ABB ACS580-07 Hardware Manual
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ABB ACS580-07 Hardware Manual

ABB ACS580-07 Hardware Manual

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ABB GENERAL PURPOSE DRIVES
ACS580-07
Hardware manual

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Summary of Contents for ABB ACS580-07

  • Page 1 — ABB GENERAL PURPOSE DRIVES ACS580-07 Hardware manual...
  • Page 3 ACS580-07 Hardware manual Table of contents 1. Safety instructions 4. Mechanical installation 5. Guidelines for planning the electrical installation 6. Electrical installation 9. Start-up 3AXD50000045815 Rev G Original instructions EFFECTIVE: 2024-05-15...

  • Page 5: Table Of Contents

    Table of contents 5 Table of contents 1 Safety instructions Contents of this chapter ............... . Use of warnings and notes .
  • Page 6 6 Table of contents Control panel ................. . . Control by PC tools .
  • Page 7 Additional requirements for braking applications ....... . . Additional requirements for ABB high-output and IP23 motors ....
  • Page 8 8 Table of contents Signals that can be run in the same cable ..........Relay cable .

  • Page 9: Table Of Contents

    Layout CCU-24 ..................Default I/O connections for ACS580 ABB standard macro ......
  • Page 10 10 Table of contents Checklist ................... . 9 Start-up Contents of this chapter .
  • Page 11 Table of contents 11 Definitions ..................Output derating .
  • Page 12 Single ACS580-07 drive, internal power supply ........
  • Page 13 Table of contents 13 Multiple ACS580-07 drives, internal power supply ....... . .
  • Page 14 14 Table of contents 16 Disconnecting EMC filter and ground-to-phase varistor When to disconnect the ground-to-phase varistor: TN-S, IT, corner-grounded delta, midpoint-grounded delta and TT systems ..........Identifying the grounding system of the electrical power network .
  • Page 15 Table of contents 15 19 CHDI-01 115/230 V digital input extension module Contents of this chapter ............... . Product overview .
  • Page 16 16 Table of contents Start-up ................... . . Setting the parameters .

  • Page 17: Safety Instructions

    Safety instructions 17 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 18: General Safety In Installation, Start-Up And Maintenance

    18 Safety instructions General safety in installation, start-up and maintenance These instructions are for all personnel who do work on the drive. WARNING! Obey these instructions. If you ignore them, injury or death, or damage to the equipment can occur. •...
  • Page 19 Safety instructions 19 • Before you adjust the drive operation limits, make sure that the motor and all driven equipment can operate throughout the set operation limits. • Before you activate the automatic fault reset or automatic restart functions of the drive control program, make sure that no dangerous situations can occur.

  • Page 20: Electrical Safety In Installation, Start-Up And Maintenance

    20 Safety instructions Electrical safety in installation, start-up and maintenance Electrical safety precautions ￭ These electrical safety precautions are for all personnel who do work on the drive, motor cable or motor. WARNING! Obey these instructions. If you ignore them, injury or death, or damage to the equipment can occur.
  • Page 21 Safety instructions 21 Measuring points of frames R4…R9 are shown below. L1, L2, L3...

  • Page 22: Additional Instructions And Notes

    22 Safety instructions Measuring points of frames R10 and R11 are shown below. You can also remove the metallic shield and measure through the holes in the clear plastic shroud behind it. L1 L2 • Make sure that the voltage between the drive output terminals (U, V, W) and the grounding (PE) busbar is zero.

  • Page 23: Printed Circuit Boards

    There are electromagnetic fields present which can interfere with the function of such devices. This can cause a health hazard. • ABB does not recommend attaching the cabinet by arc welding. If you have to, obey the welding instructions in the drive manuals. Note: •...

  • Page 24: General Safety In Operation

    24 Safety instructions • When using shielded cables, make a 360° grounding of the cable shields at the cable entries to reduce electromagnetic emission and interference. • In a multiple-drive installation, connect each drive separately to the protective earth (PE) busbar of the power supply. General safety in operation These instructions are for all personnel that operate the drive.

  • Page 25: Additional Instructions For Permanent Magnet Motor Drives

    Safety instructions 25 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 27: Introduction To The Manual

    Introduction to the manual 27 Introduction to the manual Contents of this chapter This chapter describes the intended audience and contents of the manual. It contains a flowchart of steps in examining the delivery, installing and commissioning the drive. The flowchart refers to chapters/sections in this manual and other manuals. Target audience This manual is intended for people who plan the installation, install, commission and do maintenance work on the drive, or create instructions for the end user of the drive...

  • Page 28: Quick Installation Flowchart

    28 Introduction to the manual Quick installation flowchart Task Guidelines for planning the Plan the electrical installation and acquire the accessories needed (cables, electrical installa- fuses, etc.). tion (page 79) Check the ratings, required cooling air flow, input power connection, compatibility of the motor, motor connection, and other technical data.

  • Page 29: Related Documents

    Safe torque off (IEC/EN 61800-5-2) TN system Type of supply network that provides a direct connection to ground Related documents You can find manuals on the Internet. See below for the relevant code/link. For more documentation, go to www.abb.com/drives/documents. ACS580-07 manuals...

  • Page 31: Operation Principle And Hardware Description

    Operation principle and hardware description 31 Operation principle and hardware description Contents of this chapter This chapter briefly describes the operation principle and construction of the drive.

  • Page 32: Product Overview

    32 Operation principle and hardware description Product overview The ACS580-07 is a drive module for controlling AC induction motors, synchronous reluctance motors and synchronous permanent magnet motors in open loop control. The single-line circuit of the drive is shown below.
  • Page 33 Operation principle and hardware description 33 The main circuit with brake chopper (option +D150) is shown below. ACS580-07 cabinet Drive module Brake resistor connection terminals cubicle Rectifier. Converts alternating current and voltage to direct current and voltage. Intermediate DC circuit Inverter.

  • Page 34: Layout

    34 Operation principle and hardware description Layout „ „ General information on the cabinet layout ￭ IP21 IP42 UL Type 1 UL Type 1 Filtered (option +B054) IP54 UL Type 12 (option +B055)

  • Page 35: Cabinet Layout - R4 And R5 (Bottom Entry And Exit Of Cables)

    Operation principle and hardware description 35 Cabinet layout – R4 and R5 (bottom entry and exit of cables) ￭ The cabinet layout of frame R4 with du/dt filter (option +E205) is shown below. Degree of protection IP42 (Filtered [option +B054]). Frame R5 looks similar. Cabinet door closed Input cable connection terminals Cabinet door open...

  • Page 36: Cabinet Layout - R6 And R7 (Bottom Entry And Exit Of Cables)

    36 Operation principle and hardware description Cabinet layout – R6 and R7 (bottom entry and exit of cables) ￭ The cabinet layout of frame R7 with du/dt filter (option +E205) is shown below. Degree of protection IP42 (UL Type 1 Filtered [option +B054]). Frame R6 looks similar. Cabinet door closed Auxiliary voltage transformer T21 Cabinet door open...

  • Page 37: Cabinet Layout - R4 To R7

    Operation principle and hardware description 37 Cabinet layout – R4 to R7 (top entry and exit of cables, options +H351 ￭ and +H353) Cabinet door closed Auxiliary voltage transformer T21 Cabinet door open Motor cable connection terminals Cabinet door open and motor cable cubicle Input cable connection terminals cover removed Drive control panel...

  • Page 38: Cabinet Layout - R8 And R9 (Bottom Entry And Exit Of Cables)

    38 Operation principle and hardware description Cabinet layout – R8 and R9 (bottom entry and exit of cables) ￭ The cabinet layout of frame R9 with du/dt filter (option +E205) is shown below. Degree of protection IP42 (UL Type 1 Filtered [option +B054]). Frame R8 looks similar. Cabinet door closed Input cable connection terminals Cabinet door open...

  • Page 39: Cabinet Layout - R8 And R9 (Top Entry And Exit Of Cables, Options +H351 And +H353)

    Operation principle and hardware description 39 Cabinet layout – R8 and R9 (top entry and exit of cables, options ￭ +H351 and +H353) Cabinet door closed Input cable connection terminals Cabinet door open Main switch-disconnector (Q1) Cabinet door open, mounting plates and cab- AC fuses inet shrouds removed Drive control panel...

  • Page 40: Mounting Plate - R4 To R9

    40 Operation principle and hardware description Mounting plate – R4 to R9 ￭ The components and terminals on the mounting plate of frames R6 to R9 are shown below. The layout of frames R4 and R5 is similar. +G300 Switch-disconnector and miniature circuit External main contactor control breaker for cabinet heater (option +G300) Emergency stop relay for options +Q951...
  • Page 41 Operation principle and hardware description 41 Terminals for X250 X250 Auxiliary contacts of line contactor (option +F250) X289 Auxiliary contacts of molded case circuit breaker (option +F289) X951 Push buttons for emergency stop option +Q951 or +Q963. See section Connecting the emergency stop push buttons (options +Q951 and +Q963) (page 131).

  • Page 42: Cabinet Layout - R10 And R11 (Bottom Entry And Exit Of Cables)

    42 Operation principle and hardware description Cabinet layout – R10 and R11 (bottom entry and exit of cables) ￭ Cabinet door closed AC fuses Cabinet door open Line contactor (option +F250) Gratings for cooling air out Lifting lugs Operating switch Drive control unit Drive control panel Mounting plate, see section...
  • Page 43 Operation principle and hardware description 43 Cabinet door open, mounting plates and cab- Input cable connection terminals inet shrouds removed Power and control cable entries Drive module Motor cable connection terminals Auxiliary voltage transformer T21...

  • Page 44: Cabinet Layout - R10 And R11 (Top Entry And Exit Of Cables, Options +H351 And +H353)

    44 Operation principle and hardware description Cabinet layout – R10 and R11 (top entry and exit of cables, options ￭ +H351 and +H353) Cabinet door closed Lifting lugs Cabinet door open Cubicle for motor cabling Gratings for cooling air out Drive control unit Drive control panel Mounting plate, see section...

  • Page 45: Cabinet Layout - Brake Resistor Cabling With Option +D150

    Operation principle and hardware description 45 Cabinet door open, lower shrouds and motor Auriliary voltage transformer T21 cable cubicle cover removed Input cable connection terminals behind the Drive module shroud Motor cable connection terminals Cabinet layout – Brake resistor cabling with option +D150 ￭...
  • Page 46 46 Operation principle and hardware description Drive control unit X289 Indication of the status of the molded case circuit breaker (option +F289) Emergency stop relay for options +Q951 X300 Connection terminals for cabinet heater and +Q963 (option +G300) Q95, F95 Switch-disconnector and miniature circuit X951 Connection of external emergency stop...

  • Page 47: Cooling Air Flow

    Operation principle and hardware description 47 Cooling air flow ￭ The figures below show cooling air flow trough the cabinet. Frames R4...R9 (Side view) Frames R10 and R11 (Front view)

  • Page 48: Door Switches And Lights

    48 Operation principle and hardware description Door switches and lights ￭ Label in English Label in local lan- Description guage READY Ready pilot light (option +G327) Run pilot light (option+G328) FAULT Fault pilot light (option +G329) MAIN CONTACTOR Operating switch with option +F250 OFF ON Opens the main contactor (Q2) and disables starting of the drive...

  • Page 49: Control By Pc Tools

    Operation principle and hardware description 49 Control by PC tools There is a USB connector on the front of the panel that can be used to connect a PC to the drive. When a PC is connected to the control panel, the control panel keypad is disabled.

