ABB ACS580-01 Hardware Manual
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ABB ACS580-01 Hardware Manual

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ABB general purpose drives
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ACS580-01 drives (0.75 to 250 kW)

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Summary of Contents for ABB ACS580-01

  • Page 1 ABB general purpose drives Hardware manual ACS580-01 drives (0.75 to 250 kW)

  • Page 2: List Of Related Manuals

    List of related manuals Drive manuals and guides Code (English) ACS580 firmware manual 3AXD50000016097 ACS580-01 (0.75 to 250 kW) hardware manual 3AXD50000018826 ACS580-01 quick installation and start-up guide for 3AUA0000076332 frames R0 to R3 ACS580-01 quick installation and start-up guide for...
  • Page 3 Hardware manual ACS580-01 drives (0.75 to 250 kW) Table of contents 1. Safety instructions 4. Mechanical installation 6. Electrical installation  2015 ABB Oy. All Rights Reserved. 3AXD50000018826 Rev D EFFECTIVE: 2015-11-02...

  • Page 5: Table Of Contents

    Table of contents 5 Table of contents List of related manuals ............2 1.
  • Page 6 6 Table of contents Unpacking and examining delivery, frame R5 ........43 Frame R5 cable box (IP21, UL Type 1) .
  • Page 7 Connecting the control cables ..........97 Default I/O connection diagram (ABB standard macro) ......98 Control cable connection procedure R0…R9 .
  • Page 8 8 Table of contents Fans ..............122 Replacing the cooling fan, frames R0…R4 .
  • Page 9 Table of contents 9 Compliance with the European EMC Directive ....... . 162 Compliance with the European ROHS II Directive 2011/65/EU .
  • Page 10 Providing feedback on ABB Drives manuals ........
  • Page 11 Table of contents 11 Document library on the Internet ..........225...
  • Page 12 12 Table of contents...

  • Page 13: Safety Instructions

    Safety instructions 13 Safety instructions Contents of this chapter This chapter contains the safety instructions which you must obey when you install and operate the drive and do maintenance on the drive. If you ignore the safety instructions, injury, death or damage can occur. Use of warnings and notes in this manual Warnings tell you about conditions which can cause injury or death, or damage to the equipment.

  • Page 14: General Safety In Installation, Start-Up And Maintenance

    14 Safety instructions General safety in installation, start-up and maintenance These instructions are for all personnel that install the drive and do maintenance work on it. WARNING! Obey these instructions. If you ignore them, injury or death, or damage to the equipment can occur. •...
  • Page 15 Safety instructions 15 make sure that no dangerous situations can occur. These functions reset the drive automatically and continue operation after a fault. • The maximum number of drive power-ups is five in ten minutes. Too frequent power-ups can damage the charging circuit of the DC capacitors. •...

  • Page 16: Electrical Safety In Installation, Start-Up And Maintenance

    16 Safety instructions Electrical safety in installation, start-up and maintenance  Precautions before electrical work These warnings are for all personnel who do work on the drive, motor cable or motor. WARNING! Obey these instructions. If you ignore them, injury or death, or damage to the equipment can occur.

  • Page 17: Additional Instructions And Notes

    Safety instructions 17  Additional instructions and notes WARNING! Obey these instructions. If you ignore them, injury or death, or damage to the equipment can occur. • If you install the drive on an IT system (an ungrounded power system or a high- resistance-grounded [over 30 ohms] power system), disconnect the ground-to- phase varistor;...

  • Page 18: Grounding

    18 Safety instructions WARNING! Use a grounding wrist band when you handle the printed circuit boards. Do not touch the boards unnecessarily. The boards contain components sensitive to electrostatic discharge.  Grounding These instructions are for all personnel who are responsible for the electrical installation, including the grounding of the drive.

  • Page 19: Additional Instructions For Permanent Magnet Motor Drives

    Safety instructions 19 Additional instructions for permanent magnet motor drives  Safety in installation, start-up and maintenance These are additional warnings concerning permanent magnet motor drives. The other safety instructions in this chapter are also valid. WARNING! Obey these instructions. If you ignore them, injury or death and damage to the equipment can occur.

  • Page 20: General Safety In Operation

    20 Safety instructions General safety in operation These instructions are for all personnel that operate the drive. WARNING! Obey these instructions. If you ignore them, injury or death, or damage to the equipment can occur. • Do not control the motor with the disconnector at the drive power supply; instead, use the control panel start and stop keys or commands through the I/O terminals of the drive.

  • Page 21: Introduction To The Manual

    The flowchart refers to chapters/sections in this manual. Applicability The manual applies to the ACS580-01 drives. Target audience The reader is expected to know the fundamentals of electricity, wiring, electrical components and electrical schematic symbols.

  • Page 22: Contents Of This Manual

    22 Introduction to the manual Contents of this manual The manual consists of the following chapters: • Safety instructions (page 13) gives safety instructions you must obey when installing, commissioning, operating and servicing the drive. • Introduction to the manual (this chapter, page 21) describes applicability, target audience, purpose and contents of this manual.

  • Page 23: Categorization By Frame (Size)

    Introduction to the manual 23 Categorization by frame (size) The ACS580-01 is manufactured in frames (frame sizes) R0…R9. Some instructions and other information which only concern certain frames are marked with the symbol of the frame (R0…R9). The frame is marked on the type designation label attached to...

  • Page 24: Quick Installation And Commissioning Flowchart

    24 Introduction to the manual Quick installation and commissioning flowchart Task Identify the frame of your drive: R0…R9. Operation principle and hardware description: Type designation key on page Plan the installation: select the cables, etc. Planning the electrical installation on page Check the ambient conditions, ratings and Technical data on page...
  • Page 25 Introduction to the manual 25 Terms and abbreviations Term/abbreviation Explanation ACS-BP-S Basic control panel, basic operator keypad for communication with the drive ACS-AP-x Assistant control panel, advanced operator keypad for communication with the drive. The ACS580 supports types ACS-AP-I, ACS-AP-S, ACS- AP-W assistant control panel with a Bluetooth interface and ACS-BP-S basic control panel.
  • Page 26 26 Introduction to the manual Term/abbreviation Explanation Frame (size) Refers to drive physical size, for example R0 and R1. The type designation label attached to the drive shows the frame of the drive, see section Type designation key on page 37. FSCA-01 Optional EIA-485 adapter module Input/Output...

  • Page 27: Operation Principle And Hardware Description

    Operation principle and hardware description 27 Operation principle and hardware description Contents of this chapter This chapter briefly describes the operation principle, layout, type designation label and type designation information. It also shows a general diagram of power connections and control interfaces.

  • Page 28: Operation Principle

    28 Operation principle and hardware description Operation principle The ACS580-01 is a drive for controlling asynchronous AC induction motors and permanent magnet synchronous motors. The figure below shows the simplified main circuit diagram of the drive. ACS580-01 T1/U T2/V T3/W...

