors Electromagnetic compatibility Embedded fieldbus FBIP-21 Optional BACnet/IP adapter module FCAN-01...
Page 27: Related Documents
Introduction to the manual 23 Term/abbreviation Explanation Positive temperature coefficient (PTC) refers to materials that experience an increase in electrical resistance when their temperature is raised. R3, R6, R8 Frame (size) Rectifier Converts alternating current and voltage to direct current and voltage. Safe torque off.
Page 28 Internet on the inside of the back cover. For manuals not available in the Document library, contact your local ABB representative. The codes below open an online listing of the manuals applicable to the product. ACH580-31 manuals...
Page 29: Operation Principle And Hardware Description
Operation principle and hardware description 25 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 30: Operation Principle
26 Operation principle and hardware description Operation principle The ACH580-31 is a ultra-low harmonic drive for controlling asynchronous AC induction motors, permanent magnet motors in open loop control and synchronous reluctance motors. The drive includes a line-side converter and a motor-side converter. The parameters and signals for both converters are combined into one primary user program.
Page 31: Layout
Operation principle and hardware description 27 Layout The layout of the drive is shown below. IP55 (UL Type 12) option +B056, R6 IP21 (UL Type 1) R6 UL Type 12 R6 IP20 (UL Open Type) option +P940, R3 Lifting eyes (2 pcs in frame R3, 6 pcs in Front cover frames R6 and R8) Control panel...
Page 32 28 Operation principle and hardware description Auxiliary cooling fan. For frame R3 in 14 Clamps for securing the control cables IP55 (UL Type 12 drives) only. mechanically Clamps for securing the FSO wiring 15 Input power cable entry behind the 360- degree grounding clamps mechanically 10 Power cable connection terminals...
Page 33 Operation principle and hardware description 29 The main cooling fan is at the top of the drive in frame R3 and at the bottom in frames R6 and R8. The figure below shows the layout of the external control connection terminals of the drive.
Page 34: Overview Of Power And Control Connections
30 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 du/dt, common mode or sine filter (optional), see page 221.
Page 35: Control Panel
Operation principle and hardware description 31 Control panel To remove the control panel, press the retaining clip at the top (1a) and pull the panel 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 36: Control Panel Mounting Platform Cover (Option +J424)
32 Operation principle and hardware description  Control panel mounting platform cover (option +J424) CDOM-01 control panel mounting platform cover can be used to cover the control panel mounting platform when no control panel is on it. Power and fault indication LEDs are visible on the cover.
Page 37: Type Designation Label
Operation principle and hardware description 33 Type designation label The type designation label includes IEC and UL (NEC) ratings, appropriate markings and the type designation and serial number, which allow identification of each drive. The type designation label is located on the left side of the drive. An example label is shown below.
Page 38: Type Designation Key
34 Operation principle and hardware description Type designation key The type designation contains information on the specifications and configuration of the drive. 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, ACH580-31-040A-5.
Page 39 Operation principle and hardware description 35 CODE DESCRIPTION J429 ACH-AP-W Assistant control panel with a bluetooth interface I/O (one slot available for I/O options) L501 CMOD-01 External 24 V AC/DC and digital I/O extension (2×RO and 1×DO) L512 CHDI-01 115/230 V Digital input extension (6×DI and 2×RO) L523 CMOD-02 External 24 V AC/DC and isolated PTC interface L537...
Page 40 36 Operation principle and hardware description CODE DESCRIPTION P931 Extended warranty 36 months P932 Extended warranty 60 months 3AXD10000464250...
Page 41: Mechanical Installation
Mechanical installation 37 Mechanical installation Contents of this chapter The chapter tells how to check the installation site, unpack, check the delivery and install the drive mechanically. Cabinet installation (option +P940) See also ACS580, ACH580 and ACQ580…+P940 and +P944 supplement (3AXD50000210305 [English].
Page 42: Safety
38 Mechanical installation Safety WARNING! Frames R6 and R8: Lift the drive with a lifting device. Use the lifting eyes of the drive. Do not tilt the drive. The drive is heavy and its center of gravity is high. An overturning drive can cause physical injury.
Page 43: Examining The Installation Site
Mechanical installation 39 Examining 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 • vertically side by side • horizontally alone, IP21 (UL Type 1) only. Note 1: The vibration specification in section Ambient conditions on page...
Page 44 40 Mechanical installation 200 mm (7.87 in.) 120 mm (4.72 in.) 250 mm (9.84 in.) 120 mm (4.72 in.) 300 mm (11.81 in.)
Page 45: Required Tools
Mechanical installation 41 Make sure that • installation site is sufficiently ventilated or cooled to remove heat from the drive. See section Losses, cooling data and noise on page 171. • operation conditions of the drive meet the specifications given in section Ambient conditions on page 187.
Page 46: Unpacking And Examining Delivery
42 Mechanical installation Unpacking and examining delivery 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 33.
Page 47 Mechanical installation 43 R6 IP21 (UL Type 1) 3AXD50000038252 Printed quick guides and manuals, Drive with factory installed options multilingual residual voltage warning sticker, Manuals CD Accessories Outer box Mounting template Pallet Package straps VCI bag Plastic bag To unpack: •...
Page 48 44 Mechanical installation R6 IP55 (UL Type 12) 3AXD50000038252 Printed quick guides and manuals, Drive with factory installed options multilingual residual voltage warning sticker, Manuals CD Accessories Outer box Bubble wrap Cardboard insert Mounting template Pallet Package straps VCI bag Plastic bag UL Type 12 hood To unpack:...
Page 49 Mechanical installation 45 R8 IP21 (UL Type 1) 3AXD50000106974 Printed quick guides and manuals, Cardboard sleeve multilingual residual voltage warning sticker, Manuals CD VCI bag Plywood support Mounting template Pallet Package straps 11, 12 Screw Plastic bag Drive with factory installed options Packing bracket Common mode filter (+E208) Tray...
Page 50 46 Mechanical installation R8 IP55 (UL Type 12) 3AXD50000106974 Printed quick guides and manuals, Cardboard sleeve multilingual residual voltage warning sticker, Manuals CD VCI bag Not included Bubble wrap Plywood support Mounting template Pallet Package straps UL Type 12 hood Plastic bag Drive with factory installed options.
Page 51: Installing The Drive Vertically
Mechanical installation 47 Installing the drive vertically 1. Mark the hole locations using the mounting template included in the package. See the next page. 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 195.
Page 52 48 Mechanical installation 18.7 29.6 37.2 10.3 IP21, UL Type 1 21.3 46.97 61.0 134.51 246.96 IP55, UL Type 12 23.3 51.38 138.92 260.19 R3: M5 (#10) R6: M8 (5/16″) R8: M8 (5/16″)
Page 53: Installing The Drive Vertically Side By Side
Mechanical installation 49 Installing the drive vertically side by side Drives can be installed side by side. Follow the steps in section Installing the drive vertically on page 47. Installing the drive horizontally The drive can be installed either the left or right side up. Follow the step in section Installing the drive vertically on page 47.
Page 54 50 Mechanical installation...
Page 55: Guidelines For Planning The Electrical Installation
Guidelines for planning the electrical installation 51 Guidelines for 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.
