ABB ACS580-04 Manuals

Manuals and User Guides for ABB ACS580-04. We have 6 ABB ACS580-04 manuals available for free PDF download: Hardware Manual, Quick Installation Manual, User Manual, Manual

ABB ACS580-04 Hardware Manual (298 pages)

drive modules

Brand: ABB | Category: Control Unit | Size: 53 MB

Table of Contents

7
- Table of Contents
  5
- Safety Instructions
  17
- Use of Warnings and Notes
  17
- Contents of this Chapter
  17
- General Safety in Installation, Start-Up and Maintenance
  18
- Electrical Safety in Installation, Start-Up and Maintenance
  21
- Electrical Safety Precautions
  21
- Additional Instructions and Notes
  22
- Printed Circuit Boards
  22
- Grounding
  23
- General Safety in Operation
  24
- Additional Instructions for Permanent Magnet Motor Drives
  24
- Safety in Installation, Start-Up, Maintenance
  24
- Safety in Operation
  25
- Target Audience
  27
- Categorization by Frame Size and Option Code
  27
- Applicability
  27
- Contents of this Chapter
  27
- Introduction to the Manual
  27
- Terms and Abbreviations
  28
- Quick Installation, Commissioning and Operating Flowchart
  29
- Related Documents
  30
- Operation Principle and Hardware Description
  31
- Contents of this Chapter
  31
- Product Overview
  32
- Layout
  33
- Standard Drive Module Configuration
  33
- Drive Module Configuration with Option +B051
  34
- Drive Module with Full Power Cabling Panels (Option +H381)
  36
- Control Panel
  37
- Overview of Power and Control Connections
  38
- Type Designation Label
  39
- Type Designation Key
  40
- Basic Code
  40
- Option Codes
  40
- Ordering Codes
  42
- Generic Cabinet Planning Instructions
  43
- Limitation of Liability
  43
- Cabinet Construction
  43
- Contents of this Chapter
  43
- Planning the Layout of the Cabinet
  44
- Grounding of Mounting Structures
  44
- Busbar Material and Joints
  44
- Shrouds
  44
- Tightening Torques
  44
- Electrical Connections
  44
- Mechanical Connections
  44
- Planning the Cooling
  45
- Air-Cooled Drive Systems
  45
- Air Inlets and Outlets
  45
- Cooling and Degrees of Protection
  45
- Insulation Supports
  45
- Cable Lugs
  45
- Preventing the Recirculation of Hot Air
  46
- EMC Requirements
  47
- Attaching the Cabinet
  49
- Cabinet Placement on a Cable Duct
  49
- Cabinet Heating Elements
  49
- Attaching the Control Panel on the Cabinet Door
  50
- Installation Positions of the Drive Module
  51
- Guidelines for Planning the Mechanical Installation
  51
- Contents of this Chapter
  51
- Planning the Layout
  52
- Layout Example, Door Closed
  52
Layout Example, Door Open (Standard Drive Module Configuration) ￭