  • Page 29: Layout

    Operation principle and hardware description 29 Layout Frames R0…R4 The layout of a frame R0 drive is presented below. The construction of frames R1…R3 differs to some extent. Mounting points (4 pieces) 10 EMC filter grounding switch (EMC). R0…R2: On the right side of the drive. Cover R3: On the front, near the I/O Cover screw...
  • Page 30 30 Operation principle and hardware description Frames R6…R9 The layout of a frame R6 drive is presented below. The constructions of frames R7…R9 differ to some extent. R6…R9 Mounting points (2 at the top, 2 at the 13 Varistor grounding screw (VAR), under bottom of the main part of the frame, 2 at the control panel platform the top of the cable box)

  • Page 31: Overview Of Power And Control Connections

    Operation principle and hardware description 31 Overview of power and control connections The logical diagram below shows the power connections and control interfaces of the drive. Panel port Slot 1 Slot 2 T1/U T2/V T3/W UDC+ UDC- Option slot 1 for optional fieldbus adapter modules Option slot 2 for optional I/O extension modules Panel port.

  • Page 32: External Control Connection Terminals, Frames R0

    32 Operation principle and hardware description  External control connection terminals, frames R0…R4 The layout of the external control connection terminals of the R0 frame is shown below. Layout of the external control connection terminals is identical in frames R0…R4 but the location of the control board with the terminals is different in frames R3…R4.

  • Page 33: External Control Connection Terminals, Frame R5

    Operation principle and hardware description 33  External control connection terminals, frame R5…R9 The layout of the external control connection terminals of frames R5…R9 is shown below. Description R5…R9 Analog inputs and outputs Aux. voltage output Digital inputs Safe torque off connection Connection to embedded EIA- 485 fieldbus adapter module (installed in option slot 3)

  • Page 34: Control Panel

    34 Operation principle and hardware description WARNING! Do not connect the +24 V AC cable to the control board ground when the control board is powered using an external 24 V AC supply. Control panel To remove the control panel, press the retaining clip at the top (1a) and pull it forward from the top edge (1b).

  • Page 35: Type Designation Label

    Operation principle and hardware description 35 For the use of the control panel, see ACS580 firmware manual (3AXD50000016097 [English]) and ACS-AP-X assistant control panels user’s manual (3AUA0000085685 [English]). Type designation label The type designation label includes IEC and NEMA ratings, appropriate markings and the type designation and serial number, which allow identification of each drive.

  • Page 36: Locations Of The Labels On The Drive

    36 Operation principle and hardware description  Locations of the labels on the drive...

  • Page 37: Type Designation Key

    You find the type designation on the type designation label attached to the drive. The first digits from the left express the basic configuration, for example, ACS580-01-12A6-4. The optional selections are given after that, separated by plus signs, for example, +L501. The main selections are described below. Not all selections are available for all types.
  • Page 38 38 Operation principle and hardware description CODE DESCRIPTION Fieldbus adapters K454 FPBA-01 PROFIBUS DP K457 FCAN-01 CANopen K451 FDNA-01 DeviceNet™ K473 FENA-11 Ethernet (EtherNet/IP™, Modbus/TCP, PROFINET) K469 FECA-01 EtherCAT K458 FSCA-01 Modbus/RTU K470 FEPL-02 Ethernet POWERLINK K462 FCNA-01 ControlNet™ K475 FENA-21 2-port Ethernet (EtherNet/IP™, Modbus/TCP, PROFINET) Embedded fieldbus CEIA-01 Embedded Modbus RTU adapter, EIA-485 (as standard)

  • Page 39: Mechanical Installation

    Mechanical installation 39 Mechanical installation Contents of this chapter The chapter tells how to check the installation site, unpack, check the delivery and install the drive mechanically. Safety WARNING! Frames R6…R9: Lift the drive with a lifting device. Use the lifting eyes of the drive.

  • Page 40: Checking The Installation Site

    40 Mechanical installation Checking the installation site The drive must be installed on the wall. There are two alternative ways to install it: • vertically alone. Do not install the drive upside down. Frame Vertical installation - size Free space Above (a) Below (b) Beside...

  • Page 41: Required Tools

    Mechanical installation 41 • vertically side by side Frame Vertical installation side by side - c = 0 size Free space Above (a) Below (b) Between (c) 11.8 11.8 11.8 11.8 11.8 3AXD00000586715.xls G Free space below is measured from the frame, not from the cable box used in frames R5…R9.

  • Page 42: Moving The Drive

    42 Mechanical installation Moving the drive Frames R5…R9: Move the transport package by pallet truck to the installation site. Unpacking and examining delivery, frames R0…R4 The figure below shows the drive package with its contents. Examine that all items are present and there are no signs of damage. Read the data on the type designation label of the drive to make sure that the drive is of the correct type.

  • Page 43: Unpacking And Examining Delivery, Frame R5

    Mechanical installation 43 Unpacking and examining delivery, frame R5 The figure below shows the layout of the transport package. Examine that all items are present and there are no signs of damage. Read the data on the type designation label of the drive to make sure that the drive is of the correct type. See section Type designation label on page 35.

  • Page 44: Frame R5 Cable Box (Ip21, Ul Type 1)

    44 Mechanical installation  Frame R5 cable box (IP21, UL Type 1) This illustration shows the contents of the cable box package. The package also includes an assembly drawing which shows how to install the cable box to the drive module frame.

  • Page 45: Unpacking And Examining Delivery, Frames R6

    Mechanical installation 45 Unpacking and examining delivery, frames R6…R9 The figure below shows the layout of the transport package. Examine that all items are present and there are no signs of damage. Read the data on the type designation label of the drive to make sure that the drive is of the correct type. See section Type designation label on page 35.

  • Page 46: Frame R6 Cable Box (Ip21, Ul Type 1)

    46 Mechanical installation To unpack: • Cut the straps (4). • Remove the cardboard box (3) and option tray (8). • Remove the VCI bag (5). • Attach lifting hooks to the lifting eyes of the drive (see the figure on page 39). Lift the drive with a hoist.

  • Page 47: Frame R7 Cable Box (Ip21, Ul Type 1)

    Mechanical installation 47  Frame R7 cable box (IP21, UL Type 1) The figure below shows the contents of the cable box package. The package also includes an assembly drawing which shows how to install cable box to the drive frame.

  • Page 48: Frame R8 Cable Box (Ip21, Ul Type 1)

    48 Mechanical installation  Frame R8 cable box (IP21, UL Type 1) The figure below shows the contents of the cable box package. The package also includes an assembly drawing which shows how to install the cable box to the drive frame.

  • Page 49: Frame R9 Cable Box (Ip21, Ul Type 1)

    Mechanical installation 49  Frame R9 cable box (IP21, UL Type 1) The figure below shows the contents of the cable box package. The package also includes an assembly drawing which shows how to install the cable box to the drive frame.

  • Page 50: Installing The Drive

    50 Mechanical installation Installing the drive  Installing the drive vertically, frames R0…R4 The figures show frame R0 as an example. 1. Mark the hole locations using the mounting template included in the package. Do not leave the mounting template under the drive. The drive dimensions and hole locations are also shown in the drawings in chapter Dimension drawings on page...
  • Page 51 Mechanical installation 51 4. Position the drive onto the bolts on the wall. 5. Tighten the bolts in the wall securely. × 4...