Page 56: Other Regions
52 Guidelines for planning the electrical installation  Other regions The disconnecting device must conform to the applicable local safety regulations. Examining the compatibility of the motor and drive Use an asynchronous AC induction motor, permanent magnet synchronous motor, or synchronous reluctance motor (SynRM) with the drive.
Page 57: Requirements Table
 Requirements table The following table shows how to select the motor insulation system and when ABB requires optional drive du/dt and common mode filters and insulated N-end (non-drive end) motor bearings. Ignoring the requirements or incorrect installation can shorten motor life or damage the motor bearings, and voids the warranty.
Page 58 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 (internal as standard in all frames, delivered with the drive to be installed by the customer for R8) N-end bearing: insulated motor non-drive end bearing n.a.
Page 59: Additional Requirements For Abb Motors Of Types Other Than M2_, M3_, M4_, Hx_ And
Additional requirements for ABB high-output and IP23 motors The rated output power of high output motors is higher than what is stated for the particular frame size in EN 50347 (2001). This table shows the requirements for ABB random-wound motor series (for example, M3AA, M3AP and M3BP).
Page 60: Additional Requirements For Non-Abb High-Output And Ip23 Motors
56 Guidelines for planning the electrical installation Additional requirements for non-ABB high-output and IP23 motors The rated output power of high output motors is higher than what is stated for the particular frame size in EN 50347 (2001). The table below shows the requirements for random-wound and form-wound non-ABB motors.
Page 61 Guidelines for planning the electrical installation 57 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 62: Additional Note For Sine Filters
58 Guidelines for planning the electrical installation Additional note for sine filters Sine filters protect the motor insulation system. Therefore, du/dt filter can be replaced with a sine filter. The peak phase-to-phase voltage with the sine filter is approximately 1.5 · U Selecting the power cables ...
Page 63: Additional Guidelines, Iec And North America
Guidelines for planning the electrical installation 59 the protective earthing conductor shall 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 Minimum cross-sectional area of the conductors corresponding protective conductor S (mm...
Page 64: Power Cable Types For Limited Use
60 Guidelines for planning the electrical installation Cable type Use as input power Use as motor cabling cabling Symmetrical shielded (or armored) cable with three phase conductors and a shield (or armor), and separate PE conductor/cable A separate PE conductor is required if the conductivity of the shield (or armor) is not sufficient for the PE use.
Page 65: Not Allowed Power Cable Types
General guidelines, IEC and North America on page 58. ABB recommends the use of conduit for power wiring to the drive and between the drive and the motor(s). Due to the variety of application needs, metallic and non- metallic conduit can be used. ABB prefers the use of metallic conduit. Where permitted, non-metallic conduit may be used.
Page 66 62 Guidelines for planning the electrical installation Notes 1, 3 Conduit - Metallic Electrical metallic tubing: Type EMT • Symmetrical shielded VFD cable is preferred. • Use separate conduit run for each motor. Rigid metal conduit: Type RMC • Do not run power feed wiring and motor wiring in the Liquid-tight flexible metal electrical same conduit.
Page 67: Conductor Type, Iec And North America
Guidelines for planning the electrical installation 63  Conductor type, IEC and North America The following table includes various conductor types that can be connected to the drive. For optimal drive performance, VFD cable is preferred. When not available, see the following standards in the footnotes below.
Page 68: Typical Power Cable Sizes
64 Guidelines for planning the electrical installation  Typical power cable sizes The table below gives cable types with concentric shield for the drives with nominal current.
Page 69: Iec Ratings
Guidelines for planning the electrical installation 65 IEC ratings Drive type Frame UL/NEC ACH580-31 size Cu cable type AI cable type Cu cable type AI cable type AWG/kcmil AWG/kcmil IEC ratings U = 400 V 09A5-4 3×2.5+2.5 12A7-4 3×2.5+2.5 018A-4 3×2.5+2.5 026A-4 3×6+6...
Page 70: Ul (Nec) Ratings
66 Guidelines for planning the electrical installation UL (NEC) ratings Drive type Frame UL/NEC ACH580-31 size Cu cable type AI cable type Cu cable type AI cable type AWG/kcmil AWG/kcmil 3-phase U = 480 V 07A6-4 3×2,5+2,5 012A-4 3×2,5+2,5 014A-4 3×2,5+2,5 023A-4 3×6+6...
Page 71: Signals In Separate Cables
Guidelines for planning the electrical installation 67 A double-shielded cable is the best alternative for low-voltage digital signals but single-shielded (b) twisted pair cable is also acceptable.  Signals in separate cables Run analog and digital signals in separate, shielded cables. Do not mix 24 V AC/DC and 115/230 V AC signals in the same cable.
Page 72: General Guidelines, North America
68 Guidelines for planning the electrical installation motor cables with other cables in order to decrease electromagnetic interference caused by the rapid changes in the drive output voltage. Where control cables must cross power cables, make sure they are arranged at an angle as near to 90 degrees as possible.
Page 73 Guidelines for planning the electrical installation 69 Will have this redrawn in our style. Input power cable Motor cable Conduit...
Page 74: Separate Control Cable Ducts
70 Guidelines for planning the electrical installation  Separate control cable ducts Wire 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 75: Implementing Thermal Overload And Short-Circuit Protection
Guidelines for planning the electrical installation 71 Implementing thermal overload and short-circuit protection  Protecting the drive and input power cable in short-circuits Protect the drive and input cable with fuses as follows: Size the fuses at the distribution board according to instructions given in chapter Technical data The fuses will protect the input cable in short-circuit situations, restrict drive damage and prevent damage to adjoining equipment in case of a short-circuit...
Page 76: Implementing A Ground Fault Detection Function
72 Guidelines for planning the electrical installation temperature indication given by motor temperature sensors. The user can tune the thermal model further by feeding in additional motor and load data. The most common temperature sensors are: • motor sizes IEC180…225: thermal switch, eg, Klixon •...
Page 77: Using A Safety Switch Between The Drive And The Motor
See the firmware manual. 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. This is needed to isolate the motor from the drive during maintenance work on the drive.
Page 78: Limiting Relay Output Maximum Voltages At High Installation Altitudes
74 Guidelines for planning the electrical installation Install the protective component as close to the inductive load as possible. Do not install protective components at the relay outputs. 230 V AC 230 V AC + 24 V DC Relay outputs Varistor RC filter Diode...
Page 79: Implementing A Motor Temperature Sensor Connection
Guidelines for planning the electrical installation 75 Implementing a motor temperature sensor connection WARNING! IEC 60664 and IEC 61800-5-1 require 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.
Page 80: Connection Of Motor Temperature Sensor To The Drive Via An Option Module
76 Guidelines for planning the electrical installation  Connection of motor temperature sensor to the drive via an option module This table shows what temperature sensor types you can connect to the drive option modules as well as the insulation requirement for the sensor. Option module Temperature sensor Temperature...
Page 81: Connection Of Motor Temperature Sensor To The Drive Via A Relay
Guidelines for planning the electrical installation 77  Connection of motor temperature sensor to the drive via a relay PTC (IEC 60800-5-1) Class A. This table shows the insulation requirement for a customer’s external relay, and the insulation requirement for the sensor to fulfill decisive voltage class A (double insulation).
