Page 1 — ABB DRIVES FOR HVAC ACH580-04 drive modules Hardware manual...
Page 3 ACH580-04 drive modules Hardware manual Table of contents 1. Safety instructions 6. Mechanical installation 8. Electrical installation 12. Start-up 3AXD50000048685 Rev B EFFECTIVE: 2020-08-10...
Page 5: Table Of Contents
Table of contents 5 Table of contents 1 Safety instructions Contents of this chapter ................Use of warnings and notes ............... General safety in installation, start-up and maintenance ........Electrical safety in installation, start-up and maintenance ........Electrical safety precautions ..............Additional instructions and notes .............
Page 6 Layout example, door closed ..............Layout example, door open (standard drive module configuration) ..... Layout example, door open (option +B051) ..........Planning the cooling of the ACH580-04 ............Standard drive module configuration ............Drive module with option +B051 ............. Other installation positions than vertical ............
Page 7: Table Of Contents
Availability of du/dt filter and common mode filter by drive type ..... Additional requirements for explosion-safe (EX) motors ......Additional requirements for ABB motors of types other than M2_, M3_, M4_, HX_ and AM_ ..................Additional requirements for ABB high-output and IP23 motors ......
Page 8 8 Table of contents Using power factor compensation capacitors with the drive ......... Using a safety switch between the drive and the motor ........Implementing an ATEX-certified motor thermal protection ........Controlling a contactor between drive and motor ..........Implementing a bypass connection ............. Example bypass connection ..............
Page 9 Table of contents 9 Miscellaneous ..................Input power cable entry from top ............. Attaching the drive module to a mounting plate ........... 10 Control unit Contents of this chapter ................Layout ....................Default I/O connection diagram ..............Switches ..................Additional information on I/O connections ............PNP configuration for digital inputs (X2 &...
Page 10 10 Table of contents Electrical ratings ..................IEC ratings ..................UL (NEC) ratings ................Definitions ..................Output derating ..................When is derating necessary? ..............Surrounding air temperature derating ............Altitude derating ................Switching frequency derating ..............Fuses (IEC) ..................Fuses (UL) ..................Circuit breakers (IEC) ................
Page 11 Description ..................Compliance with the European Machinery Directive ........Wiring ....................Connection principle ................Single ACH580-04 drive, internal power supply ........Single ACH580-04 drive, external power supply ........Wiring examples ................Single ACH580-04 drive, internal power supply ........Single ACH580-04 drive, external power supply ........
Page 12 12 Table of contents Protecting the system in fault situations ............ Selecting the default brake system components .......... Calculation example ................Selecting a custom brake resistor ............Mechanical installation of resistors .............. Electrical installation ................Measuring the insulation of the brake resistor circuit ........Connection diagram ................
Page 13 Table of contents 13 Product overview ................... Layout and example connections ............... Mechanical installation ................Necessary tools ................. Unpacking and examining the delivery ............Installing the module ................Electrical installation ................Necessary tools ................. Wiring .................... Start-up ....................Setting the parameters ................ Diagnostics ..................
Page 14 14 Table of contents 26 Connecting EMC filter and ground-to-phase varistor – North America Contents of this chapter ................Identifying the grounding system of the electrical power network ......When you can connect the EMC filter and ground-to-phase varistor: TN-S, IT, corner-grounded delta and mid-point-grounded delta systems ......
Page 15: Safety Instructions
Safety instructions 15 Safety instructions Contents of this chapter This chapter contains the safety instructions which you must obey when you install, start up, operate and do maintenance work on the drive. If you ignore the safety instructions, injury, death or damage can occur. Use of warnings and notes Warnings tell you about conditions which can cause injury or death, or damage to the equipment.
Page 16: General Safety In Installation, Start-Up And Maintenance
16 Safety instructions General safety in installation, start-up and maintenance These instructions are for all personnel who do work on the drive. WARNING! Obey these instructions. If you ignore them, injury or death, or damage to the equipment can occur. •...
Page 17 Safety instructions 17 • Make sure that the module does not topple over when you move it on the floor: Open the support legs by pressing each leg a little down (1, 2) and turning it aside. Whenever possible attach the module also with chains. Do not tilt the drive module. It is heavy and its center of gravity is high.
Page 18: Electrical Safety In Installation, Start-Up And Maintenance
18 Safety instructions • Vacuum clean the area around the drive before the start-up to prevent the drive cooling fan from drawing the dust inside the drive. • Make sure that debris from drilling, cutting and grinding does not enter the drive during the installation.
Page 19: Additional Instructions And Notes
Safety instructions 19 WARNING! Obey these instructions. If you ignore them, injury or death, or damage to the equipment can occur. If you are not a qualified electrical professional, do not do installation or maintenance work. Go through these steps before you begin any installation or maintenance work. 1.
Page 20: Optical Components
20 Safety instructions • Keep the cabinet doors closed when the drive is powered. With the doors open, a risk of a potentially fatal electric shock, arc flash or high-energy arc blast exists. • Make sure that the electrical power network, motor/generator, and environmental conditions agree with the drive data.
Page 21: General Safety In Operation
Safety instructions 21 • Always ground the drive, the motor and adjoining equipment. This is necessary for the personnel safety. Proper grounding also reduces electromagnetic emission and interference. • Make sure that the conductivity of the protective earth (PE) conductors is sufficient. See the electrical planning instructions of the drive.
Page 22: Additional Instructions For Permanent Magnet Motor Drives
22 Safety instructions Additional instructions for permanent magnet motor drives Safety in installation, start-up, maintenance ￭ These are additional warnings concerning permanent magnet motor drives. The other safety instructions in this chapter are also valid. WARNING! Obey these instructions. If you ignore them, injury or death, or damage to the equipment can occur.
Page 23: Introduction To The Manual
The flowchart refers to chapters/sections in this manual and other manuals. Applicability This manual applies to ACH580-04 drive modules intended for user-defined cabinet installations. Target audience This manual is intended for people who plan the installation, install, start up and do maintenance work on the drive, or create instructions for the end user of the drive concerning the installation and maintenance of the drive.
Page 24: Terms And Abbreviations
24 Introduction to the manual The option code (for example, option +E200) identifies information which concerns only a certain optional selection. The options included in the drive are listed on the type designation label. Terms and abbreviations Term Description ACH-AP-H Assistant control panel with Hand-Off-Auto functionality ACH-AP-W Assistant control panel with Hand-Off-Auto functionality and Bluetooth interface...
Page 25: Quick Installation, Commissioning And Operating Flowchart
Introduction to the manual 25 Quick installation, commissioning and operating flowchart Task Plan the mechanical and electrical installation and ac- Guidelines for planning the mechanical installa- quire the accessories needed (cables, fuses, etc.). tion (page 45) Examine the ambient conditions, ratings, required Guidelines for planning the electrical installa- cooling air flow, input power connection, compatibility tion (page 65)
Page 26: Related Documents
GD (+L537+Q971) user's manual DPMP-02/03 mounting platform for control panels installation guide 3AUA0000136205 3AXD50000308484 DPMP-04/05 mounting platform for control panels installation guide External control unit (+P906) for ACH580-04, ACQ580-04 and 3AXD50000167555 ACS580-04 drives supplement FDNA-01 DeviceNet™ adapter module user's manual 3AFE68573360...
Page 27: Operation Principle And Hardware Description
Operation principle and hardware description 27 Operation principle and hardware description Contents of this chapter This chapter describes the operating principle and construction of the drive module.
Page 28: Product Overview
28 Operation principle and hardware description Product overview The ACH580-04 is a drive module for controlling AC induction motors, synchronous reluctance motors and synchronous permanent magnet motors in open loop control. The main circuit of the drive module is shown below.
Page 29: Layout
Operation principle and hardware description 29 Layout Standard drive module configuration ￭ Lifting lugs Fastening bracket Input cable connection busbars (L1/U1, L2/V1, L3/W1) and and DC+ and DC- busbars (UDC+, UCD with option +H356) Circuit board compartment PE busbar Output cable connection terminals (T1/U2, T2/V2, T3/W2) attached and brake resistor connection busbars (R+ and R- with option +D150) Control cable duct Main cooling fans...