  • Page 52: Installing The Drive Vertically, Frame R5

    52 Mechanical installation  Installing the drive vertically, frame 1. Mark the hole locations using the mounting template included in the package. Do not leave the mounting template under the drive. The drive dimensions and hole locations are also shown in the drawings in chapter Dimension drawings on page 167.
  • Page 53 Mechanical installation 53 4. Remove the front cover: Remove the fastening screws, move the cover to the top side and then up.
  • Page 54 54 Mechanical installation 5. Attach the cable box to the drive frame. Push the box up to the drive frame and tighten the box screws. 6. Position the drive (without the cover) onto the bolts on the wall. Lift the drive with another person or with a lifting device as it is heavy.

  • Page 55: Installing The Drive Vertically, Frames R6

    Mechanical installation 55  Installing the drive vertically, frames R6…R9 1. Mark the hole locations for the six mounting holes using the mounting template included in the package. Do not leave the mounting template under the drive. The drive dimensions and hole locations are also shown in the drawings in chapter Dimension drawings on page 167.

  • Page 56: Installing The Drive Vertically Side By Side

    56 Mechanical installation 6. Remove the front cover: Remove the fastening screws (a), move the cover to the top side (b) and then up (c). 7. Attach the cable box to the drive frame. 8. Tighten the box screws: two at the top and four at the bottom. M8×6 ...

  • Page 57: Planning The Electrical Installation

    Planning the electrical installation 57 Planning the electrical installation Contents of this chapter This chapter contains instructions for planning the electrical installation of the drive, for example, for checking the compatibility of the motor and drive, selecting cables, protections and cable routing. Note: The installation must always be designed and made according to applicable local laws and regulations.

  • Page 58: Other Regions

    58 Planning the electrical installation  Other regions The disconnecting device must conform to the applicable local safety regulations. Checking the compatibility of the motor and drive Use an asynchronous AC induction motor or a permanent magnet motor with the drive.

  • Page 59: Typical Power Cable Sizes

    Planning the electrical installation 59  Typical power cable sizes The table below gives copper cable types with concentric copper shield for the drives with nominal current. The value separated by the plus sign means the diameter of the PE conductor. Drive type Frame ACSH580...

  • Page 60: Alternative Power Cable Types

    60 Planning the electrical installation  Alternative power cable types The recommended and the not allowed power cable types to be used with the drive are presented below. Recommended power cable types Symmetrical shielded cable with three phase conductors and a concentric PE conductor as the shield.

  • Page 61: Motor Cable Shield

    Planning the electrical installation 61  Motor cable shield If the motor cable shield is used as the sole protective earth conductor of the motor, make sure that the conductivity of the shield is sufficient. See section General rules above, or IEC 61439-1. To effectively suppress radiated and conducted radio-frequency emissions, the cable shield conductivity must be at least 1/10 of the phase conductor conductivity.

  • Page 62: Selecting The Control Cables

    62 Planning the electrical installation Armored cable / shielded power cable Six-conductor (three phases and three ground) type MC continuous corrugated aluminum armor cable with symmetrical grounds is available from the following suppliers (trade names in parentheses): • Anixter Wire & Cable (Philsheath) •...

  • Page 63: Relay Cable

    Planning the electrical installation 63  Relay cable The cable type with braided metallic screen (for example ÖLFLEX by LAPPKABEL, Germany) has been tested and approved by the manufacturer.  Control panel cable In remote use, the cable connecting the control panel to the drive must not exceed 100 m (330 ft).

  • Page 64: Routing The Cables

    64 Planning the electrical installation Routing the cables  General rules Route the motor cable away from other cable routes. Motor cables of several drives can be run in parallel installed next to each other. The motor cable, input power cable and control cables should be installed on separate trays.

  • Page 65: Separate Control Cable Ducts

    Planning the electrical installation 65  Separate control cable ducts Lead 24 V and 230 V (120 V) control cables in separate ducts unless the 24 V cable is insulated for 230 V (120 V) or insulated with an insulation sleeving for 230 V (120 V).

  • Page 66: Implementing Thermal Overload And Short-Circuit Protection

    66 Planning the electrical installation Implementing thermal overload and short-circuit protection  Protecting the drive and input power cable in short-circuits Protect the drive and input cable with fuses as follows: Size the fuses at the distribution board according to instructions given in chapter Technical data on page 133.

  • Page 67: Protecting The Drive Against Ground Faults

    Planning the electrical installation 67 temperature indication given by motor temperature sensors. The user can tune the thermal model further by feeding in additional motor and load data. The most common temperature sensors are: • motor sizes IEC180…225: thermal switch, eg, Klixon •...

  • Page 68: Using A Contactor Between The Drive And The Motor

    68 Planning the electrical installation Using a contactor between the drive and the motor Implementing the control of the output contactor depends on how you select the drive to operate. See also section Implementing a bypass connection on page 68. When you have selected to use •...

  • Page 69: Example Bypass Connection

    Planning the electrical installation 69  Example bypass connection An example bypass connection is shown below. Main switch for the drive Drive main contactor on/off control Bypass circuit breaker Motor power supply selection (drive or direct-on-line) Drive main contactor Start when the motor is connected direct- on-line Bypass contactor Stop when the motor is connected direct-...

  • Page 70: Protecting The Contacts Of Relay Outputs

    70 Planning the electrical installation Switching the motor power supply from drive to direct-on-line 1. Stop the drive and the motor with the drive control panel (drive in local control mode) or with the external stop signal (drive in remote control mode). 2.

  • Page 71: Limiting Relay Output Maximum Voltages At High Installation Altitudes

    Planning the electrical installation 71 230 V AC 230 V AC + 24 V DC Relay outputs Varistor RC filter Diode Limiting relay output maximum voltages at high installation altitudes See sections Isolation areas, R0…R4 (CCU-11): on page Isolation areas, R5…R9 (CCU-12): on page 156.
  • Page 72 72 Planning the electrical installation...

  • Page 73: Electrical Installation

    Electrical installation 73 Electrical installation Contents of this chapter The chapter describes how to check the insulation of the assembly and the compatibility with IT (ungrounded) and corner-grounded TN systems. It then shows how to connect the power and control cables, install optional modules and connect a Warnings WARNING! Obey the instructions in chapter Safety instructions...

  • Page 74: Checking The Insulation Of The Assembly

    74 Electrical installation Checking the insulation of the assembly  Drive Do not make any voltage tolerance or insulation resistance tests on any part of the drive as testing can damage the drive. Every drive has been tested for insulation between the main circuit and the chassis at the factory.

  • Page 75: Brake Resistor Assembly For R0

    Electrical installation 75  Brake resistor assembly for R0…R3 Check the insulation of the brake resistor assembly (if present) as follows: 1. Check that the resistor cable is connected to the resistor, and disconnected from the drive output terminals R+ and R-. 2.

  • Page 76: Ground-To-Phase Varistor

    76 Electrical installation  Ground-to-phase varistor The ground-to-phase varistor is not suitable for use on an IT (ungrounded) system. Disconnect the ground-to-phase varistor before connecting the drive to the supply network. Check the table below. WARNING! Do not install the drive with the ground-to-phase varistor connected on an IT system (an ungrounded power system or a high- resistance-grounded [over 30 ohms] power system), otherwise the varistor circuit can be damaged.