Page 82 78 Guidelines for planning the electrical installation...
Page 83: Electrical Installation - Iec
Electrical installation – IEC 79 Electrical installation – IEC Contents of this chapter The chapter describes how to check the insulation of the assembly and the compatibility with grounding systems. It then shows how to connect the power and control cables, install optional modules and connect a PC. Warnings WARNING! Obey the instructions in chapter Safety instructions...
Page 84: Grounding The Motor Cable Shield At The Motor End
80 Electrical installation – IEC Grounding the motor cable shield at the motor end 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 85: Brake Resistor Assembly
Electrical installation – IEC 81 Note: Moisture inside the motor casing will reduce the insulation resistance. If moisture is suspected, dry the motor and repeat the measurement. U1-V1, U1-W1, V1-W1 1000 V DC, U1-PE, V1-PE, W1-PE > 100 Mohm  Brake resistor assembly Measure the insulation of the brake resistor assembly (if present) as follows: 1.
Page 86: Tems
82 Electrical installation – IEC Compatibility with IT (ungrounded), corner-grounded delta, midpoint-grounded delta and TT systems The standard drive can be an be installed to a symmetrically grounded TN-S system. For other systems, see sections EMC filter Ground-to-phase varistor below. ...
Page 87: When To Disconnect Emc Filter Or Ground-To-Phase Varistor: Tn-S, It, Corner-Grounded Delta And Midpoint-Grounded Delta Systems And Tt Systems
Electrical installation – IEC 83  When to disconnect EMC filter or ground-to-phase varistor: TN-S, IT, corner-grounded delta and midpoint-grounded delta systems and TT systems Requirements for disconnecting EMC filter and varistor and additional requirements for different electrical power systems are given below. Symmetrically grounded TN systems (TN-S systems (ie.
Page 88 • Because the EMC filter screws have been disconnected, ABB does not guarantee the EMC category. • 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.
Page 89: Identifying Different Types Of Electrical Power Systems
Electrical installation – IEC 85  Identifying different types of electrical power systems To identify the electrical power system type, find out the supply transformer connection. If that is not possible, measure these voltages at the distribution board . WARNING! Only a qualified electrical professional may do the work instructed in this section.
Page 90: Disconnecting Internal Emc Filter And Ground-To-Phase Varistor - Frame R3
86 Electrical installation – IEC  Disconnecting internal EMC filter and ground-to-phase varistor – frame R3 1. Stop the drive and do the steps in section Precautions before electrical work page before you start the work. 2. Remove the front cover. See page 90. 3.
Page 91: Disconnecting Internal Emc Filter And Ground-To-Phase Varistor - Frame R6
Electrical installation – IEC 87  Disconnecting internal EMC filter and ground-to-phase varistor – frame R6 1. Stop the drive and do the steps in section Precautions before electrical work page before you start the work. 2. Remove the front cover. See page 90. 3.
Page 92: Disconnecting Internal Emc Filter And Ground-To-Phase Varistor -Frame R8
88 Electrical installation – IEC  Disconnecting internal EMC filter and ground-to-phase varistor – frame R8 1. Stop the drive and do the steps in section Precautions before electrical work page before you start the work. 2. Remove the front cover if it is not already removed. See page 90. 3.
Page 93: Connecting The Power Cables
(see page 58). If the protective PE conductor is smaller than 10 mm , you must use a second earthing conductor, see page ABB recommends 360-degree grounding if shielded cable is used. Ground the other end of the input cable shield or PE conductor at the distribution board. ABB requires 360-degree grounding.
Page 94: Connection Procedure
90 Electrical installation – IEC  Connection procedure The procedure of connecting the power cables to the standard drive is described below. For the procedure with UK gland plate (option +H358), see also UK gland plate installation guide (3AXD50000110711 [English]). 1.
Page 95 Electrical installation – IEC 91 2. Attach the residual voltage warning sticker in the local language. 3. For frames R6 and R8: Remove the shroud on the power cable terminals, 4. For frame R8: For easier installation, you can remove the side plates.
Page 96 92 Electrical installation – IEC 5. Remove the rubber grommets of the cables to be installed from the cable entry plate. Install the grommets downwards also in unused holes. 6. Cut an adequate hole into the rubber grommet. Slide the grommet onto the cable.
Page 97 Electrical installation – IEC 93 7. Prepare the ends of the cables as shown in the figure. Two different motor cable types are shown. If you use aluminum cables, put grease to the peeled aluminum cable before you connect it to the drive. Note: The bare shield will be grounded 360 degrees.
Page 98 94 Electrical installation – IEC 8. Put the cable through the hole of the cable entry plate and attach the grommet to the hole. 9. Connect the cables: • Ground the shield 360 degrees by tightening the clamp of the power cable grounding shelf onto the stripped part of the cable.
Page 99 Electrical installation – IEC 95 1.7 N·m 1.7 N·m 1.7 N·m L1, L2, L3, T1/U, T2/V, T3/W, UDC+, UDC-: 1.7 N·m 2.9 N·m 2 N·m L1, L2, L3, T1/U, T2/V, T3/W, UDC+, UDC-: 2.9 N·m 5.6 N·m...
Page 100 96 Electrical installation – IEC 9.8 N·m L1, L2, L3, T1/U, T2/V, T3/W, UDC+, UDC-: 30 N·m 2 N·m Note 1 for frame R8: Install the side plates if removed. Note 2 for frame R8: The power cable connectors can be detached. For the instructions, see section R8 power cable connection if you detach the cable connectors...
Page 101: R8 Power Cable Connection If You Detach The Cable Connectors
Electrical installation – IEC 97 11. Install the shroud onto the power cable connection terminals. R8 power cable connection if you detach the cable connectors The power cable connectors of frame R8 are detachable. If you detach them, you can connect the cables with cable lugs as follows: •...
Page 102 98 Electrical installation – IEC Alternative 2: Attach a cable lug to the conductor. Put the cable lug onto the post. Tighten the nut to a torque of 30 N·m.
Page 103: Connecting The Control Cables
Electrical installation – IEC 99 Connecting the control cables See section Default I/O connection diagram (HVAC default configuration) on page for the default I/O connections of the drive. Connect the cables as described in section Control cable connection procedure page 106.
Page 104: Default I/O Connection Diagram (Hvac Default Configuration)
100 Electrical installation – IEC  Default I/O connection diagram (HVAC default configuration) Reference voltage and analog inputs and outputs Signal cable shield (screen) Output frequency/speed reference: 0…10 V 1…10 kohm AGND Analog input circuit common +10V Reference voltage 10 V DC Actual feedback: 0…20 mA AGND Analog input circuit common...
Page 105: Switches
Electrical installation – IEC 101 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 106: Pnp Configuration For Digital Inputs
102 Electrical installation – IEC 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 107: Connection For Obtaining 0
Electrical installation – IEC 103 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 108: Connection Examples Of Two-Wire And Three-Wire Sensors
104 Electrical installation – IEC Connection examples of two-wire and three-wire sensors Note: Maximum capability of the auxiliary 24 V DC (250 mA) output must not be exceeded. Two-wire sensor/transmitter 4…20 mA Process actual value measurement or reference, 0(4)…20 mA, R = 100 ohm AGND …...