Page 30: Drive Module Configuration With Option +B051
30 Operation principle and hardware description Retractable support legs Base fastening screws behind the retractable support legs Pedestal guide plate Telescopic extraction/installation ramp Common mode filter (+E208) Drive module configuration with option +B051 ￭ The drive module configuration with clear plastic shrouds (option +B051) mounted is shown below.
Page 31 Operation principle and hardware description 31 +B051 +H370 Clear plastic shroud to be attached onto the drive Output power cable connection terminals module input power cabling (a). Lead-through shroud for side cabling (b). Option +B051. Clear plastic shrouds to be attached onto the drive Grounding terminal for output power cable shields module output power cabling with option +B051 Clear plastic shroud to be attached on top of the...
Page 32: Control Panel
32 Operation principle and hardware description Control panel ￭ ACH-AP-H hand-off-auto control panel (standard) CDUM-01 blank control panel cover (no control panel) (option +J424) ACH-AP-W hand-off-auto control panel with bluetooth interface (option +J429) DPMP-03 control panel mounting platform In the standard drive module configuration, the control panel is mounted on the upper front cover of the drive module.
Page 33: Overview Of Power And Control Connections
Operation principle and hardware description 33 Overview of power and control connections The diagram shows the power connections and control interfaces of the drive module. SLOT 1 SLOT 2 t° UDC+ UDC- T1/U2 L1/U1 T2/V2 L2/V1 T3/W2 L3/W1 Option slot 1 for optional fieldbus adapter modules Option slot 2 for optional I/O extension modules Panel port I/O terminal blocks.
Page 34: Type Designation Label
34 Operation principle and hardware description Type designation label The type designation label includes a rating, markings, a type designation and a serial number, which allow individual recognition of each drive module. The type designation label is located on the front cover. An example label is shown below. SCCR 100 kA Type designation, see section Type designation key (page...
Page 35: Type Designation Key
Operation principle and hardware description 35 Type designation key The type designation contains information on the specifications and configuration of the drive. The first digits from left express the basic drive type. The optional selections are given thereafter, separated by plus signs. Codes preceded by zero indicate the absence of the specified feature.
Page 36: Ordering Codes
36 Operation principle and hardware description Code Description ® K452 FLON-01 LonWorks adapter module K454 FPBA-01 PROFIBUS DP adapter module K457 FCAN-01 CANopen adapter module K458 FSCA-01 RS-485 (Modbus/RTU) adapter module K462 FCNA-01 ControlNet™ adapter module K465 FBIP-01 BACnet/IP adapter module, 2-port K469 FECA-01 EtherCat adapter module K470...
Page 37: Generic Cabinet Planning Instructions
The installation must always be designed and made according to applicable local laws and regulations. ABB does not assume any liability whatsoever for any installation which breaches the local laws and/or other regulations. Furthermore, if the recommendations given by ABB are not followed, the drive may experience problems that the warranty does not cover.
Page 38: Grounding Of Mounting Structures
Shrouds ￭ The installation of shrouds (touch protection) to fulfill applicable safety regulations is the responsibility of the drive system builder. Ready-made shrouding parts are available from ABB for some cabinet designs, see the ordering information. Tightening torques ￭ Unless a tightening torque is specified in the text, the following torques can be used.
Page 39: Insulation Supports
Generic cabinet planning instructions 39 Insulation supports Size Max. torque Note 5 N·m (44 lbf·in) Strength class 8.8 9 N·m (6.6 lbf·ft) Strength class 8.8 18 N·m (13.3 lbf·ft) Strength class 8.8 31 N·m (23 lbf·ft) Strength class 8.8 Cable lugs Size Max.
Page 40: Preventing The Recirculation Of Hot Air
40 Generic cabinet planning instructions Note: Use an extra exhaust fan if the air outlet is on the cabinet door. Air inlet Air outlet Arrange the cooling air flow through the components according to the technical data. See the specifications for: •...
Page 41: Emc Requirements
• The best galvanic connection between the steel panels is achieved by welding them together as no holes are necessary. If welding is not possible, ABB recommends to leave the seams between the panels unpainted and equipped with special conductive EMC strips to provide adequate galvanic connection.
Page 42 360° high-frequency grounding of the cable shields at the cable entries improves the EMC shielding of the cabinet. • ABB recommends 360° high-frequency grounding of the motor cable shields at their entries. The grounding can be implemented by a knitted wire mesh screening as shown below.
Page 43: Attaching The Cabinet
Generic cabinet planning instructions 43 Attaching the cabinet WARNING! Do not attach the cabinet by electric welding. ABB does not assume any liability for damages caused by electric welding as the welding circuit can damage electronic circuits in the cabinet.
Page 44: Mounting The Control Panel On The Cabinet Door
Mounting the control panel on the cabinet door You can use a mounting platform to mount the control panel on the cabinet door. Mounting platforms for control panels are available as options from ABB. For more information, see Manual Code (English)
Page 45: Guidelines For Planning The Mechanical Installation
Guidelines for planning the mechanical installation 45 Guidelines for planning the mechanical installation Contents of this chapter This chapter guides in planning drive cabinets and installing the drive module into a user-defined cabinet. The chapter gives cabinet layout examples and free space requirements around the module for cooling.
Page 46: Planning The Layout
Air outlet for the other equipment Air outlet for the drive module and other equipment on the cabinet roof. An exhaust fan if needed. ABB recommends this alternative instead of 2a. Drive control panel with DPMP-03 mounting platform. The control panel is connected to the drive module control unit inside the cabinet.
Page 47: Layout Example, Door Open (Standard Drive Module Configuration)
Guidelines for planning the mechanical installation 47 Layout example, door open (standard drive module configuration) ￭ L1/U1 L2/V1 L3/W1 T3/W2 T2/V2 T1/U2 A – A Supporting frame of the cabinet Motor cable including the protective ground con- ductor of the drive module Vertical (2a, 2b) and horizontal (2c, 2d) air baffles External drive module control unit (+P906).
Page 48 48 Guidelines for planning the mechanical installation Note 1: The power cable shields can also be grounded to the drive module grounding terminals. Note 2: See also section Free space requirements (page 53).
Page 49: Layout Example, Door Open (Option +B051)
Guidelines for planning the mechanical installation 49 Layout example, door open (option +B051) ￭ L1/U1 L2/V1 L3/W1 T3/W2 T2/V2 T1/U2 A – A Supporting frame of the cabinet Drive module Vertical (2a) and horizontal (2b) air baffles with Motor cable including the protective ground con- leak-proof cable entries.
Page 50: Planning The Cooling Of The Ach580-04
ABB recommends that the air outlet is on the cabinet roof. Use an extra exhaust fan if the air outlet is on the cabinet door.
Page 51: Standard Drive Module Configuration
Guidelines for planning the mechanical installation 51 Standard drive module configuration ￭ This diagram shows air baffle positions in an example cabinet. L1/U1 L2/V1 L3/W1 T3/W2 T2/V2 T1/U2 C – C A - A B - B D – D Air flow to the drive module, max.
Page 52: Drive Module With Option +B051
52 Guidelines for planning the mechanical installation Lower horizontal air baffle Cabinet grounding busbar Optional air baffle that is needed when there is no fan on the lower part of the cabinet door (1b in section Layout example, door closed (page 46)).
Page 53: Other Installation Positions Than Vertical
￭ You can install the drive module on its back. Make sure that the hot cooling air that flows upwards from the module does not cause danger. For other installation positions, contact ABB. Free space requirements ￭ Free space around the drive module is needed to make sure that sufficient cooling air flows through the module and the module cools correctly.
Page 55: Mechanical Installation
Mechanical installation 55 Mechanical installation Contents of this chapter This chapter describes how to install the drive module mechanically. Examining the installation site The material below the drive must be non-flammable and strong enough to carry the weight of the drive. See section Ambient conditions (page 148) for the allowed ambient conditions and section...