  • Page 50: Overview Of Power And Control Connections

    50 Operation principle and hardware description Overview of power and control connections This diagram shows the power connections and control interfaces of the drive frames R4 and R5. 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 d u /d t filter (option +E205) (page 53)

  • Page 51: Descriptions Of Options

    Operation principle and hardware description 51 „ This diagram shows the power connections and control interfaces of the drive frames R6…R11. SLOT 1 SLOT 2 M 3 ~ Option slot 1 for optional fieldbus adapter modules Option slot 2 for optional I/O extension modules Embedded fieldbus connector Panel port I/O terminal blocks.

  • Page 52: Degree Of Protection

    52 Operation principle and hardware description Degree of protection ￭ Definitions According to IEC/EN 60529, the degree of protection is indicated by an IP code where the first numeral means protection against ingress of solid foreign objects, and the second numeral protection against ingress of water. The IP codes of the standard cabinet and options covered in this manual are defined below.

  • Page 53: Plinth Height (Options +C164 And +C179)

    Operation principle and hardware description 53 With option +B055, this option also provides the cabinet air inlets with filter housings containing folded board air filter mats between the inner and outer metallic gratings. See also section Air outlet duct on the cabinet roof (option +C130) (page 77).

  • Page 54: Cabinet Heater With External Supply (Option +G300)

    54 Operation principle and hardware description Cabinet heater with external supply (option +G300) ￭ The option contains: • heating elements in the cubicles or supply/inverter modules • load switch for providing electrical isolation during service • miniature circuit breaker for overcurrent protection •...

  • Page 55: European Cable Entry (Option +H357)

    Connectivity for wired remote monitoring (option +K496) ￭ This option provides a gateway to connect the drive to ABB Ability™ via a local Ethernet network. Includes NETA-21 remote monitoring tool and FMBT-21 Modbus/TCP adapter module. See the appropriate manual for more information.

  • Page 56: Thermal Protection With Pt100 Relays (Option +Nl506)

    56 Operation principle and hardware description Note: The optional modules inserted in the slots of the control unit are not wired to the additional terminal block. The customer must connect the optional module control wires directly to the modules. Cables accepted by the terminals of the additional I/O terminal block: •...

  • Page 57: Type Designation Label

    Operation principle and hardware description 57 See the circuit diagrams delivered with the drive for the actual wiring. Type designation label The type designation label includes an IEC rating, appropriate markings, a type designation and a serial number, which allow identification of each unit. The type designation label is located on the front cover.

  • Page 58: Basic Code

    58 Operation principle and hardware description Basic code ￭ Code Description ACS580 Product series Type The standard delivery includes: cabinet-installed drive, IP21, main switch, AC fuses, ACS-AP- S assistant control panel, EMC filtering for second environment TN grounded systems (cat- egory C3), input choke, common mode filter in frames R10 and R11, coated boards, ACS580 standard control program, EIA/RS-485 fieldbus connector, Safe torque off function, bottom entry and exit of cables, multilingual device label sticker, USB memory stick containing dimen-...
  • Page 59 Operation principle and hardware description 59 Code Description E202 EMC/RFI filter for 1st environment TN (grounded) system, category C2 d u /d t filtering E205 E208 Common mode filtering F250 Main (line) contactor F289 MCCB circuit breaker Cabinet and module heating elements (external supply). See section Cabinet heater with ex- G300 ternal supply (option +G300) (page...
  • Page 60 60 Operation principle and hardware description Code Description M600 Starter for auxiliary motor fan, trip limit 1 … 1.6 A M601 Starter for auxiliary motor fan, trip limit 1.6 … 2.5 A M602 Starter for auxiliary motor fan, trip limit 2.5 … 4 A M603 Starter for auxiliary motor fan, trip limit 4 …...

  • Page 61: Mechanical Installation

    Mechanical installation 61 Mechanical installation Contents of this chapter This chapter describes the mechanical installation procedure of the drive. Examining the installation site Examine the installation site. Make sure that: • The installation site is sufficiently ventilated or cooled to remove heat from the drive.

  • Page 62: Necessary Tools

    62 Mechanical installation Do not install the drive on an elevated platform or a recess. The module extraction/installation ramp included with the drive is only suitable for a height difference of 50 mm (2 in) maximum (ie. the standard plinth height of the drive). Necessary tools The tools required for moving the unit to its final position, fastening it to the floor and wall and tightening the connections are listed below:...
  • Page 63 Mechanical installation 63 Vertical package (frames R10 and R11): 1088 Lifting the transport package with slings. Lifting points Lifting the transport package with forklift...

  • Page 64: Unpacking The Transport Package

    64 Mechanical installation „ Unpacking the transport package ￭ This drawing shows the layout of the horizontal transport package. Bracket for attaching the drive to the wooden Timber pallet Cardboard packing hood Drive cabinet Wooden pallet Plinth (delivered in a separate package for frames R4…R9) Straps Unpack the horizontal transport package as follows:...

  • Page 65: Examining The Delivery

    Mechanical installation 65 Examining the delivery ￭ The drive delivery contains: • drive cabinet line-up • optional modules (if ordered) installed onto the control unit(s) at the factory • appropriate drive and optional module manuals • delivery documents. Make sure that there are no signs of damage. Before attempting installation and operation, see the information on the type designation labels of the drive to verify that the delivery is of the correct type.

  • Page 66: Lifting Lugs

    Lift the cabinet to its position. Maximum allowed angle of the lifting slings is 20° (10° for frames R10 and R11, IP54). Max. 10 ° ° Max. 20 R10, R11 IP54 „ Lifting lugs Certificate of conformity The certificate is available in ABB Library at www.abb.com/drives/documents (document number 3AXD10001061361).
  • Page 67 Mechanical installation 67 Declarations of conformity...
  • Page 68 68 Mechanical installation...
  • Page 69 Mechanical installation 69 Declaration of Conformity Supply of Machinery (Safety) Regulations 2008 Manufacturer: ABB Oy Address: Hiomotie 13, 00380 Helsinki, Finland. Phone: +358 10 22 11 declare under our sole responsibility that the following products: Lifting bars, identified with material codes...

  • Page 70: Moving The Cabinet After Unpacking

    Supply of Machinery (Safety) Regulations 2008. Authorized to compile the technical file: ABB Oy, Hiomotie 13, 00380 Helsinki, Finland Helsinki, 28 May 2021 Signed for and on behalf of:...

  • Page 71: Moving The Cabinet On Rollers

    Mechanical installation 71 Moving the cabinet on rollers Lay the cabinet on the rollers and move it carefully until close to its final location. Remove the rollers by lifting the unit with a crane, forklift, pallet truck or jack. Moving the cabinet to its final position Move the cabinet into its final position with a slate bar (spud bar).
  • Page 72 72 Mechanical installation > 400 mm (15.75”) 120° Note 1: Any height adjustment must be done before attaching the cabinet sections to the floor or to each other. Height adjustment can be done by using metal shims between the cabinet bottom and floor. Note 2: Depending on the size of the cabinet, it has either bolt-on lifting eyes, or lifting bars with lifting holes.

  • Page 73: Attaching The Cabinet (Non-Marine Units)

    Mechanical installation 73 Attaching the cabinet (non-marine units) ￭ Alternative 1 – Clamping Insert the clamps (included) into the twin slots along the front and rear edges of the cabinet frame body and fasten them to the floor with a bolt. The recommended maximum distance between the clamps in the front edge is 800 mm (31.5”).

  • Page 74: Alternative 2 - Using The Holes Inside The Cabinet

    74 Mechanical installation Alternative 2 – Using the holes inside the cabinet Attach the cabinet to the floor through the bottom fastening holes with size M10…M12 (3/8”…1/2”) bolts. The recommended maximum distance between the front edge fastening points is 800 mm (31.5”). If the back fastening holes are not accessible, attach the top of the cabinet to the wall with L-brackets (not included in the delivery) bolted to the lifting eye/bar holes.

  • Page 75: Alternative 3 - Cabinets With Plinth Options +C164 And +C179

    Mechanical installation 75 Alternative 3 – Cabinets with plinth options +C164 and +C179 Frames R4…R9 Attach the plinth to the floor with the brackets included in the plinth package. Lift the cabinet onto the plinth and attach it to the plinth with the L-brackets delivered with the plinth.

  • Page 76: Miscellaneous

    Arc welding ￭ ABB does not recommend attaching the cabinet by arc welding. However, if arc welding is the only option, connect the return conductor of the welding equipment to the cabinet frame at the bottom within 0.5 meters (1’6”) of the welding point.

  • Page 77: Air Outlet Duct On The Cabinet Roof (Option +C130)

    Mechanical installation 77 Air inlet area Support the plinth of the cabinet all round. The air duct must be able to supply a sufficient volume of cooling air. See technical data for the minimum air flow values. WARNING! Make sure that the incoming air is sufficiently clean. If not, dust goes into the cabinet.

  • Page 78: Calculating The Required Static Pressure Difference

    78 Mechanical installation Calculating the required static pressure difference The required static pressure difference between the exit air duct and the drive installation room can be calculated as follows: Δ p = (1.5…2) · p where = 0.5 · ρ · v = q / A Dynamic pressure ρ...

  • Page 79: Guidelines For Planning The Electrical Installation

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

  • Page 80: Examining The Compatibility Of The Motor And Drive

    Examining the compatibility of the motor and drive Use asynchronous AC induction motors, permanent magnet synchronous motors 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 81: Requirements For Abb Motors, P

    Nominal AC line Requirement for voltage Motor insula- ABB d u /d t and common mode filters, insulated tion system N-end motor bearings < 100 kW and frame size < IEC 315 < 134 hp and frame size < NEMA 500 Random-wound ≤...

  • Page 82: Requirements For Abb Motors, P

    84). Motor type Nominal AC line Requirement for voltage Motor insula- ABB d u /d t and common mode filters, insulated tion system N-end motor bearings 100 kW ≤ P < 350 kW ≥ 350 kW IEC 315 ≤ frame size <...

  • Page 83: Requirements For Non-Abb Motors, P

    Nominal AC line Requirement for voltage Motor insula- ABB d u /d t and common mode filters, insulated tion system N-end motor bearings < 100 kW and frame size < IEC 315 < 134 hp and frame size < NEMA 500 Random-wound and ≤...

  • Page 84: Requirements For Non-Abb Motors, P

    84). Motor type Nominal AC line Requirement for voltage Motor insula- ABB d u /d t and common mode filters, insulated tion system N-end motor bearings 100 kW ≤ P < 350 kW ≥ 350 kW IEC 315 ≤ frame size <...

  • Page 85: Availability Of D U /D T 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...

  • Page 86: Additional Data For Calculating The Rise Time And The Peak Line-To-Line Voltage

    If motor power is above 350 kW: Consult the motor manufacturer. Nominal AC supply Requirement for voltage Motor insulation system ABB d u /d t and common mode filters, insulated N- end motor bearings < 100 kW or frame size 100 kW < P < 350 kW or <...

  • Page 87: Additional Note For Sine Filters

    Guidelines for planning the electrical installation 87 Û du/dt ------------ - (1/ s) l (m) du/dt ------------ - (1/ s) Û l (m) Drive with d u /d t filter Drive without d u /d t filter Motor cable length Û...

  • Page 88: Selecting The Power Cables

    88 Guidelines for planning the electrical installation Selecting the power cables General guidelines ￭ Select the input power and motor cables according to local regulations. • Current: Select a cable capable of carrying the maximum load current and suitable for the prospective short-circuit current provided by the supply network. The method of installation and ambient temperature affect the cable current carrying capacity.