Page 109: Ai1 And Ai2 As Pt100, Pt1000, Ni1000, Kty83 And Kty84 Sensor Inputs (X1)
Electrical installation – IEC 105 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 110: Control Cable Connection Procedure
106 Electrical installation – IEC  Control cable connection procedure WARNING! Obey the instructions in chapter Safety instructions on page 11. 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 111 Electrical installation – IEC 107 1.7 N·m...
Page 112 108 Electrical installation – IEC 1.7 N·m...
Page 113 Electrical installation – IEC 109 1.7 N·m...
Page 114: Installing Optional Modules
110 Electrical installation – IEC Installing optional modules  Mechanical installation of option modules See section Overview of power and control connections page for the available slots for each module. Install the option modules as follows: WARNING! Obey the instructions in chapter Safety instructions on page 11.
Page 115: Option Slot 1 (Fieldbus Adapter Modules)
Electrical installation – IEC 111 Option slot 1 (fieldbus adapter modules) 1. Put the module carefully into its position on the control unit. 2. Tighten the mounting screw (CHASSIS) to 0.8 N·m. Note: The screw tightens the connections and grounds the module. It is necessary for fulfilling the EMC requirements and for correct operation of the module.
Page 116: Reinstalling Cover(S)
112 Electrical installation – IEC Reinstalling cover(s) After installation, reinstall the covers. For UL Type 12 frame R8, connect the auxiliary cooling fan power supply wire. IP21 IP55 2 N·m 2 N·m R6, R8 IP21 IP55 2 N·m 2 N·m...
Page 117: Connecting A Pc
Electrical installation – IEC 113 Connecting a PC To be able to connect a PC to the drive, you need an assistant control panel (ACH- AP-H or ACH-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 118 114 Electrical installation – IEC...
Page 119: Electrical Installation - North America
Electrical installation – North America 115 Electrical installation – North America Contents of this chapter The chapter describes how to check the insulation of the assembly and the compatibility with other than symmetrically grounding TN-S 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 120: Drive
116 Electrical installation – North America  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. Also, there are voltage- limiting circuits inside the drive which cut down the testing voltage automatically.
Page 121: Tems
Electrical installation – North America 117 and the PE conductor by using a measuring voltage of 1000 V DC. The insulation resistance must be greater than 1 Mohm. 1000 V DC, > 1 Mohm Compatibility with IT (ungrounded), corner-grounded delta, midpoint-grounded delta and TT systems See section Compatibility with IT (ungrounded), corner-grounded delta, midpoint-...
Page 122: Connecting The Power Cables
118 Electrical installation – North America Connecting the power cables  Connection diagram Drive UDC+ UDC- T1/U T2/V T3/W 3 ~ M For alternatives, see section Selecting the supply disconnecting device on page If the protective PE conductor is smaller than 10 mm , you must use a second earthing conductor (2), see page 16.
Page 123: Connection Procedure
Electrical installation – North America 119  Connection procedure The procedure of connecting the power cables to the standard drive is described below. 1. To remove the R3 front cover (R6 and R8 upper front cover), lift the cover from the bottom outwards (1a) and then up (1b).
Page 124 120 Electrical installation – North America 2. Attach the residual voltage warning sticker in the local language. 3. For frames R6 and R8: Remove the shroud on the power cable terminals, 4. For frame R8: For easier installation, you can remove the side plates.
Page 125 Electrical installation – North America 121 5. Remove the rubber grommets of the cables to be installed from the cable entry plate. Install the grommets downwards also in unused holes. 6. Attach the cable conduits to the bottom plate holes. 7.
Page 126 122 Electrical installation – North America 10. Connect the cables: • Connect the grounding conductors to the ground terminals. • Connect the phase conductors of the motor cable to the T1/U, T2/V and T3/W terminals and the phase conductors of the input cable to the L1, L2 and L3 terminals.
Page 127 Electrical installation – North America 123 Frame L1, L2, L3, T1/U, T2/V, T3/W, UDC+, UDC- size N·m lbf·ft N·m lbf·ft...
Page 128 124 Electrical installation – North America Frame L1, L2, L3, T1/U, T2/V, T3/W, UDC+, UDC- size N·m lbf·ft) N·m lbf·ft)
Page 129 Electrical installation – North America 125 Frame L1, L2, L3, T1/U, T2/V, T3/W, UDC+, UDC-: size N·m lbf·ft) N·m lbf·ft) 22 5 Note 1 for frame R8: Install the side plates if removed. Note 2 for frame R8: The power cable connectors can be detached. For the instructions, see section R8 power cable connection if you detach the connectors on page 126.
Page 130: R8 Power Cable Connection If You Detach The Connectors
126 Electrical installation – North America 12. Install the shroud onto the power cable connection terminals. R8 power cable connection if you detach the connectors The power cable connection connectors of frame R8 are detachable. If you detach them, you can connect the cables with cable lugs as follows. For UL installations, see also section UL listed cable lugs and tools on page 175.
Page 131 Electrical installation – North America 127 Alternative 2: Attach a cable lug to the conductor. Put the cable lug onto the post. Tighten the nut to a torque of 30 N·m (22 lbf·ft). .
Page 132: Connecting The Control Cables
128 Electrical installation – North America Connecting the control cables See section Default I/O connection diagram (HVAC default configuration) on page for the default I/O connections of the drive. Connect the cables as described under Control cable connection procedure on page 131.
Page 133: Default I/O Connection Diagram (Hvac Default Configuration)
Electrical installation – North America 129  Default I/O connection diagram (HVAC default configuration) Reference voltage and analog inputs and outputs Signal cable shield (screen) Output frequency/speed reference: 0…10 V 1…10 kohm AGND Analog input circuit common +10V Reference voltage 10 V DC Actual feedback: 0…20 mA AGND Analog input circuit common...
Page 134: Switches
130 Electrical installation – North America 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 135: Control Cable Connection Procedure
Electrical installation – North America 131  Control cable connection procedure WARNING! Obey the instructions in chapter Safety instructions on page 11. 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 136 132 Electrical installation – North America...
Page 137 Electrical installation – North America 133...
Page 138 134 Electrical installation – North America...
Page 139: Installing Optional Modules
Electrical installation – North America 135 Installing optional modules See section Installing optional modules on page 110. Reinstalling cover(s) After installation, reinstall the covers. For UL Type 12 frame R8, connect the auxiliary cooling fan power supply wire. UL Type 1 UL Type 12 2 N·m (1.5 lbf·ft) 2 N·m (1.5 lbf·ft)
Page 140: Connecting A Remote Panel, Or Chaining One Panel To Several Drives
136 Electrical installation – North America Connecting a remote panel, or chaining one panel to several drives See section Connecting a remote panel, or chaining one panel to several drives page 113.
Page 141: Installation Checklist
Installation checklist 137 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 11. 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 142 138 Installation checklist Make sure that … If the drive has not been powered (either in storage or unused) over tree years: The electrolytic DC capacitors in the DC link of the drive have been reformed. See section Reforming the capacitors on page 152.