  • Page 77: Frames R0

    Electrical installation 77  Frames R0…R3 To disconnect the internal EMC filter or ground-to-phase varistor, if needed, do as follows: 1. Switch off the power from the drive. 2. Open the front cover, if not already opened, see page 81. 3.

  • Page 78: Frames R4

    78 Electrical installation  Frames R4…R9 To disconnect the internal EMC filter or ground-to-phase varistor, if needed, do as follows: 1. Switch off the power from the drive. 2. Open the cover, if not already opened. Frame R5: see page 53, frames R6…R9: see page 56.
  • Page 79 Electrical installation 79 R6…R9...

  • Page 80: Connecting The Power Cables

    80 Electrical installation Connecting the power cables  Connection diagram ACS580-01 UDC+ T1/U T2/V T3/W 3 ~ M (PE) (PE) For alternatives, see section Selecting the supply disconnecting device on page Use a separate grounding PE cable (2a) or a cable with a separate PE conductor (2b) if the conductivity of the shield does not meet the requirements for the PE conductor (see page 58).

  • Page 81: Connection Procedure, Frames R0

    Electrical installation 81  Connection procedure, frames R0…R4 1. Remove the front cover: Loosen the retaining screw with a screwdriver (1a) and lift the cover from the bottom outwards (1b). IP55, R3, R4 and IP21, R4 IP21, R0…R3 IP55, R0…R2 WARNING! If the drive will be connected on an IT (ungrounded) system, make sure you have disconnected the EMC filter and ground-to-phase varistor.
  • Page 82 82 Electrical installation 3. Remove the rubber grommets from the lead-through plate. 4. Frames R0…R2, optional: It is possible to temporarily remove the power cable grounding shelf at this point to make it easier to connect the power cable conductors and twisted shields in a tight space. The grounding shelf must be reinstalled before grounding the stripped parts of the power cables 360 degrees.
  • Page 83 Electrical installation 83 7. Slide the cable through the hole of the lead-through plate and attach the grommet to the hole. 8. Connect the motor cable: If you temporarily removed the power cable grounding shelf in step 4, connect the motor and input power cables except the 360 degree grounding, and then reinstall the grounding shelf.
  • Page 84 84 Electrical installation Input power cable 9. Cut an adequate hole into the rubber grommet. Slide the grommet onto the cable. 10. Prepare the ends of the cable as illustrated in the figure. If you use aluminum cables, put grease to the peeled aluminum cable before connecting it to the drive. Note: The bare shield will be grounded 360 degrees.
  • Page 85 Electrical installation 85 Brake resistor cable (if used) 13. Frames R0…R2: Install the grounding shelf for the brake resistor cable (included with the mounting screws in a plastic bag in the delivery) onto the grounding shelf for the power cables. R0…R2 14.
  • Page 86 86 Electrical installation 15. Connect the cable as the motor cable in step 8. Ground the shield 360 degrees (15a). Connect the twisted shield to the grounding terminal (15b) and the conductors to the R+ and R- terminals (15c) and tighten to the torque given below the figure.
  • Page 87 Electrical installation 87 17. Put the (so far) unused rubber grommets to the holes in the lead-through plate, unless you will continue with installing the control cables. R0…R2 18. Secure the cables outside the unit mechanically. 19. Ground the motor cable shield at the motor end. For minimum radio frequency interference, ground the motor cable shield 360 degrees at the lead-through of the motor terminal box.

  • Page 88: Connection Procedure, Frame R5

    88 Electrical installation  Connection procedure, frame R5 Prepare the drive and the cables WARNING! If the drive will be connected on an IT (ungrounded) system, make sure you have disconnected the EMC filter and ground-to-phase varistor. See page 75. If the drive will be connected on a corner-grounded TN system, make sure you have disconnected the EMC filter.
  • Page 89 Electrical installation 89 3. Cut adequate holes into the rubber grommets. Slide the grommets onto the cables. Prepare the ends of the cables as illustrated in the figure. If you use aluminum cables, put grease to the peeled aluminum cable before connecting it to the drive.
  • Page 90 90 Electrical installation Connect the cables 4. Connect the motor cable: • Ground the shield 360 degrees under the grounding clamps (4a). • Connect the twisted shield of the cable to the grounding terminal (4b). • Connect the phase conductors of the cable to the T1/U, T2/V and T3/W terminals (4c).
  • Page 91 Electrical installation 91 10. Ground the motor cable shield at the motor end. For minimum radio frequency interference, ground the motor cable shield 360 degrees at the lead-through of the motor terminal box.

  • Page 92: Connection Procedure, Frames R6

    92 Electrical installation  Connection procedure, frames R6…R9 WARNING! If the drive will be connected on an IT (ungrounded) system, make sure you have disconnected the EMC filter and ground-to-phase varistor. See page 75. If the drive will be connected on a corner-grounded TN system, make sure you have disconnected the EMC filter.

  • Page 93: Motor Cable

    Electrical installation 93 Motor cable 6. Cut an adequate hole into the rubber grommet. Slide the grommet onto the cable. 7. Prepare the ends of the input power cable and motor cable as illustrated in the figure. If you use aluminum cables, put grease to the peeled aluminum cable before connecting it to the drive.
  • Page 94 94 Electrical installation Note 2 for frames R8…R9: The connectors are detachable but we do not recommend that you detach them. If you do, detach and reinstall the connectors as follows. Terminals L1, L2 and L3 • Remove the combi screw that attaches the connector to its terminal post, and pull the connector off.
  • Page 95 Electrical installation 95 10. Connect the input power cable as in step 9. Use terminals L1, L2 and L3. M5×25/35 Frame size L1, L2, L3, T1/U, T2/V, T3/W N·m lbf·ft N·m lbf·ft 22.1 29.5 29.5 51.6 11. Frames R8…R9: If you install parallel cables, install the second grounding shelf for the parallel power cables (11a).

  • Page 96: Dc Connection

    96 Electrical installation 13. Reinstall the shroud on the power terminals. 14. Secure the cables outside the unit mechanically. 15. Ground the motor cable shield at the motor end. For minimum radio frequency interference, ground the motor cable shield 360 degrees at the lead-through of the motor terminal box.

  • Page 97: Connecting The Control Cables

    See section Default I/O connection diagram (ABB standard macro) on page for the default I/O connections of the ABB standard macro. For other macros, see ACS580 firmware manual (3AXD50000016097 [English]). Connect the cables as described under Control cable connection procedure R0…R9...