53
- Layout Example, Door Open (Standard Drive Module Configuration)
  53
- Cabinet Grounding Busbar (PE)
  54
- L2/V1
  54
- L3/W1
  54
- Layout Example, Door Open (Option +B051)
  54
- Optional Air Baffle that Is Needed When There Is no Fan on the Lower Part of the Cabinet Door
  54
- Supporting Frame of the Cabinet
  54
- T1/U2
  54
- T2/V2
  54
- T3/W2
  54
- Input Power Cable Including the Protective
  55
- Planning the Cooling of the ACS580-04
  55
- Standard Drive Module Configuration
  56
- Contactor
  57
- Disconnector and Fuses
  57
- Drive Module with Option +B051
  57
- Drive Module
  58
- Free Space Around the Drive Module
  58
- Free Space at the Top of the Drive Module
  58
- Free Space below the Drive Module
  58
- Free Space Requirements
  58
- Installation Positions Other than Vertical
  58
- Contents of this Chapter
  61
- Examining the Installation Site
  61
- Mechanical Installation
  61
- Moving and Unpacking the Unit
  61
- Moving the Drive Module
  61
- Unpacking the Transport Package
  62
- Examining the Delivery
  66
- Lifting the Drive Module
  66
- Drive Module with Full Cabling Panels (Option +H381)
  67
- Drive Module with IP20 Shrouds (Option +B051)
  67
- Input Power Cable Connection Terminals (Option +H370) and Ground Busbar Assembly
  67
- Installation Alternatives
  67
- Alternatives for Grounding the Drive Module
  68
- Attaching the Drive Module to a Mounting Plate or Wall
  68
- Drive Module Without Output Cable Connection Terminals (Option +0H371)
  68
- Drive Module Without Pedestal (Option +0H354)
  68
- Installing the Bottom Grille for IP20 Degree Protection (Option +B051)
  70
- Installing External Control Unit (Option +P906)
  71
- Removing the Protective Covering from the Drive Module Air Outlet
  71
- Contents of this Chapter
  73
- Guidelines for Planning the Electrical Installation
  73
- Limitation of Liability
  73
- Selecting the Main Supply Disconnecting Device
  73
- European Union and United Kingdom
  74
- Examining the Compatibility of the Motor and Drive
  74
- North America
  74
- Other Regions
  74
- Selecting the Main Contactor
  74
- Protecting the Motor Insulation and Bearings
  75
- Requirements Tables
  75
- Requirements for ABB Motors, P
  76
- Requirements for ABB Motors, P
  77
- Requirements for Non-ABB Motors, P
  78
- Abbreviations
  79
- Requirements for Non-ABB Motors, P
  79
- Additional Requirements for ABB High-Output and IP23 Motors
  80
- Additional Requirements for Braking Applications
  80
- Additional Requirements for Explosion-Safe (EX) Motors
  80
- Additional Requirements for Non-ABB High-Output and IP23 Motors
  80
- Availability of D U /D T Filter and Common Mode Filter by Drive Type
  80
- HX_ and am
  80
- Additional Data for Calculating the Rise Time and the Peak Line-To-Line Voltage
  81
- Additional Note for Sine Filters
  82
- General Guidelines
  82
- Selecting the Power Cables
  82
- Typical Power Cable Sizes
  82
- Alternate Power Cable Types
  83
- Power Cable Types
  83
- Preferred Power Cable Types
  83
- Additional Guidelines - North America
  84
- Not Allowed Power Cable Types
  84
- Metal Conduit
  85
- Power Cable Shield
  85
- Grounding Requirements
  86
- Additional Grounding Requirements - IEC
  87
- Additional Grounding Requirements - UL (NEC)
  87
- Selecting the Control Cables
  87
- Shielding
  87
- Control Panel to Drive Cable
  88
- General Guidelines - IEC
  88
- PC Tool Cable
  88
- Relay Cable
  88
- Routing the Cables
  88
- Signals in Separate Cables
  88
- Signals that Can be Run in the same Cable
  88
- General Guidelines - North America
  89
- Motor Cable
  90
- Separate Control Cable Ducts
  90
- Implementing Motor and Motor Cable Short-Circuit and Thermal Overload Protection
  91
- Protecting the Motor against Thermal Overload