Page 143: Start-Up
Start-up 139 Start-up Contents of this chapter This chapter describes the start-up procedure of the drive. Start-up procedure 1. Run setup of the drive control program according to the start-up instructions given in Quick start-up guide for ACH580 HVAC control program (3AXD50000047658 [English]) or in the firmware manual.
Page 144 140 Start-up...
Page 145: 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 146: Description Of Symbols
142 Maintenance and hardware diagnostics  Description of symbols Action Description Visual Inspection and maintenance action if needed Performance of on/off-site work (commissioning, tests, measurements or other work) Replacement of component  Recommended annual maintenance actions by the user Action Description Quality of supply voltage Spare parts...
Page 147: 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 11.
Page 148: Replacing The Main Cooling Fan, Frame R3
144 Maintenance and hardware diagnostics  Replacing the main cooling fan, frame R3 WARNING! Obey the instructions in chapter Safety instructions on page 11. If you ignore them, physical injury or death, or damage to the equipment can occur. 1. Stop the drive and disconnect it from the power line. Wait for 5 minutes and then make sure by measuring that there is no voltage.
Page 149: Replacing The Main Cooling Fan, Frame R6
Maintenance and hardware diagnostics 145  Replacing the main cooling fan, frame R6 WARNING! Obey the instructions in chapter Safety instructions on page 11. If you ignore them, physical injury or death, or damage to the equipment can occur. 1. Stop the drive and disconnect it from the power line. Wait for 5 minutes and then make sure by measuring that there is no voltage.
Page 150: Replacing The Main Cooling Fan, Frame R8
146 Maintenance and hardware diagnostics  Replacing the main cooling fan, frame R8 WARNING! Obey the instructions in chapter Safety instructions on page 11. Ignoring the instructions can cause physical injury or death, or damage to the equipment. 1. Stop the drive and disconnect it from the power line. Wait for 5 minutes and then make sure by measuring that there is no voltage.
Page 151: Replacing The Auxiliary Cooling Fan, Ip55 (Ul Type 12) Frame R3
Maintenance and hardware diagnostics 147  Replacing the auxiliary cooling fan, IP55 (UL Type 12) frame R3 WARNING! Obey the instructions in chapter Safety instructions on page 11. If you ignore them, physical injury or death, or damage to the equipment can occur.
Page 152: Replacing The Auxiliary Cooling Fan, Frame R6
148 Maintenance and hardware diagnostics  Replacing the auxiliary cooling fan, frame R6 WARNING! Obey the instructions in chapter Safety instructions on page 11. If you ignore them, physical injury or death, or damage to the equipment can occur. 1. Stop the drive and disconnect it from the power line. Wait for 5 minutes and then make sure by measuring that there is no voltage.
Page 153: Replacing The Auxiliary Cooling Fan, Frame R8
Maintenance and hardware diagnostics 149  Replacing the auxiliary cooling fan, frame R8 WARNING! Obey the instructions in chapter Safety instructions on page 11. If you ignore them, physical injury or death, or damage to the equipment can occur. 1. Stop the drive and disconnect it from the power line. Wait for 5 minutes and then make sure by measuring that there is no voltage.
Page 154: Replacing The Second Auxiliary Cooling Fan Ip55 (Ul Type 12), Frame R8
150 Maintenance and hardware diagnostics  Replacing the second auxiliary cooling fan IP55 (UL Type 12), frame WARNING! Obey the instructions in chapter Safety instructions on page 11. If you ignore them, physical injury or death, or damage to the equipment can occur.
Page 155 Maintenance and hardware diagnostics 151 Fan arrow must point up...
Page 156: Capacitors
Capacitor failure is usually followed by damage to the drive and an input cable fuse failure, or a fault trip. Contact ABB if capacitor failure is suspected. Replacements are available from the manufacturer. Do not use other than specified spare parts.
Page 157: Drive Leds
Maintenance and hardware diagnostics 153 Drive LEDs There is a green POWER and a red FAULT LED visible when the control panel is removed. If a control panel is attached to the drive, switch to remote control otherwise a fault will be generated, and then remove the panel to be able to see the LEDs. See the firmware manual on how to switch to remote control.
Page 158 154 Maintenance and hardware diagnostics...
Page 159: Technical Data
Technical data 155 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. Ratings ...
Page 160: Ul (Nec) Ratings
156 Technical data Type Input rating Max. current App. power Output ratings Frame size ACH580 Light-duty use -31- 3-phase U = 480 V 09A5-4 12.2 12A7-4 16.0 10.0 12.0 018A-4 12.0 21.4 11.6 14.0 10.0 026A-4 17.0 28.9 19.1 23.0 15.0 033A-4* 42.5...
Page 161: Definitions
The power ratings are the same regardless of the supply voltage within one voltage range. Note: ABB recommends the DriveSize dimensioning tool (available from (ttp://new.abb.com/drives/software-tools/drivesize) for selecting the drive, motor and gear combination.
Page 162: Ambient Temperature Derating, Ip21 (Ul Type 1)
158 Technical data Altitude derating (see page 161): The derating factor for 1500 m is 1 - 1/10 000 m · (1500 - 1000) m = 0.95. The minimum current becomes then 17.2 A / 0.95 = 18.1 A. Nominal current of drive type -025A-4 exceeds the current requirement of 18.1 A. ...
Page 163: Ambient Temperature Derating, Ip55 (Ul Type 12)
Technical data 159  Ambient temperature derating, IP55 (UL Type 12) The derating is the same as for degree of protection of IP21 (UL Type 1) except for drive types shown below. Temperature Derating range up to +40 °C No derating up to +104 °F +40…+50 °C Derate 1% for every 1 °C (1.8 °F) up to 45 °C (113 °F): Derate 2% for every...
Page 164: Ambient Temperature Derating In Table Format
160 Technical data  Ambient temperature derating in table format Type < 40 °C 45 °C 50 °C ACH580 IP21, IP55 IP21, IP55 IP21, IP55 -31- IEC ratings: 3-phase U = 400 V 09A5-4 12A7-4 12.6 12.0 11.3 018A-4 17.0 16.1 15.3 026A-4...
Page 165: Altitude Derating
Technical data 161 Type < 40 °C 45 °C 50 °C ACH580 UL Type 1, UL Type 12 UL Type 1, UL Type 12 UL Type 1, UL Type 12 -31- UL (NEC) ratings: 3-phase U = 480 V 07A6-4 7.22 6.84 012A-4...
Page 166 162 Technical data Installation site altitude 4000 m 13123 ft 0.80 3500 m 11429 ft 0.85 3000 m 0.90 9842 ft 0.95 2500 m 8202 ft 1.00 2000 m 6562 ft 1500 m 4921 ft 1000 m 3300 ft +20 °C +25 °C +30 °C +35 °C...
Page 167: Switching Frequency Derating
Technical data 163  Switching frequency derating The output current is calculated by multiplying the current given in the rating table by the derating factor given in the table below. Note: If you change the minimum switching frequency with parameter 97.02 Minimum switching frequency, derate according to the table below.