  • Page 98: Default I/O Connection Diagram (Abb Standard Macro)

    98 Electrical installation  Default I/O connection diagram (ABB standard macro) AI1 U/I Voltage/Current selection for AI1: AI2 U/I Voltage/Current selection for AI2: Reference voltage and analog inputs and outputs Signal cable shield (screen) Output frequency/speed reference: 0…10 V 1…10 kohm...
  • Page 99 Electrical installation 99 Notes: Current [0(4)…20 mA, R = 100 ohm] or voltage [ 0(2)…10 V, R > 200 kohm] input selected with switch S1 (AI1). Change of setting requires changing the corresponding parameter. Current [0(4)…20 mA, R = 100 ohm] or voltage [ 0(2)…10 V, R >...
  • Page 100 100 Electrical installation Switches Switch Description Position Determines whether analog input AI1 is Voltage (U) (default) used as a voltage or current input. (AI1) Current (I) Determines whether analog input AI2 is Voltage (U) used as a voltage or current input. (AI2) Current (I) (default) Determines whether analog output AO1 is...
  • Page 101 Electrical installation 101 PNP configuration for digital inputs Internal and external +24 V power supply connections for PNP configuration are shown in the figure below. Internal +24 V power supply External +24 V power supply PNP connection (source) PNP connection (source) X2 &...
  • Page 102 102 Electrical installation Connection for obtaining 0…10 V from analog output 2 (AO2) To obtain 0…10 V from analog output AO2, connect a 500 ohm resistor (or two 1 kohm resistors in parallel) between the analog output 2 AO2 and analog common ground AGND.
  • Page 103 Electrical installation 103 Connection examples of two-wire and three-wire sensors Hand/Auto, Hand/PID, and PID macros (see ACS580 firmware manual (3AXD50000016097 [English])) use analog input 2 (AI2). The macro wiring diagrams on these pages use an externally powered sensor (connections not shown). The figures below give examples of connections using a two-wire or three-wire sensor/transmitter supplied by the drive auxiliary voltage output.
  • Page 104 104 Electrical installation DI6 as frequency input If DI6 is used as a frequency input, see ACS580 firmware manual (3AXD50000016097 [English]) for how to set parameters accordingly. AI1 and AI2 as Pt100, Pt1000, Ni1000, KTY83 and KTY84 sensor inputs (X1) One, two or three Pt100 sensors;...

  • Page 105: Control Cable Connection Procedure R0

    Electrical installation 105  Control cable connection procedure R0…R9 WARNING! Obey the instructions in chapter Safety instructions on page 13. If you ignore them, injury or death, or damage to the equipment can occur. 1. Stop the drive and do the steps in section Precautions before electrical work page before you start the work.
  • Page 106 106 Electrical installation 9. Route the cable as shown in the figures on pages (R0…R2), (R3), (R5) or (R6…R9). 10. Connect the conductors to the appropriate terminals of the control board and tighten to 0.5…0.6 N·m (0.4 lbf·ft). 11. Tie all control cables to the provided cable tie mounts. Note: •...
  • Page 107 Electrical installation 107 R0…R2 R3, R4 R3: 0.5…0.6 N·m (0.4 lbf·ft) R0…R2: 0.5…0.6 N·m (0.4 lbf·ft)
  • Page 108 108 Electrical installation 0.5…0.6 N·m (0.4 lbf·ft) 0.5…0.6 N·m (0.4 lbf·ft)
  • Page 109 Electrical installation 109 R6…R9 0.5...0.6 N·m (0.4 lbf·ft) 0.5...0.6 N·m (0.4 lbf·ft) M4×20...

  • Page 110: Installing Option Modules

    110 Electrical installation Installing option modules Note: If you will install the FPBA 01 module, see section FPBA-01 PROFIBUS DP adapter module connectors on page for suitable connector types.  Mechanical installation of option modules See section Overview of power and control connections page for the available slots for each module.
  • Page 111 Electrical installation 111 Option slot 1 (fieldbus adapter modules) 6. Put the module carefully into its position on the control board. 7. Tighten the mounting screw (CHASSIS). Note: The screw tightens the connections and grounds the module. It is necessary for fulfilling the EMC requirements and for proper operation of the module.

  • Page 112: Wiring The Modules

    112 Electrical installation R6…R9  Wiring the modules See the appropriate option module manual for specific installation and wiring instructions.

  • Page 113: Reinstalling Covers

    Electrical installation 113 Reinstalling covers  Reinstalling cover, frames R0…R4 1. Reinstall the cover: Put the tabs on the cover top in their counterparts on the housing (1a) and the press the cover (1b). 2. Tighten the retaining screw at the bottom with a screwdriver. IP55, R0…R3 IP21 IP55, R3 and IP21, R4...

  • Page 114: Reinstalling Covers, Frame R5

    114 Electrical installation  Reinstalling covers, frame R5 1. Install the cover of the cable box. 2. Tighten the two retaining screws with a screwdriver. 3. Reinstall the module cover. Put the tabs on the cover top in their counterparts on the housing and then press the cover.

  • Page 115: Reinstalling Side Plates And Covers, Frames R6

    Electrical installation 115  Reinstalling side plates and covers, frames R6…R9 IP21 1. Reinstall the side plates of the cable box. Tighten the retaining screws with a screwdriver. 2. Slide the cover of the cable box on the module from below until the cover snaps into place.

  • Page 116: Connecting A Pc

    116 Electrical installation Connecting a PC To be able to connect a PC to the drive, you need an assistant control panel. Connect a PC to the drive with a USB data cable (USB Type A <-> USB Type Mini-B) as follows: 1.

  • Page 117: Installation Checklist

    Installation checklist 117 Installation checklist Contents of this chapter This chapter contains an installation checklist which you must complete before you start up the drive. Warnings WARNING! Obey the instructions in chapter Safety instructions on page 13. If you ignore them, injury or death, or damage to the equipment can occur. Checklist Do the steps in section Precautions before electrical work...
  • Page 118 118 Installation checklist Check that … There is an adequately sized protective earth (ground) conductor between the motor and the drive. All protective earth (ground) conductors have been connected to the appropriate terminals and the terminals have been tightened (pull conductors to check). The supply voltage matches the nominal input voltage of the drive.

  • Page 119: Maintenance And Hardware Diagnostics

    The manufacturer recommends annual drive inspections to ensure the highest reliability and optimum performance. Consult your local representative for more details on the maintenance. On the Internet, go to http://www.abb.com/drives. See the maintenance instructions in this chapter.

  • Page 120: Preventive Maintenance Intervals

    120 Maintenance and hardware diagnostics  Preventive maintenance intervals The table below shows the intervals for the preventive maintenance tasks allowed for the customer. For other maintenance tasks, consult your local representative, or see the complete maintenance schedule on the Internet. Years from start-up Maintenance task/object 9 10 11 12 …...

  • Page 121: Heatsink

    Maintenance and hardware diagnostics 121 Replacement (R) Replacement in harsh conditions* Other work (commissioning, tests, measurements, etc.) * Ambient temperature constantly over 40 °C, especially dusty or humid ambient conditions, cyclic heavy load, or continuous nominal (full) load. To maintain the best possible performance and reliability of the drive, inspect the drive annually.

  • Page 122: Fans

    122 Maintenance and hardware diagnostics Fans See section Maintenance intervals on page for the fan replacement interval in average operation conditions. Parameter 05.04 Fan on-time counter indicates the running time of the cooling fan. Reset the counter after a fan replacement. In a speed-controlled fan, the speed of the fan matches the cooling needs.
  • Page 123 Maintenance and hardware diagnostics 123 R1…R2 3. Install the fan assembly in reverse order.