Page 56: Moving And Unpacking The Unit
56 Mechanical installation Moving and unpacking the unit WARNING! Lift the drive module only by the lifting lugs: Make sure that the module does not topple over when you move it on the floor: Open the support legs by pressing each leg a little down (1, 2) and turning it aside. Whenever possible attach the module also with chains.
Page 57 Mechanical installation 57 3AUA0000101742 Transport package contents With option +B051: Clear plastic shrouds. See below for the box contents. With standard drive module configuration: Output cable connection terminals. See below for the box contents. Plywood support Drive module with factory installed options and multilingual residual voltage warning sticker, top guide plate, pedestal guide plate, telescopic ramp package, fastening screws in a plastic bag, control unit options, delivery documents, printed multilingual installation and start-up quick guide.
Page 58 58 Mechanical installation To unpack: • Cut the bands (A). • Unpack the additional boxes (B). • Remove the outer sheathing by lifting it (C). • Remove the sheathing by lifting it (D). • Remove the pedestal guide plate (not included with options +0H354 and +0P919) as shown below. Box B1 contents (option +B051) Paper fill Clear plastic shroud for output cabling...
Page 59 Mechanical installation 59 Box B2 contains this box Paper fill Output cable connection terminal T3/W2 Output cable connection terminal T2/V2 Output cable connection terminal T1/U2 Grounding terminal Cardboard box Screws and insulators in a plastic bag 3AXD5000009515 Box B2 contains additionally this box with option +H370 Metallic shroud with ground bar Paper fill...
Page 60: Lifting The Drive Module
60 Mechanical installation Accessories box contents Screw package Feed through Bracket for attaching the drive module from top to Rittal cabinet punched section. Support bracket for attaching the drive module from top to a mounting plate or wall. The bracket brings a gap for cooling air flow and prevents the drive module screws from chafing the plate.
Page 61: Input Power Cable Connection Terminals (Option +H370) And Ground Busbar Assembly
Mechanical installation 61 Input power cable connection terminals (option +H370) and ground ￭ busbar assembly Connect the input power cable connection terminals in the same way as the motor cable connection terminals. Install the metallic shroud as shown below. Combi screw M4×8 Torx T20 2 N·m 3AXD50000017460 Drive module without output cable connection terminals (option...
Page 62: Alternatives For Grounding The Drive Module
62 Mechanical installation M4×12 Torx Alternatives for grounding the drive module ￭ You can ground the drive module from its top back to the cabinet frame with these alternatives: 1. from the grounding hole 2. to a Rittal punched section: with fastening bracket. Tapping screw M6×12 Torx T30 (Hex) 9 N·m...
Page 63: Installing The Bottom Grille For Ip20 Degree Protection
Mechanical installation 63 Installing the bottom grille for IP20 degree protection ￭ For option +B051: If IP20 degree of protection is needed from the bottom side, install the bottom grille as shown below.
Page 64: Removing The Protective Covering From The Drive Module Air Outlet
64 Mechanical installation Removing the protective covering from the drive module air outlet WARNING! Remove the protective covering from the top of the drive module after the installation. If the covering is not removed, the cooling air cannot flow freely through the module and the drive will run to overtemperature.
Page 65: Guidelines For Planning The Electrical Installation
The installation must always be designed and made according to applicable local laws and regulations. ABB does not assume any liability whatsoever for any installation which breaches the local laws and/or other regulations. Furthermore, if the recommendations given by ABB are not followed, the drive may experience problems that the warranty does not cover.
Page 66: North America
Examining the compatibility of the motor and drive Use asynchronous AC induction motors, permanent magnet synchronous motors, AC induction servomotors or ABB synchronous reluctance motors (SynRM motors) with the drive. Select the motor size and drive type from the rating table on basis of the AC line voltage and motor load.
Page 67: Requirements Table
N-end (non-drive end) motor bearings are required. Ignoring the requirements or improper installation may shorten motor life or damage the motor bearings and voids the warranty. This table shows the requirements when an ABB motor is in use. Motor type Nominal AC supply...
Page 68 68 Guidelines for planning the electrical installation This table shows the requirements when a non-ABB motor is in use. Motor type Nominal AC supply Requirement for voltage Motor insula- ABB du/dt and common mode filters, insulated tion system N-end motor bearings <...
Page 69: Availability Of Du/Dt Filter And Common Mode Filter By Drive Type
The rated output power of high-output motors is higher than what is stated for the particular frame size in EN 50347 (2001). If you plan to use a non-ABB high-output motor or an IP23 motor, consider these additional requirements for protecting the motor insulation and bearings in drive systems: •...
Page 70: Additional Data For Calculating The Rise Time And The Peak Line-To-Line Voltage
70 Guidelines for planning the electrical installation Nominal AC supply Requirement for voltage Motor insulation system ABB du/dt and common mode filters, insulated N- end motor bearings < 100 kW or frame 100 kW < P < 350 kW or size <...
Page 71: Selecting The Power Cables
Guidelines for planning the electrical installation 71 Û du/dt ------------ - (1/s) Û du/dt ------------ - (1/s) l (m) l (m) Drive without du/dt filter 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: Û...
Page 72: Typical Power Cable Sizes
72 Guidelines for planning the electrical installation area of the protective grounding 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 conductors Minimum cross-sectional area of the corresponding protective conductor S (mm...
Page 73: Alternate Power Cable Types
Guidelines for planning the electrical installation 73 Cable type Use as input power cabling Use as motor cabling Symmetrical shielded (or armored) cable with three phase conductors and a shield (or armor), and separ- ate PE conductor/cable 1) A separate PE conductor is required if the conductivity of the shield (or armor) is not sufficient for the PE use. Alternate power cable types Cable type Use as input power cabling...
Page 74: Not Allowed Power Cable Types
Additional guidelines, North America ￭ 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 recommends the use of metallic conduit.
Page 75: Metal Conduit
Guidelines for planning the electrical installation 75 Metal conduit Couple separate parts of a metal conduit together: bridge the joints with a ground conductor bonded to the conduit on each side of the joint. Also bond the conduits to the drive enclosure and motor frame.
Page 76: Signals In Separate Cables
Relay cable ￭ The cable type with braided metallic shield (for example ÖLFLEX by LAPPKABEL, Germany) has been tested and approved by ABB. Control panel to drive cable ￭ Use EIA-485 with male RJ-45 connector, cable type Cat 5e or better. The maximum permitted length of the cable is 100 m (328 ft).
Page 77: General Guidelines - North America
Guidelines for planning the electrical installation 77 min. 300 mm (12 in) min. 300 mm (12 in) min. 500 mm (20 in) 90° min. 200 mm (8 in) min. 500 mm (20 in) Motor cable Input power cable Control cable Brake resistor or chopper cable (if any) General guidelines –...
Page 78: Continuous Motor Cable Shield/Conduit Or Enclosure For Equipment On The Motor Cable
78 Guidelines for planning the electrical installation Input power cabling Motor cabling Conduit Continuous motor cable shield/conduit or enclosure for equipment ￭ on the motor cable To minimize the emission level when safety switches, contactors, connection boxes or similar equipment are installed on the motor cable between the drive and the motor: •...
Page 79: Implementing Motor And Motor Cable Short-Circuit And Thermal Overload Protection
Guidelines for planning the electrical installation 79 Implementing motor and motor cable short-circuit and thermal overload protection Protecting the motor and motor cable in short-circuits ￭ The drive protects the motor cable and motor in a short-circuit situation when the motor cable is sized according to the nominal current of the drive.
Page 80: Protecting The Drive And Input Power Cable In Short-Circuits
You can use the circuit breakers listed in the technical data. Other circuit breakers can be used with the drive if they provide the same electrical characteristics. ABB does not assume any liability whatsoever for the correct function and protection with circuit breakers not listed.
Page 81: Implementing The Emergency Stop Function
Guidelines for planning the electrical installation 81 Note: As standard, the drive contains capacitors connected between the main circuit and the frame. These capacitors and long motor cables increase the ground leakage current and may cause nuisance faults in residual current devices. Implementing the emergency stop function For safety reasons, install the emergency stop devices at each operator control station and at other operating stations where emergency stop may be needed.