Page 168 164 Technical data Frame Type Derating factor (k) for the minimum switching frequencies size ACH580 1 kHz 2 kHz 4kHz 8 kHz 12 kHz 065A-4 0.67 0.52 077A-4 0.67 0.52 096A-4 1.00 124A-4 0.84 156A-4 0.72 180A-4 0.63 3AXD00000586715...
Page 169: Fuses (Iec)
ABB recommends the high speed aR fuses specified below. The gG fuses can be used for frames R3 and R6 if they operate rapidly enough (max. 0.1 seconds).
Page 170: Gg Fuses Din 43620 Blade Style
 gG fuses DIN 43620 blade style gG fuses can be used for frames R3 and R6 if they operate rapidly enough (max. 0.1 seconds ABB recommends, however, aR fuses. gG fuses are not allowed for frame R8. Type Min. short-...
Page 171: Calculating The Short-Circuit Current Of The Installation
Technical data 167  Calculating the short-circuit current of the installation Check that the short-circuit current of the installation is at least the value given in the fuse table. The short-circuit current of the installation can be calculated as follows: k2-ph + (Z 2 ·...
Page 172 + (22.19 mohm + 13.94 mohm) The calculated short-circuit current 2.7 kA is higher than the minimum short-circuit current of the drive gG fuse type OFAF000H100 (1000 A). -> The 500 V gG fuse (ABB Control OFAF000H100) can be used.
Page 173: Fuses (Ul)
• The specified fuses must be used in order to maintain drive UL listing. Additional protection can be used. When installing a drive always follow installation instructions and NEC requirements. Refer to local codes and regulations. For alternate recommended fuses, contact ABB.
Page 174: Circuit Breakers
170 Technical data Circuit breakers Fuses must be used with circuit breakers. Dimensions, weights and free space requirements Frame Height Width Depth Weight Height Width Depth Weight size IP21 IP55 (option +B056) * 21.3 23.3 61.0 IP20 (option +P940) 18.3 Frame Height Width...
Page 175: Losses, Cooling Data And Noise
This table shows typical heat loss values, required air flow and noise at the nominal ratings of the drive. The heat loss values can vary depending on voltage, cable conditions, motor efficiency and power factor. To obtain more accurate values for given conditions, use ABB DriveSize tool (http://new.abb.com/drives/software- tools/drivesize)
Page 176: Cooling Air Flow And Heat Dissipation For Flange Mounting (Option +C135)
124A-4 2201 2237 156A-4 2760 2796 180A-4 3320 3356 3AXD00000586715  Cooling air flow and heat dissipation for flange mounting (option +C135) Contact ABB. Type Heat dissipation Air flow Frame (option +C135) (option +C135) ACSH580 size -01- Heatsink Front Heatsink...
Page 177: Terminal And Entry Data For The Power Cables
Technical data 173 Type Heat dissipation Air flow Frame (option +C135) (option +C135) ACSH580 size -01- Heatsink Front Heatsink Front /min /min IEC ratings U = 480 V 09A5-4 12A7-4 018A-4 026A-4 033A-4 039A-4 046A-4 062A-4 073A-4 088A-4 106A-4 145A-4 169A-4 206A-4 UL (NEC) ratings U...
Page 178 174 Technical data Frame Cable entries L1, L2, L3, T1/U, T2/V, T3/W, UD+, UDC- terminals size Ø Min wire size (solid/ Max wire size (solid/ Tightening torque stranded) stranded) N·m 3AXD00000586715 Maximum cable diameter accepted. For the bottom plate hole diameters, see chapter Dimension drawings on page 195.
Page 179: Ul Listed Cable Lugs And Tools
Technical data 175 UL listed cable lugs and tools Wire size Compression lug Crimping tool kcmil/AWG Manufacturer Type Manufacturer Type No. of crimps Thomas & E10731 Thomas & TBM4S Betts 54136 Betts TBM45S Burndy YAV6C-L2 Burndy MY29-3 Ilsco CCL-6-38 Ilsco ILC-10 Thomas &...
Page 180: Terminal And Entry Data For The Control Cables
176 Technical data Terminal and entry data for the control cables  Control cable entries, wire sizes and tightening torques (T) are given below. Frame Cable entries Control cable entries and terminal sizes size Holes +24V, DCOM, DGND, EXT. 24V DI, AI/O, AGND, RO, STO cable terminals...
Page 181 Technical data 177 Frequency (f 47 to 63 Hz. This is indicated in the type designation label as typical input frequency level f1 (50/60 Hz). Imbalance Max. ± 3% of nominal phase to phase input voltage Fundamental power factor 1 (at nominal load) (cos phi Harmonic distortion Harmonics are below the limits defined in IEEE 519-2014,...
Page 182: Motor Connection Data
The decrease depends on the motor cable length and characteristics. Contact ABB for more information. Note that a sine filter (optional) at the drive output also causes a voltage decrease.
Page 183 Technical data 179 Frame Maximum motor cable length, 4 kHz size EMC limits for Category C2 Standard drive with an internal EMC filter. See notes 2 and 4 EMC limits for Category C3 Standard drive with an internal EMC filter. See notes 3 and 4.
Page 184: Ccu-24 Control Unit Connection Data
180 Technical data CCU-24 control unit connection data External power supply Maximum power: 36 W, 1.50 A at 24 V AC/DC ±10% as standard Terminal size: 0.14…2.5 mm +24 V DC output Total load capacity of this outputs is 6.0 W (250 mA / 24 V) (Term.
Page 185 Technical data 181 Analog outputs AO1 and AO2 Current/voltage input mode for AO1 selected with a (Term. 7 and 8) parameter. Current output: 0…20 mA, R : < 500 ohm load Voltage output: 0…10 V, R : > 100 kohm (AO1 only) load Terminal size: 0.14…2.5 mm Inaccuracy: ±1% of full scale (in voltage and current...
Page 186 182 Technical data Isolation areas SLOT 1 Fieldbus module 1…3 4…6 Power unit connection 7…8 10…12 24 V 13…15 16…18 EIA/R5-485 34…38 connection 40, 41 Ext. 24 V 19…21 22…24 SLOT 2 I/O extension module 25…27 Panel port Reinforced insulation (IEC/EN 61800-5-1:2016) Functional insulation (IEC/EN 61800-5-1:2016) 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...
Page 187 Technical data 183 Ground isolation diagram 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 188: Efficiency
184 Technical data Efficiency Efficiency at nominal power level: Approximately 96% for frame R3 Approximately 96.5% for frame R6 Approximately 97% for frame R8 Degree of protection Degree of protection IP20, IP21, IP55 (IEC/EN 60529) Enclosure types UL Type 1, UL Type 12, UL Type Open (UL 61800-5-1) Drive types not available for UL (NEC)
Page 189 Technical data 185 Package Plywood, cardboard and molded pulp. Foam cushions PE, PP-E, bands PP.
Page 190: Applicable Standards
186 Technical data 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.
Page 191: Ambient Conditions
Technical data 187 Ambient conditions Environmental limits for the drive are given below. The drive is to be used in a heated, indoor, controlled environment. All printed circuit boards are conformal coated. Operation Storage Transportation installed for in the protective in the protective stationary use package...