  • Page 124: Replacing The Cooling Fan, Frame R5

    124 Maintenance and hardware diagnostics  Replacing the cooling fan, frame R5 WARNING! Obey the instructions in chapter Safety instructions on page 13. Ignoring the instructions can cause physical injury or death, or damage to the equipment. 1. Stop the drive and disconnect it from the power line. Wait for 5 minutes and then make sure by measuring that there is no voltage.
  • Page 125 Maintenance and hardware diagnostics 125 1. Stop the drive and disconnect it from the power line. Wait for 5 minutes and then make sure by measuring that there is no voltage. See section Precautions before electrical work on page before you start the work. 2.

  • Page 126: Replacing The Main Cooling Fans, Frame R9

    126 Maintenance and hardware diagnostics  Replacing the main cooling fans, frame R9 WARNING! Obey the instructions in chapter Safety instructions on page 13. Ignoring the instructions can cause physical injury or death, or damage to the equipment. 1. Stop the drive and disconnect it from the power line. Wait for 5 minutes and then make sure by measuring that there is no voltage.

  • Page 127: Replacing The Auxiliary Cooling Fan, Frames R4

    Maintenance and hardware diagnostics 127  Replacing the auxiliary cooling fan, frames R4…R9 WARNING! Obey the instructions in chapter Safety instructions on page 13. Ignoring the instructions can cause physical injury or death, or damage to the equipment. 1. Stop the drive and disconnect it from the power line. Wait for 5 minutes and then make sure by measuring that there is no voltage.

  • Page 128: Capacitors

    For information on reforming the capacitors, see Converter module capacitor reforming instructions (3BFE64059629 [English]), available on the Internet (go to http://www.abb.com and enter the code in the Search field).

  • Page 129: Control Panel

    Maintenance and hardware diagnostics 129 Control panel  Cleaning the control panel Use a soft damp cloth to clean the control panel. Avoid harsh cleaners which could scratch the display window.  Replacing the battery in the assistant control panel A battery is only used in assistant control panels that have the clock function.

  • Page 130: Leds

    130 Maintenance and hardware diagnostics LEDs  Drive LEDs There is a green POWER and a red FAULT LED on the front of the drive. They are visible through the panel cover but invisible if a control panel is attached to the drive. The table below describes the drive LED indications.

  • Page 131: Control Panel Leds

    Maintenance and hardware diagnostics 131  Control panel LEDs The assistant control panel has one LED. The table below describes the control panel LED indications. For more information see ACS-AP-x assistant control panels user’s manual (3AUA0000085685 [English]). Control panel LED, at the left edge of the control panel LED off LED lit and steady LED blinking/flickering...
  • Page 132 132 Maintenance and hardware diagnostics...

  • Page 133: Technical Data

    Technical data 133 Technical data Contents of this chapter The chapter contains the technical specifications of the drive, for example ratings, sizes and technical requirements as well as provisions for fulfilling the requirements for CE, UL and other approval marks.

  • Page 134: Ratings

    134 Technical data Ratings  IEC ratings Type Input Max. Output ratings Max. Frame rating current losses size ACS580 Nominal use Light-duty use Heavy-duty use -01- 3-phase U = 400 V (380…415 V) 02A6-4 0.75 0.75 0.55 03A3-4 0.75 04A0-4 05A6-4 07A2-4 10.1...

  • Page 135: Nema Ratings

    Technical data 135  NEMA ratings Type Input Max. Output ratings Max. Air flow Frame rating current losses ACS580 size Nominal use Heavy-duty use -01- 3-phase U = 480 V (440…480 V) 02A6-4 0.75 03A3-4 04A0-4 05A6-4 07A2-4 09A4-4 12A6-4 11.0 11.4 11.0...

  • Page 136: Sizing

    The derating factor for 1500 m is 1 - 1/10 000 m · (1500 - 1000) m = 0.95. The minimum size required becomes then I = 18.18 A / 0.95 = 19.14 A. Referring to I in the ratings tables (starting from page 134), drive type ACS580-01-025A-4 exceeds the I requirement of 19.24 A.

  • Page 137: Ambient Temperature Derating, Ip21

    Technical data 137  Ambient temperature derating, IP21 Frame size Temperature range R0…R3 up to +50 °C No derating up to +122 °F R4…R9 up to +40 °C No derating up to +104 °F +40…+50 °C Derate 1% for every 1 °C (1.8 °F) +104…+122 °F The output current is calculated by multiplying the current given in the rating table by the derating factor (k, in the diagram below).

  • Page 138: Ambient Temperature Derating, Ip55

    138 Technical data  Ambient temperature derating, IP55 IP55 (UL Type 12) drive types, other than the exceptions listed in the following subheadings In the temperature range +40…50 °C (+104…122 °F), the rated output current is derated by 1% for every added 1 °C (1.8 °F). The output current can be calculated by multiplying the current given in the rating table by the derating factor (k): 1.00 0.95...

  • Page 139: Ip55 (Ul Type 12) Drive Type -363A-4

    Technical data 139 (1.8 °F). The output current can be calculated by multiplying the current given in the rating table by the derating factor (k): 1.00 0.95 0.90 0.85 0.80 0.75 … -15 °C +40 °C +45 °C +50 °C -59 °F +104 °F +113 °F...

  • Page 140: Switching Frequency Derating

    140 Technical data  Switching frequency derating The output current is calculated by multiplying the current given in the rating table by the derating factor given in the table below. Note: If you change the minimum switching frequency with parameter 97.02 Minimum switching frequency, derate according to the table below.

  • Page 141: Fuses (Iec)

    Technical data 141 Fuses (IEC) gG as well as uR or aR fuses for protection against short-circuit in the input power cable or drive are listed below. Either fuse type can be used for frames R0…R9 if it operates rapidly enough. The operating time depends on the supply network impedance and the cross-sectional area and length of the supply cable.

  • Page 142: Gg Fuses

    0.5 seconds. Obey the local regulations. Type Min. short- Input gG (IEC 60269) circuit current ACS580 Nominal Voltage ABB type IEC 60269 current -01- current rating size 3-phase U = 400 or 480 V (380…415 V, 440…480 V) 02A6-4...

  • Page 143: Ur And Ar Fuses

    Technical data 143  uR and aR fuses Type Min. short- Input uR or aR circuit current ACS580 Nominal Voltage Bussmann IEC 60269 current -01- current rating type size 3-phase U = 400 or 480 V (380…415 V, 440…480 V) 02A6-4 170M1561 03A3-4...

  • Page 144: Dimensions, Weights And Free Space Requirements

    144 Technical data Dimensions, weights and free space requirements Frame Dimensions and weights size IP21 / UL type 1 Weight 14.9 45.0 3AXD00000586715.xls G Frames with an integrated gland box Frame Dimensions and weights size IP55 / UL type 12 Weight 15.1 3AXD00000586715.xls G...
  • Page 145 Technical data 145 Symbols IP21 / UL type 1 Height back without gland box Height front without gland box Height front with gland box Height back with gland box Width Depth Frame Free space size Vertical mounting Vertical mounting stand alone side by side Above Below...