Page 82: Using A Safety Switch Between The Drive And The Motor
Using a safety switch between the drive and the motor ABB recommends to install a safety switch between the permanent magnet motor and the drive output. The switch is needed to isolate the motor from the drive during maintenance work on the drive.
Page 83: Implementing A Bypass Connection
Guidelines for 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 operates 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 Guidelines for planning the electrical installation Example bypass connection ￭ Drive main switch Bypass circuit breaker Drive main contactor Bypass contactor Drive output contactor Drive main contactor on/off control Motor power supply selection (drive or direct-on-line) Start when motor is connected direct-on-line Stop when motor is connected direct-on-line...
Page 85: Switching The Motor Power Supply From Drive To Direct-On-Line
Guidelines for 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 stop key (drive in the local control mode) or external stop signal (drive in the remote control mode). 2.
Page 86: Implementing A Motor Temperature Sensor Connection
86 Guidelines for planning the electrical installation Implementing a motor temperature sensor connection WARNING! IEC 60664 and IEC 61800-5-1 require double or reinforced insulation between live parts and accessible parts when: • the accessible parts are not conductive, or • the accessible parts are conductive, but not connected to the protective earth.
Page 87 Guidelines for planning the electrical installation 87 Option module Temperature sensor Temperature sensor insula- type tion requirement Type Insulation/Isolation Pt100, Pt1000 CMOD-02 Reinforced insulation between No special requirement the sensor connector and the CPTC-02 No special requirement other connectors of the mod- ule (including drive control unit connector).
Page 89: Electrical Installation
Electrical installation 89 Electrical installation Contents of this chapter This chapter contains instructions for electrical installation of the drive module. The chapter refers to installation example chapters which contain instructions that depend on the selected drive configuration. Safety WARNING! If you are not a qualified electrical professional, do not do installation or maintenance work.
Page 90: Measuring The Insulation
Use a measuring voltage of 1000 V DC. The insulation resistance of an ABB motor must be more than 100 Mohm (reference value at 25 °C [77 °F]). For the insulation resistance of other motors, refer to the manufacturer’s instructions.
Page 91: Grounding System Compatibility Check - Iec, Not North America
Electrical installation 91 1. Stop the drive and do the steps in section Electrical safety precautions (page 18) before you start the work. 2. Make sure that the resistor cable is connected to the resistor and disconnected from the drive output terminals. 3.
Page 92: Grounding System Compatibility Check - North America
92 Electrical installation Grounding system compatibility check – North America This section is valid for the UL (NEC) drive types. Frame Default wires – North America R10, R11 Not connected Not connected EMC filter compatibility ￭ The drive has an internal EMC filter (+E210) as standard. However, for the UL (NEC) drive types, the filter is disconnected as default.
Page 93: Connecting The Power Cables
(page 71). ABB recommends 360-degree grounding at the cabinet entry if a shielded cable is used. Ground the other end of the input cable shield or PE conductor at the distribution board. ABB recommends 360-degree grounding at the cabinet entry.
Page 94: Preparing The Cable Ends - Symmetrical Shielded Cables
94 Electrical installation The drive module frame must be connected to the cabinet frame. See section Alternatives for grounding the drive module (page 62). Note: If there is a symmetrically constructed grounding conductor in the motor cable in addition to the conductive shield, connect the grounding conductor to the grounding terminal at the drive and motor ends.
Page 95: Dc Connection
The UDC+ and UDC– terminals are intended for common DC configurations of a number of drives, allowing regenerative energy from one drive to be utilized by the other drives in the motoring mode. For more information, contact your local ABB representative. Connecting the control cables This procedure applies to the standard drive module with integrated control unit.
Page 96: Connecting A Control Panel
96 Electrical installation 6. Ground the shields of the control cables at the clamp plate. The shields should be continuous as close to the terminals of the control unit as possible. Only remove the outer jacket of the cable at the cable clamp so that the clamp presses on the bare shield. The shield (especially in case of multiple shields) can also be terminated with a lug and fastened with a screw at the clamp plate.
Page 97: Connecting A Pc
Electrical installation 97 Connecting a PC WARNING! Do not connect the PC directly to the control panel connector of the control unit as this can cause damage. A PC (with eg, the Drive composer PC tool) can be connected as follows: 1.
Page 98: Option Slot 2 (I/O Extension Modules)
98 Electrical installation Option slot 2 (I/O extension modules) ￭ 1. Put the module carefully into its position on the control unit. 2. Tighten the mounting screw. 3. Tighten the grounding screw (CHASSIS) to 0.8 N·m (7 lbf·in). The screw grounds the module.
Page 99: Option Slot 1 (Fieldbus Adapter Modules)
Electrical installation 99 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 (7 lbf·in). 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 101: Installation Example Of Drive Module With Ip20 Shrouds (Option +B051)
Installation example of drive module with IP20 shrouds (option +B051) 101 Installation example of drive module with IP20 shrouds (option +B051) Contents of this chapter In this chapter, the drive module with IP20 shrouds (option +B051) is installed in a 600 mm wide Rittal VX25 enclosure in a bookshelf way of mounting.
Page 102: Required Parts
TS 4396.500 Support rails SK 3243.200 Air filter 323 mm × 323 mm. Remove the filter mats. Customer-made parts (not ABB or Rittal parts) Air baffles See sections Preventing the recirculation of hot air (page 40) baffles for the drive module with option +B051 (page 168).
Page 103: Overall Flowchart Of The Installation Process
Installation example of drive module with IP20 shrouds (option +B051) 103 Overall flowchart of the installation process Step Task For instructions, see Install the Rittal parts, drive bottom guide plate • Installing the drive module into a cabin- and loose drive options in the drive module cu- et (page 103) bicle.
Page 104: Connecting The Power Cables And Installing The Shrouds
104 Installation example of drive module with IP20 shrouds (option +B051) Connecting the power cables and installing the shrouds Step Task (motor cables) Install the grounding terminal to the drive module base. Run the motor cables to the cabinet. Ground the cable shields 360 degrees at the cabinet entry. Connect the twisted shields of the motor cables to the grounding terminal.
Page 105: Installing The Roof And Door (Rittal Parts)
Install the side and top clear plastic shrouds to the drive module. Installing the roof and door (Rittal parts) Install the air inlet gratings to the cabinet door and the spacers on top of the cabinet as shown below. This layout has been tested by ABB. Rittal 7967.000 Rittal 3243.200 592 [23.31]...
Page 106: Miscellaneous
106 Installation example of drive module with IP20 shrouds (option +B051) Miscellaneous Input power cable entry from top ￭ If you run the input cables from top to the drive module, drill the entry holes to the top clear plastic shroud. Attaching the drive module to a mounting plate ￭...
Page 107: Control Unit
Control unit 107 Control unit Contents of this chapter This chapter contains the default I/O connection diagram, descriptions of the terminals and technical data for the drive control unit (CCU-24).
Page 108: Layout
108 Control unit Layout The layout of the external control connection terminals on the drive module control unit is shown below. SLOT 1 SLOT 1 Option slot 1 (fieldbus adapter modules) ANALOG IN/OUT 1…3 Analog input 1 4…6 Analog input 2 1…3 7…9 Analog outputs...
Page 109: Default I/O Connection Diagram
Control unit 109 Default I/O connection diagram Default control connections for the HVAC default are shown below. 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...
Page 110: Switches
110 Control unit 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 111: Npn Configuration For Digital Inputs (X2 & X3)
Control unit 111 Internal +24 V power supply External +24 V power supply PNP connection (source) PNP connection (source) X2 & X3 X2 & X3 +24V +24V 0 V DC DGND DGND +24 V DC DCOM DCOM 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 112: Connection Examples Of Two-Wire And Three-Wire Sensors To Analog Input (Ai2)
112 Control unit 8 AO2 8 AO2 1 kohm 1 kohm 500 ohm 9 AGND 9 AGND Connection examples of two-wire and three-wire sensors to analog ￭ input (AI2) Note: The maximum capability of the auxiliary voltage output (24 V DC [250 mA]) must not be exceeded.