  • Page 89: Alternate Power Cable Types

    Guidelines for planning the electrical installation 89 Cable type Use as input power cabling Use as motor cabling and as brake resistor cabling Symmetrical shielded (or ar- mored) cable with three phase conductors and symmetrically constructed PE conductor and a shield (or armor) Symmetrical shielded (or ar- mored) cable with three phase...

  • Page 90: Not Allowed Power Cable Types

    Symmetrical shielded cable with individual shields for each phase conductor Additional guidelines – North America ￭ ABB recommends the use of metallic conduit for power wiring. ABB also recommends the use of symmetrical shielded VFD cable between drive and motor(s).

  • Page 91: Metal Conduit

    Guidelines for planning the electrical installation 91 This table shows examples of methods for wiring the drive. Refer to NFPA 70 (NEC) along with state and local codes for the appropriate methods for your application. Wiring method Notes 1) 2) Conduit - Metallic Electrical metallic tubing: Type EMT Prefer symmetrical shielded VFD cable.

  • Page 92: Grounding Requirements

    92 Guidelines for planning the electrical installation Insulation jacket Helix of copper tape or copper wire Copper wire shield Inner insulation Cable core Grounding requirements This section gives general requirements for grounding the drive. When you plan the grounding of the drive, obey all the applicable national and local regulations. The conductivity of the protective earth conductor(s) must be sufficient.

  • Page 93: Additional Grounding Requirements - Iec

    ￭ Only use shielded control cables. Use a double-shielded twisted pair cable for analog signals. ABB recommends this type of cable also for the pulse encoder signals. Use one individually shielded pair for each signal. Do not use common return for different analog signals.

  • Page 94: 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, Cat 5e (or better) cable with male RJ-45 connectors. The maximum length of the cable is 100 m (328 ft).

  • Page 95: General Guidelines - North America

    Guidelines for planning the electrical installation 95 The following figure illustrates the cable routing guidelines with an example drive. Note: When motor cable is symmetrical and shielded and it has short parallel runs with other cables (< 1.5 m / 5 ft), distances between the motor cable and other cables can be reduced by half.

  • Page 96: The Motor Cable

    96 Guidelines for planning the electrical installation Input power cabling Motor cabling Conduit Continuous motor cable shield/conduit and metal enclosure for ￭ equipment on the motor cable To minimize the emission level when safety switches, contactors, connection boxes or similar equipment are installed on the motor cable between the drive and the motor: •...

  • Page 97: Situations And Against Thermal Overload

    The drive protects the motor cable and motor in a short-circuit situation when: • the motor cable is sized correctly • the motor cable type complies with the motor cable selection guidelines by ABB • the cable length does not exceed the allowed maximum length specified for the drive •...

  • Page 98: Protecting The Motor Against Thermal Overload

    98 Guidelines for planning the electrical installation WARNING! If the drive is connected to multiple motors, use a separate circuit breaker or fuses for protecting each motor cable and motor against overload. The drive overload protection is tuned for the total motor load. It may not trip due to an overload in one motor circuit only.

  • Page 99: Implementing The Emergency Stop Function

    Option User’s manual Manual code code (English) +Q951 Emergency stop, stop category 0 (option +Q951) for ACS580-07, ACH580- 3AXD50000171828 07 and ACQ580-07 drives user's manual +Q963 Emergency Stop, Category 0 (option +Q963) without opening main 3AXD50000171835 contactor with safety relay for ACS580-07, ACH580-07 and ACQ580-07...

  • Page 100: 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 101: Implementing A Bypass Connection

    IEC/EN/UL 61800-5-1, subclause 6.5.3, for example, “THIS MACHINE STARTS AUTOMATICALLY”. Bypass connection is available as a factory-installed option for some cabinet-installed drive types. Consult ABB for more information. WARNING! Never connect the drive output to the electrical power network. The connection may damage the drive.

  • Page 102: Implementing A Motor Temperature Sensor Connection

    102 Guidelines for planning the electrical installation 230 V AC 230 V AC + 24 V DC Relay output Varistor RC filter Diode Implementing a motor temperature sensor connection WARNING! IEC 61800-5-1 requires double or reinforced insulation between live parts and accessible parts when: •...

  • Page 103: Connecting A Motor Temperature Sensor To The Drive Through An Option Module

    Guidelines for planning the electrical installation 103 Connecting a motor temperature sensor to the drive through an ￭ option module This table shows: • option module types that you can use for the motor temperature sensor connection • insulation or isolation level that each option module forms between its temperature sensor connector and other connectors •...

  • Page 105: Electrical Installation

    Electrical installation 105 Electrical installation Contents of this chapter This chapter gives instructions on the wiring of the drive. Warning WARNING! If you are not a qualified electrical professional, do not do installation or maintenance work. Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur.

  • Page 106: Layout Of The Cable Entries (Frames R4

    106 Electrical installation Layout of the cable entries (frames R4…R9) The layout of the input and motor cable connection terminals of frame R9 bottom entry without du/dt filter option (+E205) is shown below. The shrouds in front of the terminals have been removed. The layout is similar for the other frame sizes. L1, L2, L3 Input power cable terminals U2, V2, W2...

  • Page 107: Layout Of The Cable Entries (Frames R10 And R11)

    Electrical installation 107 Layout of the cable entries (frames R10 and R11) The layout of the input and motor cable connection terminals of frame R10 bottom entry is shown below. The shrouds in front of the terminals are removed. The layout is similar for frame R11.

  • Page 108: 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 109: Grounding System Compatibility Check

    Electrical installation 109 Grounding system compatibility check The standard drive can be installed to a symmetrically grounded TN-S system. If you install the drive to another system, you may need to disconnect the EMC filter and ground-to-phase varistor. See sections When to disconnect the ground-to-phase varistor: TN-S, IT, corner-grounded delta, midpoint-grounded delta and TT systems (page...
  • Page 110 110 Electrical installation Prepare the ends of the cables. Put the cables through the entry plate. If the entry holes have rubber grommets, use one grommet for each cable. Cut adequate hole into the grommet and put the cable through the grommet inside the cabinet. Attach the conductive sleeves to the cable shields with cable ties.

  • Page 111: Connection Diagram

    Electrical installation 111 Connection diagram ￭ UDC+ T1/ T2/ T3/ R+ UDC- UDC- UDC+ (PE) (PE) 3 ~ M Drive cabinet Use a separate grounding PE cable (1a) or a cable with a separate PE conductor (1b) if the conduct- ivity of the shield does not meet the requirements for the PE conductor (see Selecting the power cables (page...
  • Page 112 112 Electrical installation 360° grounding is required. Line contactor (option +F250) Common mode filter (option +E208) d u /d t filter (option +E205) Use a separate grounding cable if the shield does not meet the requirements of IEC 61439-1 (see Selecting the power cables (page 88)) and there is no symmetrically constructed grounding con- ductor in the cable (see...

  • Page 113: Connection Procedure (Frames R4

    Electrical installation 113 Connection procedure (frames R4…R9) ￭ This section applies to drives with bottom entry and exit of power cables. Do the steps in section Electrical safety precautions (page 20) before you start „ the work. Open the cabinet door. For drives without option +E205: To remove the mounting plate, undo the mounting screws and unplug the connectors on top of it: •...
  • Page 114 114 Electrical installation For drives without option +E205: Knock out holes in the shroud for the motor cable conductors. Connect the twisted shields of the motor cables to the ground bar and the phase conductors to the U2, V2 and W2 terminals of the drive module. For drives with du/dt filter (option +E205), connect the phase conductors to the T1/U2, T2/V2 and T3/W2 terminals of the cabinet with cable lugs.

  • Page 115: Connection Procedure (Frames R4

    Electrical installation 115 Connection procedure (frames R4...R7 with options +H351 and +H353) ￭ Do the steps in section Electrical safety precautions (page 20) before you start the work. Open the cabinet door. Remove the shrouds.
  • Page 116 116 Electrical installation Connect the twisted shields of the motor cables to the ground bar and the phase conductors to the U2, V2 and W2 terminals of the drive module. Connect the twisted shields of the input cables and separate ground cable (if present) to the PE terminal of the cabinet and the phase conductors to the L1, L2 and L3 terminals.

  • Page 117: Connection Procedure (Frames R8 And R9 With Options +H351 And +H353)

    Electrical installation 117 Connection procedure (frames R8 and R9 with options +H351 and ￭ +H353) Do the steps in section Electrical safety precautions (page 20) before you start the work. Open the cabinet door. Remove the shrouds.
  • Page 118 118 Electrical installation Connect the twisted shields of the motor cables to the ground bar and the phase conductors to the U2, V2 and W2 terminals of the drive module. Connect the twisted shields of the input cables and separate ground cable (if present) to the PE terminal of the cabinet and the phase conductors to the L1, L2 and L3 terminals.

  • Page 119: Connection Procedure (Frames R10 And R11)

    Electrical installation 119 Connection procedure (frames R10 and R11) ￭ Do the steps in section Electrical safety precautions (page 20) before you start the work. Open the cabinet door. Remove the shroud. Remove the door fan mounting plate. See section Replacing the door fan (frames R10 and R11) (page 172)
  • Page 120 120 Electrical installation Connect the twisted shields of the motor cables to the ground bar and the phase conductors to the U2, V2 and W2 terminals of the drive. Connect the twisted shields of the input cables and separate ground cable (if present) to the PE terminal of the cabinet and the phase conductors to the L1, L2 and L3 terminals.

  • Page 121: Connection Procedure (Frames R10 And R11 With Options +H351 And +H353)

    Electrical installation 121 Connection procedure (frames R10 and R11 with options +H351 and ￭ +H353) Do the steps in section Electrical safety precautions (page 20) before you start the work. Open the cabinet door. With top entry (option +H351) and bottom exit: Undo the mounting screws and pull the shroud out.
  • Page 122 122 Electrical installation With top entry and top exit (options +H351 and +H353): Remove the shrouds and door fan (see Replacing the door fan (frames R10 and R11) (page 172)). Undo the mounting screws and pull the shrouds out.

  • Page 123: Connecting The Control Cables

    Electrical installation 123 Connect the twisted shields of the motor cables to the ground bar and the phase conductors to the U2, V2 and W2 terminals of the drive. Connect the twisted shields of the input cables and separate ground cable (if present) to the PE terminal of the cabinet and the phase conductors to the L1, L2 and L3 terminals.

  • Page 124: Overview Of Control Cable Connection Procedure

    124 Electrical installation Overview of control cable connection procedure ￭ WARNING! Obey the instructions in chapter Safety instructions. If you ignore them, injury or death, or damage to the equipment can occur. Stop the drive and do the steps in section Electrical safety precautions (page 20) before you start the work.
  • Page 125 Electrical installation 125 If the outer surface of the shield is non-conductive: • Cut the shield at the midpoint of the peeled part. Be careful not to cut the conductors or the grounding wire. • Turn the conductive side of the shield inside out over the insulation. •...

  • Page 126: Routing The Control Cables Inside The Cabinet

    126 Electrical installation Routing the control cables inside the cabinet ￭ The route of the control cables is shown below in frame R9. The route is similar for frames R4 to R8. X504 (+L504)
  • Page 127 Electrical installation 127...
  • Page 128 128 Electrical installation The route of the control cables for frames R10 and R11 is shown below. X504 (+L504)

  • Page 129: Connecting External Wiring To The Control Unit Or Optional I/O Terminal Block

    Electrical installation 129 Connecting external wiring to the control unit or optional I/O terminal ￭ block Note: Keep any signal wire pairs twisted as close to the terminals as possible. Twisting the wire with its return wire reduces disturbances caused by inductive coupling. Note: Leave slack to the control wires to make it possible to lift the control unit mounting plate a little when the drive module is replaced.