Page 192: Markings
188 Technical data Operation Storage Transportation installed for in the protective in the protective stationary use package package Vibration 10...150 Hz (IEC 60068-2:6) Amplitude ±0.075 mm, 10...57.56 Hz Constant peak acceleration 10 m/s² (1 gn), 57.56...150 Hz Vibration (ISTA) R3: Displacement, 25 mm peak to peak, 14200 vibratory impacts R6, R8 ISTA 3E): Random, overall Grms level of 0.54...
Page 193: Emc Compliance (Iec/En 61800-3:2004 + A1:2012)
Technical data 189 RCM mark Product complies with Australian and New Zealand requirements specific to EMC, telecommunications and electrical safety. For fulfilling the requirements of the standard, see section EMC compliance (IEC/EN 61800-3:2004 + A1:2012) on page 189. Eurasian Conformity mark Product complies with technical regulations of the Eurasian Customs Union.
Page 194: Category C2
190 Technical data  Category C2 The emission limits are complied with the following provisions (frames R3 and R8): 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 195: Category C4
Technical data 191  Category C4 If the provisions under Category C3 cannot be 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.
Page 196 Code (NEC) or Canadian Electrical Code). Obey also any other applicable local or provincial codes. Note: Circuit breakers must not be used without fuses in the USA. Consult ABB for suitable circuit breakers. WARNING! The opening of the branch-circuit protective device may be an indication that a fault current has been interrupted.
Page 197: Eu Declaration Of Conformity (Machinery Directive)
ABB and its affiliates are not liable for damages and/or losses related to such security breaches, any unauthorized access,...
Page 198 194 Technical data...
Page 199: Dimension Drawings
Dimension drawings 195 Dimension drawings Contents of this chapter This chapter shows the dimension drawings of the drive. The dimensions are given in millimeters and [inches].
Page 200: R3, Ip21 (Ul Type 1)
196 Dimension drawings R3, IP21 (UL Type 1)
Page 201: R3 - Option +B056 (Ip55, Ul Type 12)
Dimension drawings 197 R3 – Option +B056 (IP55, UL Type 12)
Page 202: R6, Ip21 (Ul Type 1)
198 Dimension drawings R6, IP21 (UL Type 1)
Page 203: R6 - Option +B056 (Ip55, Ul Type 12)
Dimension drawings 199 R6 – Option +B056 (IP55, UL Type 12)
Page 204: R8, Ip21 (Ul Type 1)
200 Dimension drawings R8, IP21 (UL Type 1)
Page 205: R8 - Option +B056 (Ip55, Ul Type 12)
Dimension drawings 201 R8 – Option +B056 (IP55, UL Type 12)
Page 206 202 Dimension drawings...
Page 207: The Safe Torque Off Function
The Safe torque off function 203 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 that stop the drive in case of danger (such as an emergency stop circuit).
Page 208: Compliance With The European Machinery Directive
204 The Safe torque off function The Safe torque off function of the drive complies with these standards: Standard Name IEC 60204-1:2016 Safety of machinery – Electrical equipment of machines – Part 1: General requirements EN 60204-1:2006 + A1:2009 + AC:2010 IEC 61326-3-1:2017 Electrical equipment for measurement, control and laboratory use –...
Page 209: Connection With Internal +24 V Dc Power Supply
The Safe torque off function 205 For drives with option +L537+Q971, see CPTC-02 ATEX-certified thermistor protection module, Ex II (2) GD (+L537+Q971) user's manual (3AXD50000030058 [English]).  Connection with internal +24 V DC power supply Drive Control unit OUT1 + 24 V DC OUT2 + 24 V DC SGND...
Page 210: Connection With External +24 V Dc Power Supply
206 The Safe torque off function  Connection with external +24 V DC power supply 24 V DC Drive Control unit 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 211: Activation Switch
The Safe torque off function 207 An example of a Safe torque off wiring with external +24 V DC power supply is shown below. +24 V DC external Safety PLC Drive power supply OUT1 OUT2 36 SGND Safety relay For information on the specifications of the STO input, see chapter CCU-24 control unit connection data (page 180).
Page 212: Grounding Of Protective Shields
208 The Safe torque off function  Grounding of protective shields • Ground the shield in the cabling between the activation switch and the control unit at the control unit. • Ground the shield in the cabling between two control units at one control unit only. Operation principle 1.
Page 213 The Safe torque off function 209 After wiring the Safe torque off function, validate its operation as follows. Note: If a CPTC-02 module is installed, refer to its documentation. Action WARNING! Follow the Safety instructions, page 11. If you ignore the instructions physical injury or death, or damage to the equipment can occur.
Page 214: Use
210 The 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 (wire coming to IN1). If the motor was running, it should coast to a stop.
Page 215: Maintenance
The Safe torque off function 211 WARNING! (With permanent magnet motors 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.
Page 216: Competence
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 unit for external diagnostics. Any failures of the Safe torque off function must be reported to ABB.
Page 217: Safety Data (Sil, Pl)
The Safe torque off function 213 Safety data (SIL, PL) 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. MTTF Frame SIL/...
Page 218: Abbreviations
214 The Safe torque off function  Abbreviations Abbr. Reference Description 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.
Page 219: Resistor Braking
Resistor braking 215 Resistor braking Contents of this chapter The chapter describes how to select, protect and wire external brake choppers and brake resistors for the drive. The chapter also contains installation instructions and the technical data. Operation principle and hardware description The brake chopper handles the energy generated by a decelerating motor.
Page 220: Selecting A Custom Resistor
216 Resistor braking Note: If the E value is not sufficient, it is possible to use a four-resistor assembly in which two standard resistors are connected in parallel, two in series. The E value of the four-resistor assembly is four times the value specified for the standard resistor. ...
Page 221: Minimizing Electromagnetic Interference
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 must be considered by the customer.
Page 222: Protecting The System Against Thermal Overload
1 Thermal switch The thermal switch cable must be shielded and may not be longer than the resistor cable. ABB recommends that you also wire the thermal switch to a digital input on the drive and program it as coast stop.
Page 223: Mechanical Installation
For settings of other control programs, see the appropriate firmware manual. Technical data  Ratings Contact ABB for the brake chopper and resistor specifications.  Terminals and cable lead-through data See section Terminal and entry data for the power cables...
Page 224 220 Resistor braking...
Page 225: Common Mode, Du/Dt And Sine Filters
Common mode, du/dt and sine filters 221 Common mode, du/dt and sine filters Contents of this chapter This chapter describes how to select external filters for the drive. Common mode filters For need of common mode filter, see section Examining the compatibility of the motor drive, page 52.
Page 226: Du/Dt Filters
222 Common mode, du/dt and sine filters du/dt filters  When is a du/dt filter needed? See section Examining the compatibility of the motor and drive, page 52.  du/dt filter types Type du/dt filter type ACH580 -31- IEC ratings: U = 400 V 09A5-4 NOCH0016-6x...
Page 227: Description, Installation And Technical Data Of The Filters
Common mode, du/dt and sine filters 223 NOCH0070-6x can be used if full load current is not needed Type du/dt filter type ACH580 -31- UL (NEC) ratings: U = 480 V 07A6-4 NOCH0016-6x 012A-4 NOCH0016-6x 014A-4 NOCH0016-6x or NOCH0030-6x 023A-4 NOCH0030-6x 027A-4 NOCH0070-6x...