Page 113: Ai1 And Ai2 As Pt100, Pt1000, Ni1000, Kty83 And Kty84 Sensor Inputs (X1)
Control unit 113 AI1 and AI2 as Pt100, Pt1000, Ni1000, KTY83 and KTY84 sensor inputs ￭ (X1) Sensors for motor temperature measurement can be connected between an analog input and output, an example connection is shown below. Leave the other end of the shield unconnected or ground it indirectly via a few nanofarads high-frequency capacitor, for example, 3.3 nF / 630 V.
Page 114: Technical Data
114 Control unit Technical data External power supply Maximum power: 36 W, 1.50 A at 24 V AC/DC ±10% as standard Term. 40, 41 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) minus the power taken by the option modules installed on board.
Page 115 Control unit 115 Safe torque off (STO) inputs IN1 24 V DC logic levels: "0" < 5 V, "1" > 13 V and IN2 (Term. 37 and 38) : 2.47 kohm Terminal size: 0.14…2.5 mm Embedded fieldbus (X5) Connector pitch 5 mm, wire size 2.5 mm Physical layer: EIA-485 Cable type: Shielded twisted pair cable with twisted pair for data and a wire or pair for signal ground, nominal impedance 100…165 ohms, for example...
Page 116 116 Control unit Isolation areas SLOT 1 1…3 4…6 7…8 10…12 24 V 13…15 16…18 34…38 EIA/R5-485 40, 41 Ext. 24 V SLOT 2 19…21 22…24 25…27 Panel port Power unit connection at the bottom of the control unit 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...
Page 117 Control unit 117 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 Jumper installed at factory...
Page 119: Installation Checklist
Installation checklist 119 Installation checklist Contents of this chapter This chapter contains a checklist of the mechanical and electrical installation of the drive. Checklist Examine the mechanical and electrical installation of the drive before start-up. Go through the checklist together with another person. WARNING! Obey the safety instructions of the drive.
Page 120 120 Installation checklist Make sure that … The cooling air flows freely in and out of the drive. Air recirculation inside the cabinet is not be possible (air baffle plates are on place, or there is another air guiding solution). If the drive is connected to a network other than a symmetrically grounded TN-S system: You have done all the required modifications (for example, you may need to disconnect the EMC filter or ground- to-phase varistor).
Page 121: Start-Up
Start-up 121 Start-up Contents of this chapter This chapter describes the start-up procedure of the drive. Start-up procedure 1. Make sure that the installation of the drive module has been checked according to the checklist in chapter Installation checklist (page 119), and that the motor and driven equipment are ready for start.
Page 123: Fault Tracing
Fault tracing 123 Fault tracing Contents of this chapter This chapter describes the fault tracing possibilities of the drive. LEDs Where Color When the LED is lit Control panel POWER Green Control unit is powered and +15 V is supplied to the control mounting platform panel FAULT...
Page 125: Maintenance
This chapter contains maintenance instructions of the drive module. Maintenance intervals The tables below show the maintenance tasks which can be done by the end user. The complete maintenance schedule is available on the Internet (www.abb.com/drivesservices). For more information, consult your local ABB Service representative www.abb.com/searchchannels).
Page 126: Cabinet
Note: • Maintenance and component replacement intervals are based on the assumption that the equipment is op- erated within the specified ratings and ambient conditions. ABB recommends annual drive inspections to ensure the highest reliability and optimum performance. • Long term operation near the specified maximum ratings or ambient conditions may require shorter mainten- ance intervals for certain components.
Page 127: Heatsink
Maintenance 127 Heatsink The drive module heatsink fins pick up dust from the cooling air. The drive runs into overtemperature warnings and faults if the heatsink is not clean. When necessary, clean the heatsink as follows. Cleaning the interior of the heatsink ￭...
Page 128 128 Maintenance...
Page 129: Fans
See the firmware manual for the actual signal which indicates the running time of the cooling fan. Reset the running time signal after fan replacement. Replacement fans are available from ABB. Do not use other than ABB specified spare parts. Replacing the circuit board compartment cooling fans ￭...
Page 130: Replacing The Main Cooling Fans
130 Maintenance Replacing the main cooling fans ￭ WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. 1. Stop the drive and do the steps in section Electrical safety precautions (page 18) before you start the work.
Page 131: Replacing The Drive Module
Maintenance 131 Replacing the drive module WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. Handle the drive module carefully: • Use safety shoes with a metal toe cap to prevent foot injury. •...
Page 132 132 Maintenance 3. For option +B051, remove the clear plastic shrouds on the power cables and parts in front of the drive module. 4. Disconnect the power cables. 5. Disconnect the external control cables from the drive module. 6. Remove the screws that attach the drive module to the cabinet at the top and behind the front support legs.
Page 133: Capacitors
Capacitor failure is usually followed by damage to the unit and an input cable fuse failure, or a fault trip. If you think that any capacitors in the drive have failed, contact ABB. Reforming the capacitors ￭...
Page 135: Technical Data
Technical data 135 Technical data Contents of this chapter This chapter contains the technical specifications of the drive, for example, the ratings, sizes and technical requirements, provisions for fulfilling the requirements for CE and other markings.
Page 136: Electrical Ratings
136 Technical data Electrical ratings IEC ratings ￭ ACH580-04-… Frame size Input Max. current Output ratings current Nominal use Light-duty use = 400 V 505A-4 585A-4 650A-4 725A-4 1020 820A-4 1020 880A-4 1100 3AXD00000586715 ACH580-04-… Frame size Input Max. current...
Page 137: Definitions
Note: The motor may have a derating on it too. Example 1, IEC: How to calculate the derated current The IP00 drive type is ACH580-04-725A-4, which has drive output current of 725 A. Calculate the derated drive output current (I ) at 4 kHz switching frequency, at 1500 m altitude and at 50 °C surrounding air temperature as follows:...
Page 138: Surrounding Air Temperature Derating
Surrounding air temperature derating (page 138): No derating is necessary for 35 °C surrounding air temperature. From the table in section IEC ratings (page 136), drive type ACH580-04-820A-4 exceeds the I requirement of 750 A. Surrounding air temperature derating ￭...
Page 139: Altitude Derating
1 percentage point for every added 100 m (328 ft). For example, the derating factor for 1500 m (4921 ft) is 0.95. For altitudes above 2000 m (6562 ft), contact ABB. If surrounding air temperature is below +40 °C, the derating can be reduced by 1.5 percentage points for every 1 °C reduction in temperature.
Page 140: Fuses (Iec)
Manufacturer Bussmann. Type (IEC 60269) = 3. Voltage rating 690 V. Ultrarapid (aR) fuses Type DIN 43653 (bolted style) Type DIN 43620 (blade style) Input ACH580-04-… current Nominal Nominal current current...
Page 141: Fuses (Ul)
Technical data 141 Fuses (UL) UL fuses for branch circuit protection per NEC are listed below. Obey local regulations. Input UL fuses ACH580-04-… current Manufacturer UL class Type = 480 V 505A-4 Bussmann JJS-600 585A-4 Ferraz A4BY800 650A-4 Ferraz A4BY800...
Page 142: Circuit Breakers (Iec)
142 Technical data Circuit breakers (IEC) The table below lists the circuit breakers that can be used with the drive. ACH580-04-… Frame ABB molded case circuit breaker (Tmax) size Product ID (Type) = 400 V 505A-4 1SDA054412R1 (T5H 630 PR221DS-LS/I In=630 3p F F)
Page 143 Technical data 143 Standard drive module configuration (IP00) and option +B051 (IP20 shrounds) 1662 Standard drive module configuration (IP00) and option +B051 (IP20 shrounds) Frame size Height Width Depth Weight* 57.55 13.78 20.81 65.43 13.78 20.81 Drive module with external control unit (option +P906) Frame size Height Width...
Page 144: Losses, Cooling Data And Noise
144 Technical data Losses, cooling data and noise Air flow Heat dissipation Noise Frame ACH580-04… size dB(A) 505A-4 1200 5602 585A-4 1200 6409 650A-4 1200 8122 725A-4 1200 8764 820A-4 1200 9862 880A-4 1420 10578 3AXD00000586715 Terminal and entry data for the power cables The maximum accepted cable size is 4 ×...