  • Page 130: Connecting For Wired Remote Monitoring (Option +K496)

    +L504 to the detachable terminal block X504. Connecting for wired remote monitoring (option +K496) ￭ This option provides a gateway to connect the drive to ABB Ability™ via a local Ethernet network. Includes NETA-21 remote monitoring tool and FMBT-21 Modbus/TCP adapter module.

  • Page 131: Connecting A 230/115 V Ac Auxiliary Voltage Supply (Ups, Option +G307)

    Electrical installation 131 Connecting a 230/115 V AC auxiliary voltage supply (UPS, option ￭ +G307) Wire the external control voltage to terminal block X307 as shown below. X307 Internal wiring of UPS supervision: circuit breaker or fuse off/fault = contact open. Connecting the emergency stop push buttons (options +Q951 and ￭...

  • Page 132: Frames R10 And R11

    132 Electrical installation Frames R10 and R11 Customer connections X951 Customer external emergency stop reset Customer external emergency stop button Remove bridges 3–4 and 5–6 if there is an extern- al emergency stop button. The bridge connec- tions are installed only if the cabinet door push button is in use.

  • Page 133: Connecting External Power Supply Wires For The Motor Space Heater

    „ Electrical installation 133 Frames R4...R9 X300 1 Internal wiring of the cabinet heater: heater off/fault = contact open. Frames R10...R11 104 Electrical installation Powering the heating and lighting equipment (options +G300, +G301 and +G313) 1 Internal wiring of the cabinet heater: heater X300 off/fault = contact open.

  • Page 134: Wiring The Pt100 Relays (Option +Nl506)

    134 Electrical installation Wiring the Pt100 relays (option +nL506) ￭ External wiring of sensor modules is shown below. Contact load capacity 250 V AC 10 A. For the actual wiring, see the circuit diagram delivered with the drive. X506 1xPt100 Sensor 1 Internal wiring for overheat indication Sensor 1...3 overtemperature = contact open...

  • Page 135: Connecting A Pc

    Electrical installation 135 Connecting a PC WARNING! Do not connect the PC directly to the control panel connector of the control unit. It can cause damage. A PC (with, for example, the Drive Composer PC tool) can be connected as follows: To connect a control panel to the unit, either •...

  • Page 136: Installing Option Modules

    136 Electrical installation Installing option modules Option slot 1 (fieldbus adapter modules) ￭ WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. If you are not a qualified electrical professional, do not do installation, commissioning or maintenance work.

  • Page 137: Option Slot 2 (I/O Extension Modules)

    Electrical installation 137 If you must remove the option module after it is installed into the drive, use a suitable tool (for example, small pliers) to carefully pull out the lock. Option slot 2 (I/O extension modules) ￭ WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur.

  • Page 139: Control Unit

    Control unit 139 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 units CCU-23 and CCU-24. CCU-23 is used in frames R4 and R5 and CCU-24 in frames R6…R11.

  • Page 140: Layout Ccu-23

    140 Control unit Layout CCU-23 The layout of the external control connection terminals on the drive module control unit is shown below. SLOT 1 Option slot 1 (fieldbus adapter modules) ANALOG IN/OUT 1…3 Analog input 1 4…6 Analog input 2 7…9 Analog outputs 1…3...

  • Page 141: Layout Ccu-24

    Control unit 141 Layout CCU-24 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 142: Default I/O Connections For Acs580 Abb Standard Macro

    142 Control unit Default I/O connections for ACS580 ABB standard macro Connection Term Description X1 Reference voltage and analog inputs and outputs Signal cable shield (screen) Output frequency reference: 0…10 V 1...10 kohm AGND Analog input circuit common +10V Reference voltage 10 V DC...
  • Page 143 Control unit 143 Connection Term Description OUT1 Safe torque off. Factory connection. Both circuits must be closed for the drive to OUT2 start. Connected with jumpers at the fact- ory. SGND Refer to The Safe torque off func- tion (page 303) X10 24 V AC/DC (CCU-24 only) 24 V External 24 V AC/DC input to power up the...

  • Page 144: Additional Information On The Control Connections

    144 Control unit DI5: In scalar control (default): See Menu - Primary settings - Ramps or parameter group 28 Frequency ref- erence chain. In vector control: See Menu - Primary settings - Ramps or parameter group 23 Speed reference ramp. Ramp Parameters Scalar control (default)

  • Page 145: Connecting Motor Temperature Sensors To The Drive

    Control unit 145 Connection examples are shown below. With signal ground reference terminal Without signal ground reference terminal 100 ohm Automation controller Drive Termination switch. The devices at the ends of the fieldbus must have termination on. All other devices must have termination off. Biasing switch.

  • Page 146: Pnp Configurations For Digital Inputs

    146 Control unit If DI6 is to be used for another purpose, change the overtemperature supervision wiring from DI6 to another free digital input either on the control unit or on the CMOD-01 multifunction extension module. Activate the overtemperature supervision in the new digital input with these parameter settings: Select the correct digital input from parameter 31.01 External event 1 source.

  • Page 147: Pnp Configurations Without Option +L504

    Control unit 147 PNP configurations without option +L504 Internal and external +24 V power supply connections without option +L504 for PNP configuration are shown below. Internal +24 V DC power source External +24 V DC power source DIGITAL IN DIGITAL IN +24V +24V DGND...

  • Page 148: Connection For Obtaining 0

    148 Control unit Internal +24 V DC voltage source External +24 V DC voltage source DIGITAL IN DIGITAL IN +24 V +24 V DGND DGND +24 V DC DCOM DCOM 0 V DC Note: Frames R4 and R5: NPN connection is not supported because DI6 is used for internal overtemperature supervision.

  • Page 149: Di5 As Frequency Input

    Control unit 149 feeds the supply voltage (+24 V DC). Thus the output signal must be 4…20 mA, not 0…20 mA. 4…20 mA AGND +24V DGND DI5 as frequency input ￭ For setting the parameters for the digital frequency input, see the firmware manual. Safe torque off (X4) ￭...
  • Page 150 150 Control unit Digital inputs DI1…DI6 Input type: NPN/PNP Terminal size: 0.14 … 1.5 mm (26 … 16 AWG) (Term. 13…18) DI1…DI4 (Term. 13…16) 12/24 V DC logic levels: "0" < 4 V, "1" > 8 V : 3 kohm Hardware filtering: 0.04 ms, digital filtering: 2 ms sampling DI5 (Term.17) Can be used as a digital or frequency input.
  • Page 151 Control unit 151 Safe torque off (STO) inputs 24 V DC logic levels: "0" < 5 V, "1" > 13 V IN1 and IN2 (Term. 37 and 38) : 2.47 kohm CCU-23: Terminal size: 0.14 … 1.5 mm (26 … 16 AWG) CCU-24: terminal size: 0.14 …...
  • Page 152 152 Control unit Isolation areas (CCU-23) AI/AO 24 V SLOT1 SLOT2 Panel port Fieldbus extension I/O extension Reinforced insulation (IEC/EN 61800-5-1:2007, UL 61800-5-1 First edition) Functional insulation (IEC/EN 61800-5-1:2007, UL 61800-5-1 First edition) Below altitudes 4000 m (13123 ft): The terminals on the control unit fulfill the Protective Extra Low Voltage (PELV) requirements (EN 50178): There is reinforced insulation between the user terminals which only accept ELV voltages and terminals that accept higher voltages (relay outputs).
  • Page 153 Control unit 153 Ground isolation diagram (CCU-23) 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 Jumper installed at factory...
  • Page 154 154 Control unit Isolation areas (CCU-24) 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 botto- mof the control unit Reinforced insulation (IEC/EN 61800-5-1:2007, UL 61800- 5-1 First edition)
  • Page 155 Control unit 155 Ground isolation diagram (CCU-24) 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 157: Installation Checklist

    Installation checklist 157 Installation checklist Contents of this chapter This chapter contains a checklist for the mechanical and electrical installation of the drive. Checklist Examine the mechanical and electrical installation of the drive before start-up. Go through the checklist together with another person. WARNING! Obey the safety instructions of the drive.
  • Page 158 158 Installation checklist Make sure that … If the drive is connected to a network other than a symmetrically grounded TN-S system: You have done all the required modifications (for example, you may need to disconnect the EMC filter or ground-to-phase varistor) the electrical installation instructions. There is an adequately sized protective earth (ground) conductor(s) between the drive and the switchboard, the conductor is connected to correct terminal, and the terminal is tightened to the correct torque.

  • Page 159: Start-Up

    ABB recommends to set the operating temperatures of the relay, typically for example, as fol- lows: • 120…140 °C when only tripping is in use...
  • Page 160 160 Start-up Action Connecting voltage to the input terminals and auxiliary circuit Note: Before you close the door, make sure that the main protective circuit breaker (F21) for the auxiliary voltage supply is closed. Make sure that it is safe to connect voltage. Make sure that: •...

  • Page 161: Fault Tracing

    Fault tracing 161 Fault tracing Contents of this chapter This chapter describes the fault tracing possibilities of the drive. Warning and fault messages See the firmware manual for the descriptions, causes and remedies of the drive control program warning and fault messages.

  • Page 163: Maintenance

    Contents of this chapter This chapter contains preventive maintenance instructions. Maintenance intervals The tables below show the maintenance tasks that can be done by the end user. For the ABB Service offering, contact your local ABB Service representative (www.abb.com/searchchannels). Description of symbols ￭...
  • Page 164 164 Maintenance Recommended annual maintenance actions by the user Action Description Tightness of terminals Dustiness, corrosion or temperature Heatsink cleaning Component Years from start-up Cooling Fans, IP21 frames R4…R9 Main cooling fan R4 and R5 Main cooling fans R6…R9 LONGLIFE Auxiliary cooling fan for circuit boards R5…R9 LONGLIFE Fans, IP55 frames R4…R9 Main cooling fan R4 and R5...

  • Page 165: Cleaning The Interior Of The Cabinet

    • The maintenance and component replacement intervals are based on the assumption that the equipment operates within the specified ratings and ambient conditions. ABB recommends annual drive inspections to ensure the highest reliability and optimum performance. • Long-term operation near the specified maximum ratings or ambient conditions may require shorter maintenance intervals for certain components.
  • Page 166 166 Maintenance WARNING! Prevent water from entering the drive. Never use excessive amount of water, a hose, steam, etc.

  • Page 167: Cleaning The Air Inlet (Door) Meshes (Ip42 / Ul Type 1 Filtered)

    Maintenance 167 Cleaning the air inlet (door) meshes (IP42 / UL Type 1 Filtered) Check the dustiness of the air inlet meshes. If the dust cannot be removed by vacuum cleaning from outside through the grating holes with a small nozzle, proceed as follows: Stop the drive and do the steps in section Electrical safety precautions (page 20) before you start the work.

  • Page 168: Replacing The Air Filters (Ip54 / Ul Type 12)

    168 Maintenance Replacing the air filters (IP54 / UL Type 12) Check the air filters and replace if necessary. Inlet (door) filters (IP54 / UL Type 12) ￭ Stop the drive and do the steps in section Electrical safety precautions (page 20) before you start the work.

  • Page 169: Cleaning The Interior Of The Heatsink (Frames R10 And R11)

    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.

  • Page 170: Replacing The Door Fan (Frames R4

    170 Maintenance Replacing the door fan (frames R4…R9) ￭ Note: The fan is not present in all cabinet configurations. WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. If you are not a qualified electrical professional, do not do installation, commissioning or maintenance work.