  91
- Protecting the Motor and Motor Cable in Short-Circuits
  91
- Protecting the Motor Cables against Thermal Overload
  91
- Circuit Breakers
  92
- Protecting the Drive and Input Power Cable in Short-Circuits
  92
- Protecting the Motor against Overload Without Thermal Model or Temperature Sensors
  92
- Implementing the Emergency Stop Function
  93
- Implementing the Power Loss Ride-Through Function
  93
- Implementing the Safe Torque off Function
  93
- Protecting the Drive against Ground Faults
  93
- Protecting the Drive against Thermal Overload
  93
- Protecting the Input Power Cable against Thermal Overload
  93
- Residual Current Device Compatibility
  93
- Tested Circuit Breakers
  93
- Using Power Factor Compensation Capacitors with the Drive
  94
- Controlling a Contactor between Drive and Motor
  95
- Implementing an ATEX-Certified Motor Thermal Protection
  95
- Using a Safety Switch between the Drive and the Motor
  95
- Example Bypass Connection
  96
- Implementing a Bypass Connection
  96
- Protecting the Contacts of Relay Outputs
  97
- Switching the Motor Power Supply from Direct-On-Line to Drive
  97
- Switching the Motor Power Supply from Drive to Direct-On-Line
  97
- Connecting a Motor Temperature Sensor to the Drive through an Option Module
  98
- Implementing a Motor Temperature Sensor Connection
  98
- Contents of this Chapter
  101
- Electrical Installation
  101
- Grounding the Motor Cable Shield at the Motor End
  101
- Safety
  101
- Measuring the Insulation
  102
- Measuring the Insulation Resistance of the Brake Resistor Circuit
  102
- Measuring the Insulation Resistance of the Drive
  102
- Measuring the Insulation Resistance of the Input Power Cable
  102
- Measuring the Insulation Resistance of the Motor and Motor Cable
  102
- EMC Filter Compatibility
  103
- Ground-To-Phase Varistor Compatibility
  103
- Grounding System Compatibility Check - IEC, Not North America
  103
- EMC Filter Compatibility
  104
- Ground-To-Phase Varistor Compatibility
  104
- Grounding System Compatibility Check - North America
  104
- Connecting the Power Cables
  105
- Power Cable Connection Diagram
  105
- Preparing the Cable Ends - Symmetrical Shielded Cables
  106
- Connecting the Control Cables
  107
- DC Connection
  107
- Integrated Control Unit
  107
- Power Cable Connection Process
  107
- Connecting a Control Panel
  108
- External Control Unit (Option +P906)
  108
- Connecting a PC
  110
- Connecting a Remote Panel, or Chaining One Panel to Several Drives
  110
- Installing Option Modules
  110
- Option Slot 2 (I/O Extension Modules)
  111
- Option Slot 1 (Fieldbus Adapter Modules)
  112
- Wiring the Optional Modules
  112
- Contents of this Chapter
  113
- Installation Example of Drive Module with IP20 Shrouds (Option +B051)
  113
- Required Parts
  113
- Safety
  113
- Installing the Drive Module into the Enclosure
  114
- Overall Flowchart of the Installation Process
  114
- Required Tools
  114
- Connecting the Power Cables and Installing the Shrouds
  115
- Installing the Roof and Door (Rittal Parts)
  117
- Installing the Roof and Door (ABB Air Filters and Roof)
  118
- Attaching the Drive Module to a Mounting Plate or Wall
  119
- Input Power Cable Entry from Top
  119
- Miscellaneous
  119
- Removing the Protective Covering from the Drive Module Air Outlet
  119
- Contents of this Chapter
  121
- Installation Example with Full Cabling Panels (Option +H381)
  121
- Safety
  121
- Required Parts
  122
- Required Tools
  122
- Connecting the Power Cables
  123
- Installing the Mechanical Accessories into the Enclosure
  123
- Overall Flowchart of the Installation Process
  123
- Power Cable Connection Procedure
  123
- Installation Procedure
  125
- Installing the Drive Module into the Enclosure