Page 145: Typical Power Cable Sizes
The table below gives copper and aluminium cable types with concentric copper shield for the drives with nominal current. See also section Terminal and entry data for the power cables (page 144). ACH580-04-… Cu cable Al cable = 400 V 505A-4 3 ×...
Page 146: Terminal Data For The Control Cables
Control unit (page 107). Electrical power network specification Voltage (U ACH580-04-xxxx-4 drive modules: 380...480 V AC 3-phase ±10%. This is indicated in the type designation label as typical input voltage levels 3~400/480 V AC. Network type TN (grounded) and IT (ungrounded) systems...
Page 147: Brake Resistor Connection Data
Note: Long cables cause a motor voltage decrease which limits the available motor power. 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 148: Ambient Conditions
148 Technical data Ambient conditions Environmental limits for the drive are given below. The drive is to be used in a heated, indoor, controlled environment. Operation Storage Transportation in the protective package in the protective package Installation site altitude For TN and TT neutral- grounded network systems and IT non-corner-groun- ded network systems: 0 to...
Page 149: Applicable Standards
IEC 62635 guidelines. To aid recyc- ling, plastic parts are marked with an appropriate identification code. Contact your local ABB distributor for further information on environmental aspects and recycling instructions for professional recyclers. End of life treatment must follow international and local regulations.
Page 150: Emc Compliance (Iec/En 61800-3:2004 + A2012)
150 Technical data BTL (BACnet Testing Laboratories) mark Product has BACnet conformance certificate. UL Listed mark for USA and Canada Product has been tested and evaluated against the relevant North American standards by the Un- derwriters Laboratories. Valid with rated voltages up to 600 V. EAC (Eurasian Conformity) mark Product complies with the technical regulations of the Eurasian Customs Union.
Page 151: Category C3
Technical data 151 Drive of category C1: drive of rated voltage less than 1000 V and intended for use in the first environment. Drive of category C2: drive of rated voltage less than 1000 V and intended to be installed and started up only by a professional when used in the first environment.
Page 152: Category C4
152 Technical data Category C4 ￭ The drive complies with the C4 category with these provisions: 1. It is ensured that no excessive emission is propagated to neighboring low-voltage networks. In some cases, the natural suppression in transformers and cables is sufficient. If in doubt, the supply transformer with static screening between the primary and secondary windings can be used.
Page 153: Ul And Csa Checklist
Technical data 153 UL and CSA checklist WARNING! Operation of this drive requires detailed installation and operation instructions provided in the hardware and software manuals. The manuals are provided in electronic format in the drive package or on the Internet. Keep the manuals with the drive at all times.
Page 154: Disclaimers
ABB and its affiliates are not liable for damages and/or losses related to such security breaches, any unauthorized...
Page 155: Dimension Drawings
Dimension drawings 155 Dimension drawings Contents of this chapter This chapter contains dimension drawings of the drive modules.
Page 156: R10 Standard Configuration
156 Dimension drawings R10 standard configuration...
Page 157: R10 With +E208+0H354+H356+H370+0H371
Dimension drawings 157 R10 with +E208+0H354+H356+H370+0H371...
Page 158: R10 With Option +B051
158 Dimension drawings R10 with option +B051...
Page 159: R10 With Option +E208 +H356 +P906
Dimension drawings 159 192 Tools R10-3-1 R10 with option +E208 +H356 +P906...
Page 160: R10 With Option +E208+0H371+H356+0H354+H370+P906
160 Dimension drawings Tools 191 R10-2-1 R10 with option +E208+0H371+H356+0H354+H370+P906...
Page 161: R10 With Option +B051 +P906
Dimension drawings 161 190 Tools R10 with option +B051 +P906 R10-1-1...
Page 162: R11 Standard Configuration
162 Dimension drawings R11 standard configuration...
Page 163: R11 With Option +E208+0H371+H356+0H354+H370
Dimension drawings 163 R11 with option +E208+0H371+H356+0H354+H370...
Page 164: R11 With Option +B051
164 Dimension drawings R11 with option +B051...
Page 165: R11 With Option +E208 +H356 +P906
Dimension drawings 165 R11 with option +E208 +H356 +P906...
Page 166: R11 With Option +E208+0H371+H356+0H354+H370+P906
166 Dimension drawings R11 with option +E208+0H371+H356+0H354+H370+P906...
Page 167: R11 With Option +B051 +P906
Dimension drawings 167 R11 with option +B051 +P906...
Page 168: Air Baffles For The Drive Module With Option +B051
168 Dimension drawings Air baffles for the drive module with option +B051 This drawing shows the dimensions of the hole in the air baffle around the drive module with option +B051. The drawing also shows the correct vertical location area of the air baffle as measured from the top grill.
Page 169: Example Circuit Diagram
Example circuit diagram 169 Example circuit diagram Contents of this chapter This chapter shows an example circuit diagram for a cabinet-installed drive module. Note that the diagram includes components which are not included in a basic delivery (* plus code options, ** other options, *** to be acquired by the customer). Example circuit diagram This diagram is an example for the main wiring of a drive cabinet.
Page 170 170 Example circuit diagram V20 V10 SOIA BGDR Cabinet Control panel CCU control unit ***Main contactor **Motor temperature supervision ***Switch fuse disconnector *Common mode filter **du/dt filter or sine filter Drive module Input and output signals Alarm Supply 360 degree grounding recommended...
Page 171: The Safe Torque Off Function
The Safe torque off function 171 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 172: Compliance With The European Machinery Directive
172 The Safe torque off function Standard Name IEC 61326-3-1:2017 Electrical equipment for measurement, control and laboratory use – EMC requirements – Part 3-1: Immunity requirements for safety-related systems and for equipment intended to perform safety-related functions (functional safety) – General industrial applications IEC 61508-1:2010 Functional safety of electrical/electronic/programmable electronic safety- related systems –...
Page 173: Wiring
The Safe torque off function 173 Wiring For the electrical specifications of the STO connection, see the technical data of the control unit. Connection principle ￭ Single ACH580-04 drive, internal power supply OUT1 + 24 V DC OUT2 + 24 V DC SGND...
Page 174: Wiring Examples
174 The Safe torque off function Drive Control unit Control logic To motor Activation switch Wiring examples ￭ Single ACH580-04 drive, internal power supply OUT1 OUT2 SGND Drive Safety PLC Safety relay Single ACH580-04 drive, external power supply 24 V DC...
Page 175: Multiple Ach580-04 Drives, Internal Power Supply
The Safe torque off function 175 Multiple ACH580-04 drives, internal power supply OUT1 + 24 V DC OUT2 + 24 V DC SGND OUT1 OUT2 SGND OUT1 OUT2 SGND Drive Control unit Activation switch...
Page 176: Multiple Ach580-04 Drives, External Power Supply
176 The Safe torque off function Multiple ACH580-04 drives, external power supply 24 V DC – OUT1 + 24 V DC OUT2 + 24 V DC SGND OUT1 OUT2 SGND OUT1 OUT2 SGND Drive Control unit Activation switch Activation switch ￭...
Page 177: Cable Types And Lengths
The Safe torque off function 177 • In case a manually operated activation switch is used, the switch must be of a type that can be locked out to the open position. • The contacts of the switch or relay must open/close within 200 ms of each other. •...
Page 178: Operation Principle
178 The Safe torque off function Operation principle 1. The Safe torque off activates (the activation switch is opened, or safety relay contacts open). 2. The STO inputs of the drive control unit de-energize. 3. The control unit cuts off the control voltage from the output IGBTs. 4.
Page 179: Start-Up Including Acceptance Test
The Safe torque off function 179 Start-up including acceptance test To ensure the safe operation of a safety function, validation is required. The final assembler of the machine must validate the function by performing an acceptance test. The acceptance test must be performed •...
Page 180 180 The Safe torque off function Action Test the operation of the STO function when the motor is running. • Start the drive and make sure the motor is running. • Open the STO circuit. The motor should stop. The drive generates an indication if one is defined for the 'running' state in parameter 31.22 (see the firmware manual).