  • Page 146: Cooling Data And Noise

    146 Technical data Cooling data and noise The air flow direction is from bottom to top. The table below specifies the heat dissipation in the main circuit at nominal load and in the control circuit with minimum load (I/O, options and panel not in use) and maximum load (all digital inputs and relays in the ON state, and the panel, fieldbus and fan in use).

  • Page 147: Terminal And Lead-Through Data For The Power Cables

    Technical data 147 Terminal and lead-through data for the power cables Input, motor, resistor and DC cable lead-throughs, maximum wire sizes (per phase) and terminal screw sizes and tightening torques (T) are given below. Frame Cable lead- L1, L2, L3, T1/U, T2/V, Grounding throughs T3/W terminals...

  • Page 148: Terminal And Lead-Through Data For The Control Cables

    148 Technical data Frame Cable lead- R+, R-, UDC+ and UDC- terminals throughs size Ø Min wire Max wire T (Wire screw) cable size (solid/ size (solid/ type stranded) stranded) M… N·m 0.20/0.25 0.5…0.6 0.20/0.25 0.5…0.6 0.5/0.5 16/16 1.2…1.5 0.5/0.5 35/25 2.5…4.1 0.5/0.5...

  • Page 149: Electrical Power Network Specification

    Technical data 149 Electrical power network specification Voltage (U Input voltage range 3~ 380…480 V AC. This is indicated in the type designation label as typical input voltage levels 3~ 400/480 V AC. Network type Public low voltage networks. TN (grounded), IT (ungrounded) and corner-grounded TN systems.
  • Page 150 150 Technical data Maximum recommended motor Operational functionality and motor cable length cable length The drive is designed to operate with optimum performance with the following maximum motor cable lengths. Note: Conducted and radiated emissions of these motor cable lengths do not comply with EMC requirements. Frame Maximum motor cable length, 4 kHz size...
  • Page 151 Technical data 151 Frame Maximum motor cable length, 4 kHz size EMC limits for Category C2 Standard drive with an internal EMC filter. See notes 2, 3 and 5. EMC limits for Category C3 Standard drive with an internal EMC filter. See notes 3 and 4. 3AXD00000586715.xls G See the terms in section Definitions...

  • Page 152: Brake Resistor Connection Data For Frames R0

    152 Technical data Note 2: Radiated emissions are according to C2 with an internal EMC filter. Note 3: The internal EMC filter must be connected. Note 4: Radiated and conducted emissions are according to category C3 with an internal filter and these cable lengths.
  • Page 153 Technical data 153 Digital inputs DI1…DI6 Input type: NPN/PNP (Term. 13…18) Terminal size: Frames R0…R4: 0.14…1.5 mm Frames R5…R9: 0.14…2.5 mm DI1…DI5 (Term.13…17) 12/24 V DC logic levels: “0” < 4 V, “1” > 8 V : 3 kohm Hardware filtering: 0.04 ms, digital filtering: 2 ms sampling DI6 (Term.18) Can be used as a digital or frequency input.
  • Page 154 154 Technical data STO cable Maximum cable length 300 m (984 ft) between activation switch (K) and drive control board, see sections Wiring examples on page Safety data on page Control panel - drive connection EIA-485, male RJ-45 connector, max. cable length 100 m Control panel - PC connection USB Type Mini-B, max.
  • Page 155 Technical data 155 Isolation areas, R0…R4 (CCU-11): Panel port AI/AO Power unit connection 24 V SLOT1 SLOT3 SLOT2 I/O extension Symbol Description Reinforced insulation (IEC/EN 61800-5-1:2007) Functional insulation (IEC/EN 61800-5-1:2007) Below altitudes 2000 m (6562 ft): The terminals on the control board fulfil the Protective Extra Low Voltage (PELV) requirements (EN 50178): There is adequate insulation between the user terminals which only accept ELV voltages and terminals that accept higher voltages (relay...
  • Page 156 156 Technical data Isolation areas, R5…R9 (CCU-12): SLOT1 X1:1…3 X1:4…6 X1:7…8 Power unit connection 24 V X3:1…3 X3:4…6 SLOT3 Ext. 24 V SLOT2 I/O extension Panel port Symbol Description Reinforced insulation (IEC/EN 61800-5-1:2007) The terminals on the control board fulfil 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 157 Technical data 157 Grounding of frames R0…R4 (CCU-11) Slot 1 Slot 2 AGND +10V AGND AGND X2 & X3 +24V DGND DCOM X6, X7, X8 RO1C RO1A RO1B RO2C RO2A RO2B RO3C RO3A RO3B DGND OUT1 OUT2 SGND Ground Jumper installed at factory...
  • Page 158 158 Technical data Grounding of frames R5…R9 (CCU-12) Slot 1 Slot 2 AGND +10V AGND AGND X2 & X3 +24V DGND DCOM X6, X7, X8 RO1C RO1A RO1B RO2C RO2A RO2B RO3C RO3A RO3B DGND OUT1 OUT2 SGND 24VAC/DC-in 24VAC/DC+in Ground Jumper installed at factory...

  • Page 159: Efficiency

    Technical data 159 Auxiliary circuit power consumption Maximum external power supply: Frames R0…R4: 25 W, 1.04 A at 24 V AC/DC (with option modules CMOD-01, CMOD-02) Frames R5…R9: 36 W, 1.50 A at 24 V AC/DC (as standard, terminals 40…41) Efficiency Approximately 98% at nominal power level Degree of protection...
  • Page 160 160 Technical data Contamination levels IEC 60721-3- IEC 60721-3- IEC 60721-3- 3:2002: 1:1997 2:1997 Classification of environmental conditions - Part 3-3: Classification of groups of environmental parameters and their severities - Stationary use of weather protected locations Chemical gases Class 3C2 Class 1C2 Class 2C2 Solid particles...

  • Page 161: Materials

    Technical data 161 Materials Drive enclosure • PC/ABS 3 mm, color NCS 1502-Y (RAL 9002 / PMS 1C Cool Grey) and RAL 9002 • PC+10%GF 3.0mm, Color RAL 9002 (in frames R0…R3 only) • hot-dip zinc coated steel sheet 1.5 to 2.5 mm, thickness of coating 100 micrometers, color NCS 1502-Y Package Plywood, cardboard and moulded pulp.

  • Page 162: Ce Marking

    162 Technical data NEMA 250:2008 Enclosures for Electrical Equipment (1000 Volts Maximum) CE marking A CE mark is attached to the drive to verify that the drive follows the provisions of the European Low Voltage, EMC, RoHS and WEEE Directives.The CE marking also verifies that the drive, in regard to its safety functions (such as Safe torque off), conforms with the Machinery Directive as a safety component.

  • Page 163: Compliance With The En 61800-3:2004 + A1:2012

    Technical data 163 Compliance with the EN 61800-3:2004 + A1:2012  Definitions EMC stands for Electromagnetic Compatibility. It is the ability of electrical/electronic equipment to operate without problems within an electromagnetic environment. Likewise, the equipment must not disturb or interfere with any other product or system within its locality.