  • Page 171: Replacing The Cabinet Fan (Frames R4

    Maintenance 171 Replacing the cabinet fan (frames R4…R9) ￭ Note: The fan is not present in all cabinet configurations. WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. If you are not a qualified electrical professional, do not do installation, commissioning or maintenance work.

  • Page 172: Replacing The Door Fan (Frames R10 And R11)

    172 Maintenance Replacing the door fan (frames R10 and R11) ￭ WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. If you are not a qualified electrical professional, do not do installation, commissioning or maintenance work.
  • Page 173 Maintenance 173...

  • Page 174: Replacing The Cabinet Fan (Frames R10 And R11, Ip54 / Ul Type 12)

    174 Maintenance Replacing the cabinet fan (frames R10 and R11, IP54 / UL Type 12) ￭ WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. If you are not a qualified electrical professional, do not do installation, commissioning or maintenance work.

  • Page 175: Replacing The Drive Module Main Cooling Fan (Frame R4)

    Maintenance 175 Replacing the drive module main cooling fan (frame R4) ￭ WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. If you are not a qualified electrical professional, do not do installation, commissioning or maintenance work.

  • Page 176: Replacing The Drive Module Main Cooling Fan (Frames R5

    176 Maintenance Replacing the drive module main cooling fan (frames R5…R8) ￭ WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. If you are not a qualified electrical professional, do not do installation, commissioning or maintenance work.

  • Page 177: Replacing The Drive Module Main Cooling Fans (Frame R9)

    Maintenance 177 Replacing the drive module main cooling fans (frame R9) ￭ WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. If you are not a qualified electrical professional, do not do installation, commissioning or maintenance work.

  • Page 178: Replacing The Drive Module Main Cooling Fans (Frames R10 And R11)

    178 Maintenance Replacing the drive module main cooling fans (frames R10 and R11) ￭ WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. If you are not a qualified electrical professional, do not do installation, commissioning or maintenance work.

  • Page 179: Replacing The Auxiliary Cooling Fan Of The Drive Module, Ip55 (Ul Type 12) Frame R4; Ip21 And Ip55 (Ul Type 1 And Ul Type 12) Frame R5

    Maintenance 179 Replacing the auxiliary cooling fan of the drive module, IP55 ￭ (UL Type 12) frame R4; IP21 and IP55 (UL Type 1 and UL Type 12) frame WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur.

  • Page 180: Replacing The Auxiliary Cooling Fan Of The Drive Module (Frames R6

    180 Maintenance Replacing the auxiliary cooling fan of the drive module (frames R6…R9) ￭ WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. If you are not a qualified electrical professional, do not do installation, commissioning or maintenance work.

  • Page 181: Replacing The Circuit Board Compartment Cooling Fans (Frames R10 And R11)

    Maintenance 181 Replacing the circuit board compartment cooling fans (frames R10 ￭ and R11) WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. If you are not a qualified electrical professional, do not do installation, commissioning or maintenance work.

  • Page 182: Replacing The Drive Module (Frames R4

    182 Maintenance Replacing the drive module (frames R4…R9) This replacing procedure requires: preferably two persons, a set of screw drivers with extension bar and a torque wrench, chains for securing the module during the installation. The drawings below show a cabinet of frame size R7. The procedure is the same for the other frame sizes.
  • Page 183 Maintenance 183 Tap screw M6x16 T30 (hex) Torx M6x16 Torx M6x16 Torx M6x16 Unplug the wires connected to the mounting plate connectors (if present). Remove the mounting plate (four screws). Remove the shroud (two screws). Remove the shroud on the power cable connection terminals.
  • Page 184 184 Maintenance Disconnect the option modules from the control unit. For drives with additional I/O terminal block (option +L504), disconnect the upper terminals and remove any fastening. Move the wires aside before you lift the module out. Note: Mark the wires for reconnection!
  • Page 185 Maintenance 185 10. For drives without additional I/O terminal block (option +L504), disconnect the customer-installed wires from the control unit. Note: Mark the wires for reconnection! 11. For drives with line contactor (option +F250), disconnect the input power cables from the output of the contactor. 12.
  • Page 186 186 Maintenance 13. Secure the drive module with chains from the lifting eyes. 14. Undo the mounting screws of the flange. 15. Slide the drive module forwards along the sliding bars. 16. Lift the module out of the cabinet with a lifting device.
  • Page 187 Maintenance 187 17. Remove the flange. Combiscrew M6×25 T25 lbf·ft M6 nut, 6 N·m (4.5 lbf·ft) M6 nut, 6 N·m (4.5 lbf·ft) M6×10 T30, 6 N·m (4.5 lbf·ft) 18. Install the new module in reverse order.

  • Page 188: Replacing The Drive Module (Frames R10 And R11)

    188 Maintenance Replacing the drive module (frames R10 and R11) WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. If you are not a qualified electrical professional, do not do installation, commissioning or maintenance work. This replacing procedure requires: preferably two persons, extraction/installation ramp, a set of screw drivers and a torque wrench with an extension bar of 500 mm (20 in), chains for securing the module during the installation.
  • Page 189 Maintenance 189...
  • Page 190 190 Maintenance Remove the mounting plate.
  • Page 191 Maintenance 191 Disconnect the drive module input busbars with a torque wrench with an extension bar of 500 mm (20 in). Combi screw M12, 70 N·m (52 lbf·ft). Disconnect the drive module output busbars. M12, 70 N·m (52 lbf·ft).
  • Page 192 192 Maintenance Remove the shroud. Undo the screws that attach the drive module to the cabinet at the top and behind the front support legs.
  • Page 193 Maintenance 193 10. Attach the extraction ramp to the cabinet base with two screws. 11. Attach the drive module lifting lugs to the cabinet lifting lug with chains. 12. Pull the drive module carefully out of the cabinet preferably with help from another person.

  • Page 194: Replacing The Drive Module (Frames R10 And R11, Ip54 / Ul Type 12)

    194 Maintenance Replacing the drive module (frames R10 and R11, IP54 / UL Type 12) WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. If you are not a qualified electrical professional, do not do installation, commissioning or maintenance work.
  • Page 195 Maintenance 195...
  • Page 196 196 Maintenance Remove the mounting plate.
  • Page 197 Maintenance 197 Disconnect the drive module input busbars with a torque wrench withn an extension bar of 500 mm (20 in). Combi screw M12, 70 N·m (52 lbf·ft). Disconnect the drive module output busbars. M12, 70 N·m (52 lbf·ft).
  • Page 198 198 Maintenance Remove the shroud. Undo the screws that attach the drive module to the cabinet at the top and behind the front support legs.
  • Page 199 Maintenance 199 10. Attach the extraction ramp to the cabinet base with two screws.

  • Page 200: 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 ￭ The capacitors must be reformed if the drive has not been powered (either in storage or unused) for a year or more.
  • Page 201 Maintenance 201 Stop the drive and do the steps in section Electrical safety precautions (page 20) before you start the work. Open the cabinet door. Remove the shrouding from in front of the switch fuse. Replace the fuses with the fuse handle which is in the cabinet. Reinstall the shrouding removed earlier and close the cabinet door.

  • Page 202: Replacing Ac Fuses (Frames R10 And R11)

    202 Maintenance Replacing AC fuses (frames R10 and R11) ￭ WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. If you are not a qualified electrical professional, do not do installation, commissioning or maintenance work. Stop the drive and do the steps in section Electrical safety precautions (page 20) before you start the work.

  • Page 203: Functional Safety Components

    Note that some of the components may already have been renewed earlier, restarting their mission time. The remaining mission time of the whole circuit is however determined by its oldest component. Contact your local ABB service representative for more information.

  • Page 205: Technical Data

    Technical data 205 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. Electrical ratings IEC ratings ￭...
  • Page 206 206 Technical data IEC RATINGS ACS580- Frame size Input Output ratings 07… rating Nominal ratings Light-duty use Heavy-duty use 0293A-4 246* 0363A-4 0430A-4 363** 0505A-4 0585A-4 0650A-4 0725A-4 1020 0820A-4 1020 0880A-4 1100 725*** IEC RATINGS ACS580- Frame size Input Output ratings 07…...

  • Page 207: Ul (Nec) Ratings

    Technical data 207 UL (NEC) ratings ￭ UL (NEC) RATINGS ACS580- Frame size Input Output ratings 07… rating Nominal ratings Light-duty use Heavy-duty use = 480 V 0052A-4 0065A-4 0077A-4 0096A-4 0124A-4 0156A-4 0180A-4 0240A-4 0260A-4 240* 0361A-4 0414A-4 361** 0505A-4 0585A-4 0650A-4...

  • Page 208: Output Derating

    Note 2: To achieve the rated motor power given in the table, the rated current of the drive must be higher than or equal to the rated motor current. The DriveSize dimensioning tool available from ABB is recommended for selecting the drive, motor and gear combination.

  • Page 209: Altitude Derating

    Technical data 209 Altitude derating ￭ At altitudes more than 1000 m (3281 ft) above sea level, the output current derating is 1 percentage point for every added 100 m (328 ft). For example, the derating factor for 1500 m (4921 ft) is 0.95. The maximum permitted installation altitude is given in the technical data.

  • Page 210: Deratings For Special Settings In The Drive Control Program

    210 Technical data Deratings for special settings in the drive control program ￭ If you change the minimum switching frequency with parameter 97.02 Minimum switching frequency, multiply the output current given in Electrical ratings (page 205) by the coefficient value given in this table. Frame size 1.5 kHz 2 kHz...

  • Page 211: Fuses (Iec)

    Technical data 211 Fuses (IEC) The standard drive is equipped with aR fuses listed below. ACS580- Input Ultrarapid (aR) fuses (one fuse per phase) 07… current Type Type Size (Bussmann) (Mersen) = 400 V 0062A-4 1350 170M3812D W320363 0073A-4 2600 170M3813D Y320365 0089A-4...

  • Page 212: Fuses (Ul)

    212 Technical data Fuses (UL) The drive with option +C129 and option +F289 is equipped with standard fuses listed below for internal circuit protection. The fuses restrict drive damage and prevent damage to adjoining equipment in case of a short-circuit inside the drive. The drive also requires external fuses for branch circuit protection per NEC, see section Fuses for branch circuit protection (page...

  • Page 213: Fuses For Branch Circuit Protection

    480 V maximum when the input cable is protected with UL class T or L fuses. The fuses for branch circuit protection per NEC must be selected according to the table below. Obey local regulations. ACS580-07… Input cur- Fuse (one fuse per phase)

  • Page 214: Dimensions And Weights

    214 Technical data Dimensions and weights Frame size Height Depth Weight Width 2145 2145 2145 2145 2145 2145 2145 R10 (option 2315 +B055) 2145 R11 (option 2315 +B055) 1) For frames R4…R9 additional width with options +H351 and +H353: 128 mm. For frames R10 and R11 additional width with option +H353: 153 mm.

  • Page 215: Free Space Requirements

    Technical data 215 Free space requirements Free space requirements for cooling are given below. Front Side Above * 5.91 15.75 * measured from the base plate of the cabinet top. > 400 mm (15.75”) Free space for door opening: R4...R7: 400 mm (15.75 in) R8, R9: 500 mm (19.68 in) R10, R11: 800 mm (31.50 in) Maximum allowed plinth height for the...
  • Page 216 216 Technical data ACS580- Frame size 07… Cu cable type Al cable type Cu cable type AWG/kcmil per phase 0145A-4 3×95 3×120 0169A-4 3×120 3×150 250 MCM 0206A-4 3×150 3×240 300 MCM 0246A-4 2×(3×70) 2×(3×95) 2×2/0 0293A-4 2×(3×95) 2×(3×120) 2×3/0 0363A-4 2×(3×120) 2×(3×185)

  • Page 217: Losses, Cooling Data And Noise

    Technical data 217 Losses, cooling data and noise ACS580-07… Air flow Heat dissipation Noise IP21, IP42 (UL Type 1) IP54 (UL Type 12) dB(A) = 400 V and 480 V 0062A-4 0073A-4 0089A-4 1059 0106A-4 1290 0145A-4 2487 0169A-4 2497...