Page 181: Use
The Safe torque off function 181 1. Open the activation switch, or activate the safety functionality that is wired to the STO connection. 2. The STO inputs on the drive control unit de-energize, and the control unit cuts off the control voltage from the output IGBTs.
Page 182: Maintenance
If any wiring or component change is needed after start up, or the parameters are restored, do the test given in section Acceptance test procedure (page 179). Use only spare parts approved by ABB. Record all maintenance and proof test activities in the machine logbook. Competence ￭...
Page 183: Fault Tracing
See the firmware manual of the drive control program for the indications generated by the drive, and for details on directing fault and warning indications to an output on the control unit for external diagnostics. Any failures of the Safe torque off function must be reported to ABB.
Page 184: Safety Data
184 The 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. MTTF SIL/ Frame size...
Page 185: Tüv Certificate
Mission time: the period of time covering the intended use of the safety function/device. After the mission time elapses, the safety device must be replaced. Note that any T values given cannot be regarded as a guarantee or warranty. TÜV certificate ￭ The TÜV certificate is available on the Internet at www.abb.com/drives/documents.
Page 186: Declaration Of Conformity
186 The Safe torque off function Declaration of conformity ￭...
Page 187: Resistor Braking
Resistor braking 187 Resistor braking Contents of this chapter This chapter describes how to select, protect and wire brake choppers and resistors. The chapter also contains the technical data. When is resistor braking necessary? Resistor braking is necessary for high capacity braking if a regenerative drive cannot be used.
Page 188: Resistor Cables
IGBT semiconductors of the brake chopper. Note: ABB has not verified that the EMC requirements are fulfilled with custom brake resistors and cabling. The customer must consider the EMC compliance of the complete installation.
Page 189: Placing The Brake Resistor
Note: If an external brake chopper (outside the drive module) is used, ABB always requires a main contactor.
Page 190: Selecting A Custom Brake Resistor
190 Resistor braking Selecting a custom brake resistor ￭ If you use other than ABB resistor, 1. make sure that the resistance of the custom resistor is greater than or equal to the resistance of the default ABB resistor. where...
Page 191: Mechanical Installation Of Resistors
Resistor braking 191 3. make sure that the resistor can dissipate the energy transferred to it during the braking: • Braking energy is not greater than the resistor heat dissipation capacity (E ) during the period specified. See the custom resistor specification. •...
Page 192: Connection Procedure
192 Resistor braking Connection procedure ￭ • Connect the resistor cables to the R+ and R- terminals in the same way as the other power cables. If a shielded three-conductor cable is used, cut the third conductor and ground the twisted shield of the cable (protective earth conductor of the resistor assembly) at both ends.
Page 193: Technical Data
Resistor braking 193 Technical data Ratings ￭ The table below gives the ratings for resistor braking. Internal brake chopper Example brake resistor(s) ACH580- brcont Rcont 04-… Type = 400 V 505A-4 2×SAFUR125F500 7200 584A-4 2×SAFUR200F500 10800 650A-4 2×SAFUR200F500 10800 725A-4 3×SAFUR200F500 16200 820A-4...
Page 194: Dimensions, Weights And Ordering Codes
194 Resistor braking Dimensions, weights and ordering codes 5 5 Ø 7 Brake resistor type Weight ABB ordering code SAFUR125F500 25 kg (55 lb) 68759285 SAFUR200F500 30 kg (66 lb) 68759340 Terminals and cable entry data ￭ See section Terminal and entry data for the power cables (page 144)
Page 195: External Control Unit (Option +P906)
External control unit (option +P906) 195 External control unit (option +P906) Contents of this chapter This chapter describes how to install CCU-24 as external control unit (option +P906). Dimension drawing is included. Product overview Option +P906 allows the drive control unit to be installed separately from the main drive module, for instance in a separate compartment.
Page 196: Layout
196 External control unit (option +P906) Layout ￭ Attaching points Duct for cables from drive module to be connec- ted to the ZBIB board at the back of the control unit. Connectors. For descriptions, see chapter Control unit. Cables ￭ These cables connect the control unit and the drive.
Page 197: Unpacking The Delivery
The external control unit is in a separate box inside the main drive module box. The control cables that will connect the external control unit to the drive module are connected to the drive module for safe transit. ABB recommends that you disconnect them before you install the drive module: 1.
Page 198: Installing The Control Unit
198 External control unit (option +P906) Installing the control unit Determine where the control unit is to be located. Take into account the cable lengths, the physical dimensions and mounting points of the control unit assembly (see section Dimension drawing (page 206)).
Page 199 External control unit (option +P906) 199 3. Pull the cables through the control unit assembly, so they appear in the opening at the rear of the control unit. Do not pull the ground conductor through, leave it outside the assembly. Check that the cables are not against sharp edges or bare live parts. 4.
Page 200 200 External control unit (option +P906) 5. Connect the grounding wire. 6. The kit includes a plate for the customer cable screens. Attach the small bracket (a) first, then the full clamp plate (b).
Page 201 External control unit (option +P906) 201 7. Mark and drill the required holes in the mounting plate for attaching the control unit. Be careful to control the swarf from the drill. 8. Lift the control unit onto the mounting screws. Tighten the screws. 9.
Page 202 202 External control unit (option +P906) 10. Ground the shields of the control cables at the clamp plate. The shields should be continuous as close to the terminals of the control unit as possible. Only remove the outer jacket of the cable at the cable clamp so that the clamp presses on the bare shield. The shield (especially in case of multiple shields) can also be terminated with a lug and fastened with a screw at the clamp plate.
Page 203: Connecting The Control Unit To The Drive Module
External control unit (option +P906) 203 Connecting the control unit to the drive module ￭ 1. Remove the middle front cover of the the drive module. A view of drive module with optional clear plastic shrouds is shown below. 2. Remove the cover plate from the control cable entry and put the rubber grommet in its place.
Page 204 204 External control unit (option +P906) 3. Connect the control cables to the drive module . Make sure that that cables are not against sharp edges or bare live parts Drive module ZBIB BPOW BGDR SOIA M4×8 Torx T20 2 N·m (18 lbf·in) BPOW X3:1 X3:1...
Page 205: Maintenance
External control unit (option +P906) 205 4. Connect the ground connection at the drive module end. Maintenance With the external control unit option +P906, the drive module removal procedure differs slightly from the instructions given in chapter Maintenance: before you detach the drive module, you must disconnect the control unit cables from the drive module in the following way: 1.
Page 206: Dimension Drawing
206 External control unit (option +P906) Dimension drawing...
Page 207: Chdi-01 115/230 V Digital Input Extension Module
CHDI-01 115/230 V digital input extension module 207 CHDI-01 115/230 V digital input extension module Contents of this chapter This chapter describes the optional CHDI-01 115/230 V digital input extension module. Product overview The CHDI-01 115/230 V digital input extension module expands the inputs of the drive control unit.
Page 208: Layout And Connection Examples
208 CHDI-01 115/230 V digital input extension module Layout and connection examples RO4C 115/230 V AC HDI7 RO4A 24 V DC HDI8 RO4B NEUTRAL 3-pin terminal blocks for 115/230 V inputs (1) Relay outputs (2) HDI7 115/230 V input 1 RO4C Common, C HDI8...
Page 209: Mechanical Installation
CHDI-01 115/230 V digital input extension module 209 Mechanical installation Necessary tools ￭ • Screwdriver and a set of suitable bits. Unpacking and examining the delivery ￭ 1. Open the option package. Make sure that the package contains: • the option module •...
Page 210: Parameter Setting Example For Relay Output
210 CHDI-01 115/230 V digital input extension module 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 Reverse...
Page 211: Dimension Drawing
CHDI-01 115/230 V digital input extension module 211 Dimension drawing The dimensions are in millimeters and [inches].
Page 213: Cmod-01 Multifunction Extension Module (External 24 V Ac/Dc And Digital I/O)
CMOD-01 multifunction extension module (external 24 V AC/DC and digital I/O) 213 CMOD-01 multifunction extension module (external 24 V AC/DC and digital I/O) Contents of this chapter This chapter describes the optional CMOD-01 multifunction extension module (external 24 V AC/DC and digital I/O). 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.