  125
- Assembly Drawing of Installing the Drive Module to the Enclosure (Frame R10)
  129
- Assembly Drawing of Installing the Drive Module to the Enclosure (Frame R11)
  130
- Assembly Drawing of Installing the Roof and Door
  131
- Installations with Input and Motor Cables of Size 4 × 240 MM 2 Per Phase
  132
- Installing the Rubber Grommet
  132
- Miscellaneous
  132
- Removing the Protective Covering from the Drive Module Air Outlet
  132
- Contents of this Chapter
  135
- Control Unit
  135
- Layout
  136
- Default I/O Connection Diagram
  137
- Additional Information on I/O Connections
  139
- PNP Configuration for Digital Inputs (X2 & X3)
  139
- Switches
  139
- Connection Examples of Two-Wire and Three-Wire Sensors to Analog Input (AI2)
  140
- Connection for Obtaining 0
  140
- NPN Configuration for Digital Inputs (X2 & X3)
  140
- AI1 and AI2 as Pt100, Pt1000, Ni1000, KTY83 and KTY84 Sensor Inputs (X1)
  141
- DI5 as Frequency Input
  141
- DI6 as PTC Input
  141
- Safe Torque off (X4)
  142
- Technical Data
  142
- Contents of this Chapter
  147
- External Control Unit (Option +P906)
  147
- Product Overview
  147
- Layout
  148
- Cables
  149
- Unpacking the Delivery
  150
- Installation Procedure
  151
- Installing the Control Unit
  151
- Connecting the Control Unit to the Drive Module
  155
- Dimension Drawing
  158
- Checklist
  159
- Contents of this Chapter
  159
- Installation Checklist
  159
- Contents of this Chapter
  161
- Reforming the Capacitors
  161
- Start-Up
  161
- Start-Up Procedure
  161
- Contents of this Chapter
  163
- Fault Tracing
  163
- Leds
  163
- Warning and Fault Messages
  163
- Contents of this Chapter
  165
- Description of Symbols
  165
- Maintenance
  165
- Maintenance Intervals
  165
- Cabinet
  167
- Cleaning the Interior of the Cabinet
  167
- Cleaning the Interior of the Heatsink
  168
- Heatsink
  168
- Fans
  169
- Replacing the Circuit Board Compartment Cooling Fans
  169
- Replacing the Main Cooling Fans
  170
- Replacing the Drive Module
  171
- Replacing the Drive Module with Option +H381
  173
- Functional Safety Components
  175
- Capacitors
  176
- Control Panel
  176
- Reforming the Capacitors
  176
- Contents of this Chapter
  177
- Electrical Ratings
  177
- IEC Ratings
  177
- Technical Data
  177
- Definitions
  178
- UL (NEC) Ratings
  178
- Output Derating
  179
- When Is Derating Necessary
  179
- Surrounding Air Temperature Derating
  180
- Altitude Derating
  181
- Switching Frequency Derating
  181
- Fuses (IEC)
  182
- Calculating the Short-Circuit Current of the Installation
  183
- Circuit Breakers (IEC)
  184
- Fuses (UL)
  184
- Dimensions, Weights and Free Space Requirements
  185
- Drive Modules with Optional Cabling Panels (+H381)
  187
- Drive Modules Without Output Cable Connection Terminals (+0H371) and with a Common Mode Filter (+E208)
  187
- Losses, Cooling Data and Noise
  187
- Terminal and Entry Data for the Power Cables
  187
- Typical Power Cable Sizes
  188
- Electrical Power Network Specification
  189
- Terminal Data for the Control Cables
  189
- Brake Resistor Connection Data
  190
- Control Panel Type
  190
- Control Unit Data
  190
- DC Connection Data
  190
- Efficiency
  190
- Motor Connection Data
  190
- Ambient Conditions
  191
- Energy Efficiency Data (Ecodesign)
  191
- Protection Classes for Module
  191
- Colors
  192
- Drive Module
  192
- Materials
  192
- Package Materials for Module Products
  192
- Applicable Standards
  193
- Disposal
  193
- Materials of Manuals
  193
- Package Materials for Options, Accessories and Spare Parts
  193
- Markings
  194
- Category C3
  195
- Definitions
  195
- EMC Compliance (IEC/EN 61800-3)
  195
- Category C4
  196
- Declarations of Conformity
  196
- Design Lifetime Expectancy
  197