  • Page 218: Terminal And Entry Data For The Power Cables

    218 Technical data Terminal and entry data for the power cables Number and diameter of the holes in the entry plate for the input power cable and motor cable are given below. Busbars for user power connections are tin-plated copper. Frame Input power cable Motor cable...

  • Page 219: Iec - With Option +E205

    Technical data 219 IEC – With option +E205 ￭ Input and motor cable terminal bolt sizes, maximum accepted wire sizes (per three phases) and tightening torques are given below. Frame L1, L2, L3, U2, V2, W2 PE (grounding) size Max. wire size Bolt size Tightening Bolt size...

  • Page 220: With Option +E205

    220 Technical data US – With option +E205 ￭ Input and motor cable terminal bolt sizes, maximum accepted wire sizes (per three phases) and tightening torques are given below. Frame L1, L2, L3, U2, V2, W2 PE (grounding) size Max. wire size Bolt size Tightening Bolt size...
  • Page 221 Technical data 221 Frame R4: Input and motor cable terminal dimensions (bottom entry and exit, switch fuse OS250)
  • Page 222 222 Technical data Frame R4: Input and motor cable terminal dimensions (bottom entry and exit, switch fuse OS100)
  • Page 223 Technical data 223 Frame R4: Input and motor cable terminal dimensions (option +F289, XT2H 125)
  • Page 224 224 Technical data Frame R4: Input and motor cable terminal dimensions (bottom entry and exit, switch fuse OS100, du/dt filter [option +E205])
  • Page 225 Technical data 225 Frame R4: Input and motor cable terminal dimensions (bottom entry and exit, options +F289 XT2H 125 and +E205)
  • Page 226 226 Technical data Frame R5: Input and motor cable terminal dimensions (bottom entry and exit, switch fuse OS250)
  • Page 227 Technical data 227 Frame R5: Input and motor cable terminal dimensions (bottom entry and exit, switch fuse OS200)
  • Page 228 228 Technical data Frame R5: Input and motor cable terminal dimensions (bottom entry and exit, switch fuse OS200, du/dt filter [option +E205])
  • Page 229 Technical data 229 Frames R4 and R5: Input and motor cable terminal dimensions (option +F289, XT4H 250)
  • Page 230 230 Technical data Frames R4 and R5: Input and motor cable terminal dimensions (bottom entry and exit, options +F289 XT4H 250 and +E205)
  • Page 231 Technical data 231 „ Frame R6: Input and motor cable terminal dimensions (bottom entry and exit, switch fuse OS250) DET A...
  • Page 232 232 Technical data Frame R6: Input and motor cable terminal dimensions (bottom entry and exit, switch fuse OS400) DET A...
  • Page 233 Technical data 233 Frame R6: Input and motor cable terminal dimensions (option +F289) DET A...
  • Page 234 234 Technical data Frame R7: Input and motor cable terminal dimensions (bottom entry and exit, switch fuse OS250) DET A...
  • Page 235 Technical data 235 Frame R7: Input and motor cable terminal dimensions (bottom entry and exit, switch fuse OS400) DET A...
  • Page 236 236 Technical data Frame R7: Input and motor cable terminal dimensions (bottom entry and exit, option +F289)
  • Page 237 Technical data 237 Frames R6 and R7: Input and motor cable terminal dimensions (bottom entry and exit, switch fuse OS250, du/dt filter [option +E205])
  • Page 238 238 Technical data Frames R6 and R7: Input and motor cable terminal dimensions (bottom entry and exit, switch fuse OS400, du/dt filter [option +E205])
  • Page 239 Technical data 239 Frames R6 and R7: Input and motor cable terminal dimensions (bottom entry and exit, options +F289 and +E205)
  • Page 240 240 Technical data Frames R6 and R7: Input and motor cable terminal dimensions (top entry and exit, options +H351 and +H353)
  • Page 241 Technical data 241 Frame R8: Input and motor cable terminal dimensions (bottom entry and exit, switch-disconnector OT400) DET A...
  • Page 242 242 Technical data Frame R8: Input and motor cable terminal dimensions (bottom entry and exit, switch-disconnector OT400, du/dt filter [option +E205])
  • Page 243 Technical data 243 Frame R8: Input and motor cable terminal dimensions (bottom entry and exit, option +F289)
  • Page 244 244 Technical data Frame R9: Input and motor cable terminal dimensions (bottom entry and exit, switch-disconnector OT630) DET A...
  • Page 245 Technical data 245 Frame R9: Input and motor cable terminal dimensions (bottom entry and exit, switch-disconnector OT630, du/dt filter [option +E205])
  • Page 246 246 Technical data Frame R9: Input and motor cable terminal dimensions (option +F289)
  • Page 247 Technical data 247 Frames R8 and R9: Input and motor cable terminal dimensions (bottom entry and exit, options +F289 and +E205)
  • Page 248 248 Technical data Frames R8 and R9: Input and motor cable terminal dimensions (top entry and exit, options +H351 and +H353)
  • Page 249 Technical data 249 Frame R10: Input and motor cable terminal dimensions (bottom entry and exit) C''-1 276 [ 10,86"] 190 [ 7,48"] 103 [ 4,05"] [ 13,54"] L 1, L2, L [ 0,51"] V2, W2 3LILI 0 1- 3 L1 L2 86 [3 ,38"] -tj- [ 7,16"]...
  • Page 250 250 Technical data Frame R10: Input and motor cable terminal dimensions (bottom entry and exit, option +E205) [10,86"] [13,55"] [7,48"] [0,51"] _ 190 [4,05"] � � [4,25"] [1,65"] L1 L2 [1,65"] I I I s;;1- s;;1- [2,44"] [7,75"] [0,51"] U2, V2, W2 o [13,07"] s;;j­...
  • Page 251 -�'-----------� �MS 4pcs 1 .. ::::, (.) "O - -� .c: +-' - � 1/J +-' Cust. Doc. No. Prepared 19.10.2022 Title ACS580-07-065 1---------------------------+------------------------I ·;:: Customer Approved Generated by ADG2 SINGLE DRIVE Project � • • Jll 1111 •111 ■...
  • Page 252 252 Technical data Frame R10: Input and motor cable terminal dimensions (top entry and exit)
  • Page 253 Technical data 253 Frame R10: Input and motor cable terminal dimensions (top entry and exit, option +D150)
  • Page 254 254 Technical data Frame R11: Input and motor cable terminal dimensions (bottom entry and exit) [ 10,86"] ---- [ 7,48"] [ 13,70"] [ 4,09"] ("I � L1, L2, J.Q,t [ 0,51"] U2, V2, ¢13 L1 L2 C"i [ 3,38"] ---- [ 1,65"] �...
  • Page 255 Technical data 255 Frame R11: Input and motor cable terminal dimensions (bottom entry and exit, option +E205) [ 10,86"] [ 7,48"] � [ 13,70"] _ 190 [ 4,09"] L2, L [ 0,51"] � ¢13 L1 L2 L3 [ 4,25"] [ 1,65"] s;j­...
  • Page 256 256 Technical data Frame R11: Input and motor cable terminal dimensions (bottom entry and exit, option +D150)
  • Page 257 Technical data 257 Frame R11: Input and motor cable terminal dimensions (top entry and exit)
  • Page 258 258 Technical data Frame R11: Input and motor cable terminal dimensions (top entry and exit, option +D150)

  • Page 259: Terminal And Connection Data For Auxiliary Control Circuits

    Technical data 259 Terminal and connection data for auxiliary control circuits Maximum acceptable voltage and current values and wire sizes in terminal blocks are given below. Terminal block Maximum acceptable voltage and current values and wire sizes X250 230V AC / 24V DC, 2A •...

  • Page 260: Electrical Power Network Specification

    260 Technical data Electrical power network specification Voltage ( U ACS580-07-xxxxx-4 drives: 380…480 VAC 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 261: Energy Efficiency Data (Ecodesign)

    Technical data 261 The efficiency is not calculated according to the ecodesign standard IEC 61800-9-2. Energy efficiency data (ecodesign) Energy efficiency data is not provided for the drive. The cabinet-installed drives comprising drive modules which are in conformity with the regulation are exempt from the EU ecodesign requirements (Regulation EU/2019/1781, §2.3.e) and the UK ecodesign requirements (Regulation SI 2021 No.

  • Page 262: Ambient Conditions

    Installation site altitude 0 to 2000 m (6561 ft) above sea level. For alti- tudes over 2000 m, con- tact ABB. Output derated above 1000 m (3281 ft). See section Output derating Air temperature -0 to +50 °C (32 to 122...

  • Page 263: Transportation

    Storage conditions The table below specifies the storage conditions for the drive. Store the drive in its package. ABB recommends seaworthy package (option +P912) if the drive is in long-term storage. The storage conditions must also comply with the environmental...

  • Page 264: Auxiliary Circuit Power Consumption

    264 Technical data Package type Storage conditions (IEC 60721-3-1) Standard package 1K20: Up to 24 months in enclosed conditions (full temperature and humidity control). Wooden crate 1K22: Up to 6 months in enclosed conditions (no temperature or humidity Vertical control). 1K23, 1K24: Up to 3 months in sheltered conditions (roof providing protection from direct rain and sun).

  • Page 265: Materials

    European Chemicals Agency's SCIP database. SCIP is the database for information on Substances of Concern In articles as such or in complex objects (Products) established under the Waste Framework Directive (2008/98/EC). For further information, contact your local ABB distributor or consult European Chemicals Agency's...

  • Page 266: Package Dimensions And Weights For Drives Without Empty Cubicles (Without Options +C196

    SCIP database to find out which SVHCs are used in the drive, and to find out where those components are located. Contact your local ABB distributor for further information on environmental aspects. End of life treatment must follow international and national regulations.

  • Page 267: Applicable Standards

    Technical data 267 Frame size Standard +P912 Applicable standards The drive complies with the standards below. The compliance with the European Low Voltage Directive is verified according to standard EN 61800-5-1. EN 61800-5-1:2007 Adjustable speed electrical power drive systems. Part 5-1: Safety requirements –...

  • Page 268: Ce Marking

    Product is compliant with the People’s Republic of China Electronic Industry Standard (SJ/T 11364-2014) about hazardous substances. The EFUP is 20 years. China RoHS II Declaration of Conformity is available from https://library.abb.com. CMIM mark Product complies with Morocco's safety standard for marketing of toys and electrical products.

  • Page 269: Compliance With The European Emc Directive

    Technical data 269 Compliance with the European EMC Directive ￭ The EMC Directive defines the requirements for immunity and emissions of electrical equipment used within the European Union. The EMC product standard (EN 61800-3:2004) covers requirements stated for drives. See section Compliance with the EN 61800-3:2004 below.

  • Page 270: Category C3

    270 Technical data The drive is equipped with EMC filter option +E202. The motor and control cables are selected as specified in the hardware manual. The drive is installed according to the instructions given in the hardware manual. Maximum motor cable length is 100 meters. WARNING! The drive may cause radio interference if used in a residential or domestic environment.

  • Page 271: Ul Marking

    Technical data 271 Medium voltage network Equipment Neighboring network Supply transformer Point of measurement Static screen Low voltage Drive Equipment (victim) An EMC plan for preventing disturbances is drawn up for the installation. A template is available in Technical guide No. 3 EMC compliant installation and configuration for a power drive system (3AFE61348280 [English]).