Page 214: Layout And Example Connections
214 CMOD-01 multifunction extension module (external 24 V AC/DC and digital I/O) Layout and example connections Grounding screw Diagnostic LED Hole for mounting screw 2-pin terminal block for external power supply (5) 3-pin terminal blocks for relay outputs (3) RO4C RO4A 24V AC/DC + in 24 V DC...
Page 215: Mechanical Installation
CMOD-01 multifunction extension module (external 24 V AC/DC and digital I/O) 215 Mechanical installation Necessary tools ￭ • Screwdriver and a set of suitable bits. Unpacking and examining the delivery ￭ 1. Open the option package. Make sure that the package contains: •...
Page 216: Start-Up
216 CMOD-01 multifunction extension module (external 24 V AC/DC and digital I/O) Start-up Setting the parameters ￭ 1. Power up the drive. 2. If no warning is shown, • make sure that the value of both parameters 15.01 Extension module type and 15.02 Detected extension module is CMOD-01.
Page 217: Diagnostics
CMOD-01 multifunction extension module (external 24 V AC/DC and digital I/O) 217 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 Installation Into an option slot on the drive control unit...
Page 218: Dimension Drawing
218 CMOD-01 multifunction extension module (external 24 V AC/DC and digital I/O) CMOD-01 24 V Plugged to drive SLOT2 Reinforced insulation (IEC 61800-5-1:2007) Functional insulation (IEC 61800-5-1:2007) Dimension drawing The dimensions are in millimeters and [inches].
Page 219: Cmod-02 Multifunction Extension Module (External 24 V Ac/Dc And Isolated Ptc Interface)
CMOD-02 multifunction extension module (external 24 V AC/DC and isolated PTC interface) 219 CMOD-02 multifunction extension module (external 24 V AC/DC and isolated PTC interface) Contents of this chapter This chapter describes the optional CMOD-02 multifunction extension module (external 24 V AC/DC and isolated PTC interface). 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...
Page 220: Layout And Example Connections
220 CMOD-02 multifunction extension module (external 24 V AC/DC and isolated PTC interface) Layout and example connections 2-pin terminal block for external power supply (3) 2-pin terminal block for relay output (4) CMOD-02 RO PTC C 24V AC/DC + in 24 V AC/DC 24V AC/DC - in PTC B...
Page 221: Unpacking And Examining The Delivery
CMOD-02 multifunction extension module (external 24 V AC/DC and isolated PTC interface) 221 Unpacking and examining the delivery ￭ 1. Open the option package. Make sure that the package contains: • the option module • a mounting screw. 2. Make sure that there are no signs of damage. Installing the module ￭...
Page 222: Diagnostics
222 CMOD-02 multifunction extension module (external 24 V AC/DC and isolated PTC interface) 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 Installation Into option slot 2 on the drive control unit...
Page 223: Dimension Drawing
CMOD-02 multifunction extension module (external 24 V AC/DC and isolated PTC interface) 223 CMOD-02 24 V RO PTC Plugged to drive SLOT2 Reinforced insulation (IEC 61800-5-1:2007) Functional insulation (IEC 61800-5-1:2007) Dimension drawing The dimensions are in millimeters and [inches].
Page 225: Filters
The du/dt filter types for the drive module types are given below. Frame du/dt filter type FOCH0610-70 FOCH0875-70 Ordering codes Filter type ABB ordering code FOCH-0610-70 68550483 FOCH-0875-70 3AUA0000125245 Description, installation and technical data of the FOCH filters See FOCH du/dt filters hardware manual (3AFE68577519 [English]).
Page 227: Ground-To-Phase Varistor Disconnecting Instructions - Iec, Not North America
Ground-to-phase varistor disconnecting instructions – IEC, not North America 227 Ground-to-phase varistor disconnecting instructions – IEC, not North America Contents of this chapter This chapter describes when and how to disconnect the ground-to-phase varistor. It gives guidelines for identifying power system types. Identifying the grounding system of the electrical power network WARNING!
Page 228: When To Disconnect Ground-To-Phase Varistor: Tn-S, It, Corner-Grounded Delta And Mid-Point-Grounded Delta Systems
228 Ground-to-phase varistor disconnecting instructions – IEC, not North America The table below shows the line-to-ground voltages in relation to the line-to-line voltage for each grounding system. Electrical power system type L1-G L2-G L3-G Symmetrically grounded TN system (TN-S sys- 0.58·X 0.58·X 0.58·X...
Page 229 Ground-to-phase varistor disconnecting instructions – IEC, not North America 229 Do not disconnect VAR wire. IT systems (ungrounded or highresistance-grounded [>30 ohms]) Disconnect VAR wire.
Page 230: Guidelines For Installing The Drive To A Tt System
Note: • 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 231: Connecting Emc Filter And Ground-To-Phase Varistor - North America
Connecting EMC filter and ground-to-phase varistor – North America 231 Connecting EMC filter and ground-to-phase varistor – North America Contents of this chapter This chapter describes when and how to Connect the EMC filter and ground-to-phase varistor. It gives guidelines for identifying power system types. Identifying the grounding system of the electrical power network WARNING!
Page 232: When You Can Connect The Emc Filter And Ground-To-Phase Varistor: Tn-S, It, Corner-Grounded Delta And Mid-Point-Grounded Delta Systems
232 Connecting EMC filter and ground-to-phase varistor – North America The table below shows the line-to-ground voltages in relation to the line-to-line voltage for each grounding system. Electrical power system type L1-G L2-G L3-G Symmetrically grounded TN system (TN-S sys- 0.58·X 0.58·X 0.58·X...
Page 233: Connecting Emc Filter - North America
If you are concerned with EMC issues, and install the drive to a symmetrically grounded TN-S system, corner-grounded delta or mid-point-grounded delta system, you can connect the internal EMC filter. Contact ABB for the connection instructions. Connecting ground-to-phase varistor – North America This section is valid the UL (NEC) drive types.
Page 235: Step-By-Step Drawings For An Installation Example Of A Drive Module With The +B051 Option In A Rittal Vx25 600 Mm Wide Enclosure
Step-by-step drawings for an installation example of a drive module with the +B051 option in a Rittal VX25 600 mm wide enclosure 235 27. Step-by-step drawings for an installation example of a drive module with the +B051 option in a Rittal VX25 600 mm wide enclosure...
Page 236 236 Step-by-step drawings for an installation example of a drive module with the +B051 option in a Rittal VX25 600 mm wide enclosure Tapping screw M6×12 Torx Combi screw M8×30 (Hex) Tapping screw M6×12 Torx Rittal 8617.030 T30 (Hex) 9 N·m (80 lbf·in) T30 (Hex) 9 N·m (80 lbf·in) 20 N·m (14.75 lbf·ft) Combi screw M4×8 Torx...
Page 237 Step-by-step drawings for an installation example of a drive module with the +B051 option in a Rittal VX25 600 mm wide enclosure 237 Combi screw M12×25 Hex 70 N·m (52 lbf·ft) Combi screw M8×16 Hex Hex nut M12 70 N·m (52 lbf·ft) 20 N·m (14.75 lbf·ft) Combi screw M12×25 Hex Combi screw M6×12 Torx T25...
Page 238 238 Step-by-step drawings for an installation example of a drive module with the +B051 option in a Rittal VX25 600 mm wide enclosure lbf·ft) Hex nut M12 70 N·m (52 Washer M12 or equal Hex screw M12×35 full thread 70 N·m (52 lbf·ft) Washer M12 or equal +B051...
Page 239 Step-by-step drawings for an installation example of a drive module with the +B051 option in a Rittal VX25 600 mm wide enclosure 239 Note: These air baffles are compatible with option +B051 only. For the standard drive module configuration see section Standard drive module configuration.
Page 240 240 Step-by-step drawings for an installation example of a drive module with the +B051 option in a Rittal VX25 600 mm wide enclosure...
Page 241: Further Information
Product and service inquiries Address any inquiries about the product to your local ABB representative, quoting the type designation and serial number of the unit in question. A listing of ABB sales, support and service contacts can be found by navigating to www.abb.com/searchchannels.

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