Page 228: Sine Filters
224 Common mode, du/dt and sine filters Sine filters See section Examining the compatibility of the motor and drive, page 52. Contact ABB for sine filter specifications.  Derating See section Switching frequency derating on page 163.
Page 229: Optional I/O Extension Modules
Optional I/O extension modules 225 Optional I/O extension modules What this chapter contains This chapter describes how to install and start up the optional CHDI-01, CMOD-01 and CMOD-02 IO multifunction extension modules. The chapter also contains diagnostics and technical data. CHDI-01 115/230 V digital input extension module ...
Page 230: Layout
226 Optional I/O extension modules Layout Grounding screw Hole for mounting screw 3-pin terminal blocks for relay outputs Terminal descriptions on page 3-pin terminal block for 115/230 V inputs Terminal descriptions on page Diagnostic LED Terminal descriptions on page  Mechanical installation Necessary tools and instructions •...
Page 231: Installing The Module
Optional I/O extension modules 227 Installing the module See section Installing optional modules on page 110.  Electrical installation Warnings WARNING! Obey the instructions in chapter Safety instructions on page 11. If you ignore them, injury or death, or damage to the equipment can occur. If you are not a qualified electrical professional, do not do electrical work.
Page 232: General Cabling Instructions
228 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 Guidelines for planning the electrical installation on page 51.
Page 233: Start-Up
Optional I/O extension modules 229  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 234: Technical Data
230 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 unit Degree of protection: IP20 Ambient conditions: See the drive technical data. Package: Cardboard...
Page 235 Optional I/O extension modules 231 Isolation areas: CHDI-01 Plugged to drive SLOT2 Symbol Description Reinforced insulation (IEC 61800-5-1:2016) Functional insulation (IEC 61800-5-1:2016) Relay outputs (50…52, 53…55): • Wire size max. 1.5 mm • Minimum contact rating: 12 V / 10 mA •...
Page 236: Cmod-01 Multifunction Extension Module (External 24 V Ac/Dc And Digital I/O)
232 Optional I/O extension modules CMOD-01 multifunction extension module (external 24 V AC/DC and digital I/O)  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 unit. It has two relay outputs and one transistor output, which can function as a digital or frequency output.
Page 237: Layout
Optional I/O extension modules 233 Layout Grounding screw Mechanical installation on page Hole for mounting screw Mechanical installation on page 3-pin terminal blocks for relay outputs Terminal descriptions on page 3-pin terminal block for transistor output Terminal descriptions on page 2-pin terminal block for external power Terminal descriptions on page supply...
Page 238: Unpacking And Checking The Delivery
234 Optional I/O extension modules Unpacking and checking the delivery 1. Open the option package. 2. Make sure that the package contains: • CMOD-01 multifunction extension module • mounting screw • support part (Note: The support part is needed only for the following frame R1 drive types -02A7, -03A4, -04A1, -05A7, -07A3, -09A5 and -12A7).
Page 239: General Cabling Instructions
Optional I/O extension modules 235 Transistor output Marking Description DO1 SRC Source input DO1 OUT Digital or frequency output DO1 SGND Ground (earth) potential 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 unit.
Page 240 236 Optional I/O extension modules Digital output connection example DO1 SRC 24 V DC DO1 OUT DO1 SGND CMOD-01 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 241: Start-Up
Optional I/O extension modules 237  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 15.01Extension module type is CMOD-01. If warning A7AB Extension I/O configuration failure is shown, •...
Page 242: Diagnostics
238 Optional I/O extension modules 15.33 Freq out 1 source 01.01 Motor speed used 15.34 Freq out 1 src min 15.35 Freq out 1 src max 1500.00 15.36 Freq out 1 at src min 0 Hz 15.37 Freq out 1 at src max 10000 Hz ...
Page 243: Technical Data
Optional I/O extension modules 239  Technical data Dimension drawing: The dimensions are in millimeters and [inches]. Installation: Into an option slot on the drive control unit Degree of protection: IP20 Ambient conditions: See the drive technical data. Package: Cardboard...
Page 244 240 Optional I/O extension modules Isolation areas: CMOD-01 Plugged to 24 V drive SLOT2 Symbol Description Reinforced insulation (IEC 61800-5-1:2016) Functional insulation (IEC 61800-5-1:2016) Relay outputs (50…52, 53…55): • Wire size max. 1.5 mm • Minimum contact rating: 12 V / 10 mA •...
Page 245: Hardware Description
Optional I/O extension modules 241 CMOD-02 multifunction extension module (external 24 V AC/DC and isolated PTC interface)  Hardware description Product overview The CMOD-02 multifunction extension module (external 24 V AC/DC and isolated PTC interface) has a motor thermistor connection for supervising the motor temperature and one relay output, which indicates the thermistor status.
Page 246: Layout
242 Optional I/O extension modules Layout Grounding screw Mechanical installation on page Hole for mounting screw Mechanical installation on page 2-pin terminal block for motor thermistor Terminal descriptions on page connection 2-pin terminal block for relay output Terminal descriptions on page 2-pin terminal block for external power Terminal descriptions on page supply...
Page 247: Unpacking And Checking The Delivery
Optional I/O extension modules 243 Unpacking and checking the delivery 1. Open the option package. 2. Make sure that the package contains: • CMOD-02 multifunction extension module • mounting screw • support part (Note: The support part is needed only for the following frame R1 drive types -02A7, -03A4, -04A1, -05A7, -07A3, -09A5 and -12A7).
Page 248: General Cabling Instructions
244 Optional I/O extension modules Marking Description RO PTC B Normally open, NO 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 unit. Note: CMOD external +24 V power supply terminals are not in use with CCU-24 control unit.
Page 249: Start-Up
Optional I/O extension modules 245 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 unit ground when the control unit is powered using an external 24 V AC supply.
Page 250: Diagnostics
246 Optional I/O extension modules  Diagnostics Faults and warning messages Warning A7AB Extension I/O configuration failure. LEDs The extension module has one diagnostic LED. Color Description Green The extension module is powered up.  Technical data Dimension drawing: The dimensions are in millimeters and [inches].
Page 251 Optional I/O extension modules 247 Installation: Into an option slot on the drive control unit Degree of protection: IP20 Ambient conditions: See the drive technical data. Package: Cardboard Isolation areas: CMOD-02 Plugged to 24 V RO PTC drive SLOT2 Symbol Description Reinforced insulation (IEC 61800-5-1:2016) Functional insulation (IEC 61800-5-1:2016)
Page 252 248 Optional I/O extension modules External power supply (40…41): • Wire size max. 1.5 mm • 24 V AC / V DC ±10% (GND, user potential) • Maximum power consumption: 25 W, 1.04 A at 24 V DC...
Page 253 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 abb.com/searchchannels. Product training For information on ABB product training, navigate to new.abb.com/service/training.

ABB ACH580-31 Series Hardware Manual

Quick Links

Related Manuals for ABB ACH580-31 Series

Summary of Contents for ABB ACH580-31 Series