  • Page 272: Design Lifetime Expectancy

    272 Technical data • Make sure that the drive type designation label includes the applicable marking. • DANGER - Risk of electric shock. After disconnecting the input power, always wait for 5 minutes to let the intermediate circuit capacitors discharge before you start working on the drive, motor or motor cable.

  • Page 273: Disclaimers

    ABB and its affiliates are not liable for damages and/or losses related to such security breaches, any unauthorized access, interference, intrusion, leakage and/or theft of...

  • Page 274: Declarations Of Conformity

    274 Technical data Declarations of conformity Link to Declaration of conformity according to EU Machinery Directive 2006/42/EU (3AXD10000675677) Link to Declaration of conformity according to UK Supply of Machinery (Safety) Regulations 2008 (3AXD10001329536) Link to Declaration of China RoHS II conformity (3AXD10001497378)

  • Page 275: Dimension Drawings

    Dimension drawings 275 Dimension drawings Example dimension drawings are shown below.

  • Page 276: Frames R4 And R5 (+B052: Ip21)

    276 Dimension drawings Frames R4 and R5 (+B052: IP21)

  • Page 277: Frames R4 And R5 (+B054: Ip42)

    Dimension drawings 277 Frames R4 and R5 (+B054: IP42)

  • Page 278: Frames R4 And R5 (+B055: Ip54)

    278 Dimension drawings Frames R4 and R5 (+B055: IP54)

  • Page 279: Frames R4 And R5 (+B054: Ul Type 1 Filtered)

    Dimension drawings 279 Frames R4 and R5 (+B054: UL Type 1 Filtered)

  • Page 280: Frames R4 And R5 (+B055: Ul Type 12)

    280 Dimension drawings Frames R4 and R5 (+B055: UL Type 12)

  • Page 281: Frames R4 And R5 (+F289)

    Dimension drawings 281 Frames R4 and R5 (+F289)

  • Page 282: Frames R6 And R7 (+B052: Ip21, Ul Type 1)

    282 Dimension drawings Frames R6 and R7 (+B052: IP21, UL Type 1)

  • Page 283: Frames R6 And R7 (+B054: Ip42, Ul Type 1 Filtered)

    Dimension drawings 283 Frames R6 and R7 (+B054: IP42, UL Type 1 Filtered)

  • Page 284: Frames R6 And R7 (+B055: Ip54, Ul Type 12)

    284 Dimension drawings Frames R6 and R7 (+B055: IP54, UL Type 12)

  • Page 285: Frames R4 To R7 (+H351 And +H353: Top Entry And Exit)

    Dimension drawings 285 Frames R4 to R7 (+H351 and +H353: top entry and exit)

  • Page 286: Frames R6 And R7 (+F289)

    286 Dimension drawings Frames R6 and R7 (+F289)

  • Page 287: Frames R4 To R7 (+F289, +H351, +H353)

    Dimension drawings 287 Frames R4 to R7 (+F289, +H351, +H353)

  • Page 288: Frames R8 And R9 (Ip21, Ul Type 1)

    288 Dimension drawings Frames R8 and R9 (IP21, UL Type 1)

  • Page 289: Frames R8 And R9 (+B054: Ip42, Ul Type 1 Filtered)

    Dimension drawings 289 Frames R8 and R9 (+B054: IP42, UL Type 1 Filtered)

  • Page 290: Frames R8 And R9 (+B055: Ip54, Ul Type 12)

    290 Dimension drawings Frames R8 and R9 (+B055: IP54, UL Type 12)

  • Page 291: Frames R8 And R9 (+H351 And +H353: Top Entry And Exit)

    Dimension drawings 291 Frames R8 and R9 (+H351 and +H353: top entry and exit)

  • Page 292: Frames R8 And R9 (+F289)

    292 Dimension drawings Frames R8 and R9 (+F289)

  • Page 293: Frames R8 And R9 (+F289, +H351, +H353)

    Dimension drawings 293 Frames R8 and R9 (+F289, +H351, +H353)

  • Page 294: Frames R10 And R11 (Ip21, Ul Type 1)

    294 Dimension drawings Frames R10 and R11 (IP21, UL Type 1)

  • Page 295: Frames R10 And R11 (+B054: Ip42, Ul Type 1 Filtered)

    Dimension drawings 295 Frames R10 and R11 (+B054: IP42, UL Type 1 Filtered)

  • Page 296: Frames R10 And R11 (+B055: Ip54, Ul Type 12)

    296 Dimension drawings Frames R10 and R11 (+B055: IP54, UL Type 12)

  • Page 297: Frames R10 And R11 (+F289)

    Dimension drawings 297 Frames R10 and R11 (+F289)

  • Page 298: Frames R10 And R11 (+H351, +H353)

    298 Dimension drawings Frames R10 and R11 (+H351, +H353)

  • Page 299: Frames R10 And R11 (+B054: Ip42, Ul Type 1 Filtered, +H351, +H353)

    Dimension drawings 299 Frames R10 and R11 (+B054: IP42, UL type 1 filtered, +H351, +H353)

  • Page 300: Frames R10 And R11 (+B055: Ip54, Ul Type 12, +H351, +H353)

    300 Dimension drawings Frames R10 and R11 (+B055: IP54, UL type 12, +H351, +H353)

  • Page 301: Dimensions Of Empty Cubicles (Options +C196

    Dimension drawings 301 Dimensions of empty cubicles (options +C196…+C201) IP22/IP42 ￭...

  • Page 302: Ip54

    302 Dimension drawings IP54 ￭...

  • Page 303: The Safe Torque Off Function

    The Safe torque off function 303 The Safe torque off function Contents of this chapter This chapter describes the Safe torque off (STO) function of the drive and gives instructions for its use. Description The Safe torque off function can be used, for example, as the final actuator device of safety circuits (such as an emergency stop circuit) that stop the drive in case of danger.

  • Page 304: Chinery (Safety) Regulations

    304 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-re- lated 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 305: Wiring

    The Safe torque off function 305 Wiring For the electrical specifications of the STO connection, see the technical data of the control unit. Connection principle ￭ Single ACS580-07 drive, internal power supply OUT1 + 24 V DC OUT2 + 24 V DC SGND...

  • Page 306: Wiring Examples

    306 The Safe torque off function Drive Control unit Control logic To motor Activation switch Wiring examples ￭ Single ACS580-07 drive, internal power supply OUT1 OUT2 SGND Drive Safety PLC Safety relay Single ACS580-07 drive, external power supply 24 V DC...
  • Page 307 The Safe torque off function 307 Multiple ACS580-07 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 308: Activation Switch

    308 The Safe torque off function Multiple ACS580-07 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 309: Cable Types And Lengths

    A CPTC thermistor protection module or an FSPS safety functions module can also be used. For more information, see the module documentation. Cable types and lengths ￭ • ABB recommends double-shielded twisted-pair cable. • Maximum cable lengths: • 300 m (1000 ft) between activation switch [K] and drive control unit •...

  • Page 310: Operation Principle

    310 The Safe torque off function Operation principle The Safe torque off activates (the activation switch is opened, or safety relay contacts open). The STO inputs of the drive control unit de-energize. The control unit cuts off the control voltage from the output IGBTs. The control program generates an indication as defined by parameter 31.22 (see the firmware manual of the drive).
  • Page 311 The Safe torque off function 311 Start-up including validation test To ensure the safe operation of a safety function, validation is required. The final assembler of the machine must validate the function by performing a validation test. The test must be performed at initial start-up of the safety function after any changes related to the safety function (circuit boards, wiring, components, settings, replacement of inverter module, etc.)
  • Page 312 312 The Safe torque off function Action Test the operation of the STO function when the motor is stopped. • Give a stop command for the drive (if running) and wait until the motor shaft is at a standstill. Make sure that the drive operates as follows: •...
  • Page 313 The Safe torque off function 313 Open the activation switch, or activate the safety functionality that is wired to the STO connection. The STO inputs on the drive control unit de-energize, and the control unit cuts off the control voltage from the output IGBTs. The control program generates an indication as defined by parameter 31.22 (see the firmware manual of the drive).
  • Page 314 314 The Safe torque off function potential hazards. The assembler of the machine must inform the final user about the residual risks.

  • Page 315: Maintenance

    If any wiring or component change is needed after start-up, or the parameters are restored, do the test given in section Validation test procedure (page 311). Use only spare parts approved by ABB. Record all maintenance and proof test activities in the machine logbook. Competence ￭...
  • Page 316 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 317: Safety Data

    The Safe torque off function 317 Safety data The safety data for the Safe torque off function is given below. Note: The safety data is calculated for redundant use, and applies only if both STO channels are used.
  • Page 318 318 The Safe torque off function...

  • Page 319: Terms And Abbreviations

    The Safe torque off function 319 • Relevant failure modes: • The STO trips spuriously (safe failure) • The STO does not activate when requested • A fault exclusion on the failure mode “short circuit on printed circuit board” has been made (EN 13849-2, table D.5). The analysis is based on an assumption that one failure occurs at one time.

  • Page 320: Tüv Certificate

    320 The Safe torque off function Term or Reference Description abbreviation IEC 61508-6 Proof test interval. T is a parameter used to define the probabilistic failure rate (PFH or PFD) for the safety function or subsystem. Performing a proof test at a maximum interval of T is required to keep the SIL capability valid.

  • Page 321: Resistor Braking

    Resistor braking 321 Resistor braking Contents of this chapter This chapter contains information and instructions on resistor braking, brake choppers and brake resistors. Operation principle and hardware description You can order the drive with a built-in brake chopper (option +D150). Brake resistors are available as add-on kits.

  • Page 322: Planning The Braking System

    Layout ￭ For the brake chopper option, ABB adds a side box onto left side of the cabinet. The side box contains the terminals for the resistor cable, and the resistor cable entries. The grounding terminals (PE) are inside the main cubicle.
  • Page 323 • The sum energy generated by the motor during the resistor heat dissipation period is: 2.2 × 4500 kJ = 9900 kJ. This value is lower than the ABB default resistor assembly E value. Thus, the ABB default brake resistor can be used.

  • Page 324: Protecting The System Against Thermal Overload

    324 Resistor braking brmax 400 s Selecting the brake resistor cable ￭ ABB recommends a cable which is identical with the drive input power cable (size, type, ratings). Refer also to Protecting the resistor cable against short-circuits. Maximum brake resistor cable length ￭...

  • Page 325: Minimizing Electromagnetic Interference

    Resistor braking 325 Selecting the temperature sensor cable ￭ Specification: Twisted pair, shielding recommended, voltage rating ≥ 750 V, insulation test voltage > 2.5 kV. Minimizing electromagnetic interference ￭ Make sure that the installation is compliant with the EMC requirements. Obey these rules in order to minimize electromagnetic interference caused by the rapid voltage and current changes in the resistor cables: •...
  • Page 326 326 Resistor braking Electrical installation of brake resistor cables Measuring the insulation resistance of the brake resistor circuit ￭ WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. If you are not a qualified electrical professional, do not do installation, commissioning or maintenance work.

  • Page 327: Connection Diagram

    Resistor braking 327 Connection diagram ￭ This diagram shows the connections of the brake resistor cable and the resistor temperature sensor cable. This is applicable when the brake resistor assembly consist of two parallel-connected resistors. +t° +t° Connection procedure ￭ WARNING! Obey the safety instructions of the drive.