- UL Checklist
  197
- Cybersecurity Disclaimer
  198
- Disclaimers
  198
- Generic Disclaimer
  198
- Contents of this Chapter
  199
- Dimension Drawings
  199
- R10, Standard Configuration
  200
- R10 with Options +E208+0H354+H356+H370+0H371
  201
- R10 with Option +B051
  202
- R10 with Options +E208+H356+P906
  203
- R10 with Options +E208+0H371+H356+0H354+H370+P906
  204
- R10 with Options +B051+P906
  205
- R10 with Options +E208+H356+H381+P906
  206
- R10 - Cabling Panels (+H381) Installed into a Rittal VX25 Enclosure
  207
- R11, Standard Configuration
  208
- R11 with Options +E208+0H371+H356+0H354+H370
  209
- R11 with Option +B051
  210
- R11 with Options +E208+H356+P906
  211
- R11 with Options +E208+0H371+H356+0H354+H370+P906
  212
- R11 with Options +B051+P906
  213
- R11 with Options +E208+H356+H381+P906
  214
- R11 - Cabling Panels (+H381) Installed into a Rittal VX25 Enclosure
  215
- Air Baffles for the Drive Module with Option +B051
  216
- Air Baffles for Option +H381 in Rittal VX25 400 MM Wide Enclosure Installation
  217
- Material of the Air Baffles
  217
- Bottom Plate for Option +H381 in Rittal VX25 400 MM Wide Enclosure Installation
  218
- Contents of this Chapter
  219
- Example Circuit Diagram
  219
- Contents of this Chapter
  221
- Description
  221
- The Safe Torque off Function
  221
- Chinery (Safety) Regulations
  222
- Connection Principle
  223
- Single ACS580-04 Drive, External Power Supply
  223
- Single ACS580-04 Drive, Internal Power Supply
  223
- Wiring
  223
- Single ACS580-04 Drive, External Power Supply
  224
- Single ACS580-04 Drive, Internal Power Supply
  224
- Wiring Examples
  224
- Multiple ACS580-04 Drives, Internal Power Supply
  225
- Activation Switch
  226
- Multiple ACS580-04 Drives, External Power Supply
  226
- Cable Types and Lengths
  227
- Grounding of Protective Shields
  227
- Operation Principle
  228
- Competence
  229
- Start-Up Including Validation Test
  229
- Validation Test Procedure
  229
- Validation Test Reports
  229
- Use
  231
- Competence
  233
- Maintenance
  233
- Fault Tracing
  234
- Safety Data
  235
- Terms and Abbreviations
  237
- TÜV Certificate
  238
- Declarations of Conformity
  239
- Contents of this Chapter
  241
- Generic Guidelines
  241
- Operation Principle and Hardware Description
  241
- Planning the Braking System
  241
- Resistor Braking
  241
- When Is Resistor Braking Necessary
  241
- Protecting the System against Thermal Overload
  242
- Resistor Cables
  242
- Resistor Thermal Switch
  242
- Calculation Example
  243
- EMC Compliance of the Complete Installation
  243
- Placing the Brake Resistors
  243
- Protecting the System in Fault Situations
  243
- Selecting the Default Brake System Components
  243
- Selecting a Custom Brake Resistor
  244
- Connection Diagram
  245
- Connection Procedure
  245
- Electrical Installation
  245
- Measuring the Insulation of the Brake Resistor Circuit
  245
- Mechanical Installation of Resistors
  245
- Start-Up
  245
- Parameter Settings
  246
- Ratings
  246
- Technical Data
  246
- Dimensions, Weights and Ordering Codes
  247
- SAFUR Resistors
  247
- Terminals and Cable Entry Data
  247
- CAIO-01 Bipolar Analog I/O Adapter Module
  249
- Contents of this Chapter
  249
- Product Overview
  249
- Layout
  250
- Electrical Installation
  251
- Installing the Module
  251
- Mechanical Installation
  251
- Necessary Tools
  251
- Unpacking and Examining the Delivery
  251
- Wiring
  251
- Diagnostics
  252
- Leds
  252
- Setting the Parameters
  252
- Start-Up
  252
- Technical Data
  252
- Isolation Areas
  253
- Dimension Drawings
  254
- CBAI-01 Bipolar Analog IO Adapter Module
  255
- Contents of this Chapter
  255
- Product Overview
  255
- Installing the Module
  256
- Layout
  256