  • Page 328: Parameter Settings

    328 Resistor braking Start-up WARNING! Make sure that there is sufficient ventilation. New brake resistors can have a protective grease coating. When the resistor warms up for the first time, the grease burns off and can produce some smoke. WARNING! If you disable the brake chopper by parameter, also disconnect the brake resistor cable from the drive.

  • Page 329: Technical Data

    Minimum permitted resistance value for the brake resistor Resistance value of the ABB default brake resistor Energy pulse that the ABB default brake resistor withstands and can dissipate every 400 seconds Continuous heat dissipation capacity (power) of the resistor when placed correctly Rrcont The ratings apply at an ambient temperature of 40 °C (104 °F).
  • Page 330 68759340 Resistance Energy pulse that the ABB default brake resistor withstands during a 400 s duty cycle. This energy will heat the resistor element from 40 °C to the maximum allowable temperature. Continuous heat dissipation capacity (power) of the resistor when placed correctly...
  • Page 331 Resistor braking 331 Dimension drawings – Drive with the brake chopper (option +D150) IP21 enclosure ￭...
  • Page 332 332 Resistor braking IP54 enclosure ￭...
  • Page 333 Resistor braking 333 Brake resistor cable exits and terminals ￭ Bottom cable exit (standard) B - B Top cable exit (option +H353) A - A...
  • Page 335 Disconnecting EMC filter and ground-to-phase varistor 335 Disconnecting EMC filter and ground-to-phase varistor When to disconnect the ground-to-phase varistor: TN-S, IT, corner-grounded delta, midpoint-grounded delta and TT systems Symmetrically grounded TN systems (TN-S systems, ie, center-grounded wye) R4…R9: Do not remove EMC or VAR screws. R10…R11: Do not disconnect VAR wire.
  • Page 336 336 Disconnecting EMC filter and ground-to-phase varistor R4…R5: Not evaluated R6…R9: Do not remove EMC AC or VAR screws. Remove EMC DC screw. R10…R11: Do not disconnect VAR wire. Midpoint-grounded delta systems R4…R5: Not evaluated R6…R9: Do not remove EMC AC or VAR screws. Remove EMC DC screw.
  • Page 337 Residual current device has to be installed in the supply sys- tem. Note: • Because the EMC filter screws have been removed, ABB does not guarantee the EMC category. • ABB does not guarantee the functioning of the ground leakage detector built inside the drive.
  • Page 338 338 Disconnecting EMC filter and ground-to-phase varistor 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 0.58·X 0.58·X 0.58·X TN-S system (symmetrically grounded) Corner-grounded delta system (nonsymmet- 1.0·X 1.0·X rical)
  • Page 339 Disconnecting EMC filter and ground-to-phase varistor 339 Disconnecting the EMC filter and ground-to-phase varistor (IEC frames R4 and R5) To disconnect the internal EMC filter or ground-to-phase varistor, if needed, do as follows: Switch off the power from the drive. Open the cover, if not already opened.
  • Page 340 340 Disconnecting EMC filter and ground-to-phase varistor Disconnecting the EMC filter and ground-to-phase varistor (UL/NEC frames R4 and R5) Extra screws to configure the drive for different networks are provided in the drive shipment. To disconnect the internal EMC filter or ground-to-phase varistor: Do the steps in section Electrical safety precautions (page 20) before you start...
  • Page 341 Disconnecting EMC filter and ground-to-phase varistor 341 Disconnecting the EMC filter and ground-to-phase varistor (IEC frames R6…R9) To disconnect the internal EMC filter or ground-to-phase varistor, do as follows: Switch off the power from the drive. Open the cover, if not already opened. To disconnect the internal EMC filter, remove the two EMC screws.
  • Page 342 342 Disconnecting EMC filter and ground-to-phase varistor R6…R9 Screw EMC (DC) EMC (AC) Disconnecting the ground-to-phase varistor (frames R10 and R11) Varistor (VAR) grounding wire is attached next to the control circuit compartment. Insulate the end of the varistor grounding wire. Attach the wire to the module frame with a cable tie.

  • Page 343: Contents Of This Chapter

    CAIO-01 bipolar analog I/O adapter module 343 CAIO-01 bipolar analog I/O adapter module Contents of this chapter This chapter describes how to install and start up the optional CAIO-01 multifunction extension module. The chapter also contains diagnostics and technical data. Product overview The CAIO-01 bipolar analog I/O module expands the inputs and outputs of the drive control unit.
  • Page 344 344 CAIO-01 bipolar analog I/O adapter module Layout 1, 2, 3 Analog inputs 4, 5 Analog outputs SHIELD Cable shield connection SHIELD Cable shield connection AI3+ Analog input 3 positive signal Analog output 3 signal AI3- Analog input 3 negative signal AGND Analog ground potential SHIELD...

  • Page 345: Mechanical Installation

    CAIO-01 bipolar analog I/O adapter module 345 Mechanical installation Necessary tools ￭ • Screwdriver and a set of suitable bits. Unpacking and examining the delivery ￭ Open the option package. Make sure that the package contains: • the option module •...

  • Page 346: Setting The Parameters

    346 CAIO-01 bipolar analog I/O adapter module Start-up Setting the parameters ￭ Power up the drive. 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 CAIO-01. If warning A7AB Extension I/O configuration failure is shown, •...
  • Page 347 CAIO-01 bipolar analog I/O adapter module 347 Maximum wire size 1.5 mm Output voltage (AO+ and AO-) 0 V … +11 V Output current (AO+ and AO-) 0 mA … +22 mA Output resistance < 20 ohm Recommended load >10 kohm Inaccuracy ±...
  • Page 348 348 CAIO-01 bipolar analog I/O adapter module Dimension drawings The dimensions are in millimeters.
  • Page 349 CBAI-01 bipolar analog IO adapter module 349 CBAI-01 bipolar analog IO adapter module Contents of this chapter This chapter describes how to install and start up the optional CBAI-01 adapter module. The chapter also contains diagnostics and technical data. Product overview The CBAI-01 includes two bipolar analog inputs, two unipolar analog outputs, and a switch which can be used to select scaling of the analog output level.

  • Page 350: Unpacking And Examining The Delivery

    350 CBAI-01 bipolar analog IO adapter module Layout Analog inputs (1) Analog outputs (3) AI3+ Analog input 3 positive signal Analog output 3 signal AI3- Analog input 3 negative signal AGND Analog ground potential Cable shield connection Cable shield connection AI4+ Analog input 4 positive signal Analog output 4 signal...
  • Page 351 CBAI-01 bipolar analog IO adapter module 351 Electrical installation WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. Stop the drive and do the steps in section Electrical safety precautions (page 20) before you start the work.
  • Page 352 352 CBAI-01 bipolar analog IO adapter module Parameter Setting Default 32.06 Supervision 1 action Fault No action 32.07 Supervision 1 signal Frequency 32.09 Supervision 1 low 0.00 Diagnostics LEDs ￭ The adapter module has one diagnostic LED. Color Description Green The adapter module is powered up.

  • Page 353: Dimension Drawing

    364 Optional I/O extension modules CBAI-01 bipolar analog IO adapter module 353 Isolation areas: CBAI-01 Symbol Description Plugged to drive control unit SLOT2 Plugged to drive SLOT2 Switch SWITCH Reinforced insulation (IEC 61800-5-1:2007) Reinforced insulation (IEC 61800-5-1:2007) Functional insulation (IEC 61800-5-1:2007) Functional insulation (IEC 61800-5-1:2007) Dimension drawing Analog inputs (80...82, 83...85)
  • Page 355 CHDI-01 115/230 V digital input extension module 355 CHDI-01 115/230 V digital input extension module Contents of this chapter This chapter describes how to install and start up the optional CHDI-01 multifunction extension module. The chapter also contains diagnostics and technical data. Product overview The CHDI-01 115/230 V digital input extension module expands the inputs of the drive control unit.
  • Page 356 356 CHDI-01 115/230 V digital input extension module Layout and connection examples 3-pin terminal blocks for 115/230 V inputs Relay outputs RO4C 115/230 V AC HDI7 RO4A 24 V DC HDI8 RO4B NEUTRAL HDI7 115/230 V input 1 RO4C Common, C HDI8 115/230 V input 2 RO4B...
  • Page 357 CHDI-01 115/230 V digital input extension module 357 Mechanical installation Necessary tools ￭ • Screwdriver and a set of suitable bits. Unpacking and examining the delivery ￭ Open the option package. Make sure that the package contains: • the option module •...

  • Page 358: Fault And Warning Messages

    358 CHDI-01 115/230 V digital input extension module Parameter Setting 15.07 RO4 source Reverse 15.08 RO4 ON delay 15.09 RO4 OFF delay Fault and warning messages Warning A7AB Extension I/O configuration failure. Technical data Installation Into an option slot on the drive control unit Degree of protection IP20 / UL Type 1 Ambient conditions...
  • Page 359 CHDI-01 115/230 V digital input extension module 359...

  • Page 361: 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) 361 CMOD-01 multifunction extension module (external 24 V AC/DC and digital I/O) Contents of this chapter This chapter describes how to install and start up the optional CMOD-01 multifunction extension module.
  • Page 362 362 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 3-pin terminal blocks for relay outputs RO4C 24V AC/DC + in RO4A 24 V DC 24 V AC/DC...
  • Page 363 CMOD-01 multifunction extension module (external 24 V AC/DC and digital I/O) 363 Mechanical installation Necessary tools ￭ • Screwdriver and a set of suitable bits. Unpacking and examining the delivery ￭ Open the option package. Make sure that the package contains: •...

  • Page 364: Faults And Warning Messages

    364 CMOD-01 multifunction extension module (external 24 V AC/DC and digital I/O) Examples are given below. Parameter setting example for relay output This example shows how make relay output RO4 of the extension module indicate the reverse direction of rotation of the motor with a one-second delay. Parameter Setting 15.07 RO4 source...
  • Page 365 CMOD-01 multifunction extension module (external 24 V AC/DC and digital I/O) 365 Ambient conditions See the drive technical data. Package Cardboard Reley outputs (50…52, 53…55) Maximum wire size 1.5 mm Minimum contact rating 12 V / 10 mA Maximum contact rating 250 V AC / 30 V DC / 2 A Maximum breaking capa- 1500 VA...
  • Page 366 366 CMOD-01 multifunction extension module (external 24 V AC/DC and digital I/O)

  • Page 367: 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) 367 CMOD-02 multifunction extension module (external 24 V AC/DC and isolated PTC interface) Contents of this chapter This chapter describes how to install and start up the optional CMOD-02 multifunction extension module.

  • Page 368: Necessary Tools

    368 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 sup- 2-pin terminal block for relay output CMOD-02 RO PTC C 24V AC/DC + in 24 V AC/DC 24V AC/DC - in PTC B OUT1...
  • Page 369 CMOD-02 multifunction extension module (external 24 V AC/DC and isolated PTC interface) 369 Unpacking and examining the delivery ￭ Open the option package. Make sure that the package contains: • the option module • a mounting screw. Make sure that there are no signs of damage. Installing the module ￭...
  • Page 370 370 CMOD-02 multifunction extension module (external 24 V AC/DC and isolated PTC interface) 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 Degree of protection IP20 / UL Type 1 Ambient conditions...
  • Page 371 CMOD-02 multifunction extension module (external 24 V AC/DC and isolated PTC interface) 371 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 373: Further Information

    Product and service inquiries Address any inquiries about the product to your local ABB representative, quoting the type designation and serial number of the unit in question. A listing of ABB sales, support and service contacts can be found by navigating to www.abb.com/contact-centers.
  • Page 374 3AXD50000045815G © Copyright 2024 ABB. All rights reserved. Specifications subject to change without notice.

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