- Mechanical Installation
  256
- Necessary Tools
  256
- Unpacking and Examining the Delivery
  256
- Electrical Installation
  257
- Necessary Tools
  257
- Parameter Setting Example for AI1
  257
- Setting the Parameters
  257
- Start-Up
  257
- Wiring
  257
- Diagnostics
  258
- Leds
  258
- Technical Data
  258
- Dimension Drawing
  259
- CHDI-01 115/230 V Digital Input Extension Module
  261
- Contents of this Chapter
  261
- Product Overview
  261
- Layout and Connection Examples
  262
- Electrical Installation
  263
- Installing the Module
  263
- Mechanical Installation
  263
- Necessary Tools
  263
- Parameter Setting Example for Relay Output
  263
- Setting the Parameters
  263
- Start-Up
  263
- Unpacking and Examining the Delivery
  263
- Wiring
  263
- Dimension Drawing
  264
- Fault and Warning Messages
  264
- Technical Data
  264
- CMOD-01 Multifunction Extension Module
  267
- Contents of this Chapter
  267
- Product Overview
  267
- Layout and Example Connections
  268
- Electrical Installation
  269
- Installing the Module
  269
- Mechanical Installation
  269
- Necessary Tools
  269
- Setting the Parameters
  269
- Start-Up
  269
- Unpacking and Examining the Delivery
  269
- Wiring
  269
- Diagnostics
  270
- Faults and Warning Messages
  270
- Leds
  270
- Technical Data
  270
- Dimension Drawing
  271
- CMOD-02 Multifunction Extension Module
  273
- Contents of this Chapter
  273
- Product Overview
  273
- Layout and Example Connections
  274
- Mechanical Installation
  274
- Necessary Tools
  274
- Diagnostics
  275
- Electrical Installation
  275
- Faults and Warning Messages
  275
- Installing the Module
  275
- Necessary Tools
  275
- Setting the Parameters
  275
- Start-Up
  275
- Unpacking and Examining the Delivery
  275
- Wiring
  275
- Leds
  276
- Technical Data
  276
- Dimension Drawing
  277
- Contents of this Chapter
  279
- Description, Installation and Technical Data of the FOCH Filters
  279
- Filters
  279
- Ordering Codes
  279
- Selection Table
  279
- When Is a Du/Dt Filter Necessary
  279
- Contents of this Chapter
  281
- Ground-To-Phase Varistor Disconnecting Instructions - IEC, Not North America
  281
- Identifying the Grounding System of the Electrical Power Network
  281
- MID-Point-Grounded Delta Systems
  282
- Guidelines for Installing the Drive to a TT System
  283
- Disconnecting the Ground-To-Phase Varistor - IEC, Not North America
  284
- Connecting EMC Filter and Ground-To-Phase Varistor - North America
  285
- Contents of this Chapter
  285
- Identifying the Grounding System of the Electrical Power Network
  285
- Corner-Grounded Delta and MID-Point-Grounded Delta Systems
  286
- Connecting EMC Filter - North America
  287
- Connecting Ground-To-Phase Varistor - North America
  287
- Installation Procedure
  293
- VX25 400 MM Wide Enclosure
  293
- Installation Procedure (Continued)
  294
- Further Information
  297

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Table of Contents
3
1 Manual Introduction

5
2 Safety Instructions

5
- Contents
  5
- Safety of Installation and Maintenance
  5
3 Guide on Installation and Debugging of Filters

7
- Contents
  7
- Product Overview
  7
- Mechanical Installation
  11
- Electrical Connection
  12
- Model Information
  14
- Technical Data
  16
Further Information

21

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Table of Contents
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1 Introduction

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- Contents of this Chapter
  5
- Applicability
  5
- Target Audience
  6
- Purpose of the Manual
  6
- Safety Instructions
  6
2 Reforming the Capacitors

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Further Information

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