  • Page 164: Category C2

    164 Technical data  Category C2 The emission limits are complied with the following provisions: 1. The motor and control cables are selected as specified in this manual. 2. The drive is installed according to the instructions given in this manual. 3.

  • Page 165: Category C4

    Technical data 165  Category C4 If the provisions under Category C3 cannot be met, the requirements of the standard can be met as follows: 1. It is ensured that no excessive emission is propagated to neighboring low-voltage networks. In some cases, the inherent suppression in transformers and cables is sufficient.

  • Page 166: Ul Checklist

    166 Technical data  UL checklist The drive is to be used in a heated, indoor controlled environment. The drive must be installed in clean air according to enclosure classification. Cooling air must be clean, free from corrosive materials and electrically conductive dust. See page 159. •...

  • Page 167: Dimension Drawings

    Dimension drawings 167 Dimension drawings Contents of this chapter This chapter shows the dimension drawings of the ACS580. The dimensions are given in millimeters and [inches].

  • Page 168: Frame R0, Ip21

    168 Dimension drawings Frame R0, IP21...

  • Page 169: Frame R0, Ip55

    Dimension drawings 169 Frame R0, IP55...

  • Page 170: Frame R1, Ip21

    170 Dimension drawings Frame R1, IP21...

  • Page 171: Frame R1, Ip55

    Dimension drawings 171 Frame R1, IP55...

  • Page 172: Frame R2, Ip21

    172 Dimension drawings Frame R2, IP21...

  • Page 173: Frame R2, Ip55

    Dimension drawings 173 Frame R2, IP55...

  • Page 174: Frame R3, Ip21

    174 Dimension drawings Frame R3, IP21...

  • Page 175: Frame R3, Ip55

    Dimension drawings 175 Frame R3, IP55...

  • Page 176: Frame R4, Ip21

    176 Dimension drawings Frame R4, IP21...

  • Page 177: Frame R4, Ip55

    Dimension drawings 177 Frame R4, IP55...

  • Page 178: Frame R5, Ip21

    178 Dimension drawings Frame R5, IP21...

  • Page 179: Frame R5, Ip55

    Dimension drawings 179 Frame R5, IP55...

  • Page 180: Frame R6, Ip21

    180 Dimension drawings Frame R6, IP21...

  • Page 181: Frame R6, Ip55

    Dimension drawings 181 Frame R6, IP55...

  • Page 182: Frame R7, Ip21

    182 Dimension drawings Frame R7, IP21...

  • Page 183: Frame R7, Ip55

    Dimension drawings 183 Frame R7, IP55...

  • Page 184: Frame R8, Ip21

    184 Dimension drawings Frame R8, IP21...

  • Page 185: Frame R8, Ip55

    Dimension drawings 185 Frame R8, IP55...

  • Page 186: Frame R9, Ip21

    186 Dimension drawings Frame R9, IP21...

  • Page 187: Frame R9, Ip55

    Dimension drawings 187 Frame R9, IP55...
  • Page 188 188 Dimension drawings...

  • Page 189: Resistor Braking

    Resistor braking 189 Resistor braking Contents of this chapter The chapter describes how to select the brake resistor and cables, protect the system, connect the brake resistor and enable resistor braking. Operation principle and hardware description The brake chopper handles the energy generated by a decelerating motor. The chopper connects the brake resistor to the intermediate DC circuit whenever the voltage in the circuit exceeds the limit defined by the control program.

  • Page 190: Resistor Braking, Frames R0

    190 Resistor braking Resistor braking, frames R0…R3  Planning the braking system Selecting the brake resistor Frames R0…R3 have an built-in brake chopper as standard equipment. The brake resistor is selected using the table and equations presented in this section. 1.
  • Page 191 Resistor braking 191 The table shows reference resistor types for the maximum braking power. Type Reference resistor types BRmax ACS580-01 Danotherm 3-phase U = 400 or 480 V (380…415 V, 440…480 V) 0246-4 CBH 360 C T 406 210R 03A3-4...
  • Page 192 192 Resistor braking Selecting and routing the brake resistor cables Use a shielded cable with the conductor size specified in section Terminal and lead- through data for the power cables on page 147. Minimizing electromagnetic interference Follow these rules in order to minimize electromagnetic interference caused by the rapid current changes in the resistor cables: •...
  • Page 193 Resistor braking 193 Placing the brake resistor Install the resistors outside the drive in a place where they will cool. Arrange the cooling of the resistor in a way that: • no danger of overheating is caused to the resistor or nearby materials •...

  • Page 194: Mechanical Installation

    194 Resistor braking We recommend that you also wire the thermal switch to a digital input of the drive. L1 L2 L3 Θ ACS580 ACS580 L1 L2 L3 +24V  Mechanical installation All brake resistors must be installed outside the drive. Follow the resistor manufacturer’s instructions.

  • Page 195: Start-Up

    Resistor braking 195  Start-up Note: Protective oil on the brake resistors will burn off when the brake resistor is used for the first time. Make sure that the airflow is sufficient. Set the following parameters: 1. Disable the overvoltage control of the drive with parameter 30.30 Overvoltage control.
  • Page 196 196 Resistor braking...

  • Page 197: Safe Torque Off Function

    Safe torque off function 197 Safe torque off function What this chapter contains This chapter describes the Safe torque off (STO) function of the drive and gives instructions for its use. Description The Safe torque off function can be used, for example, to construct safety or supervision circuits that stop the drive in case of danger.

  • Page 198: Compliance With The European Machinery Directive

    198 Safe torque off function The Safe torque off function of the drive complies with these standards: Standard Name EN 60204-1:2006 + A1: Safety of machinery – Electrical equipment of machines – Part 1: 2009 + AC:2010 General requirements IEC 61326-3-1:2008 Electrical equipment for measurement, control and laboratory use –...

  • Page 199: Connection Principle

    Safe torque off function 199 Connection principle  Connection with internal +24 V DC power supply Drive Control board OUT1 + 24 V DC OUT2 + 24 V DC SGND UDC+ T1/U, Control logic T2/V, T3/W UDC-  Connection with external +24 V DC power supply 24 V DC Drive Control board...

  • Page 200: Wiring Examples

    200 Safe torque off function Wiring examples An example of a Safe torque off wiring with internal +24 V DC power supply is shown below. Safety PLC Drive OUT1 OUT2 36 SGND Safety relay An example of a Safe torque off wiring with external +24 V DC power supply is shown below.

  • Page 201: Cable Types And Lengths

    Safe torque off function 201  Cable types and lengths • Double-shielded twisted-pair cable is recommended. • Maximum cable length 300 m (984 ft) between activation switch (K) and drive control board. Note: A short-circuit in the wiring between the switch and an STO terminal causes a dangerous fault and therefore it is recommended to use a safety relay (including wiring diagnostics), or a wiring method (shield grounding, channel separation) which reduces or eliminates the risk caused by the short-circuit.

  • Page 202: Start-Up Including Acceptance Test

    202 Safe torque off function Start-up including acceptance test To ensure the safe operation of a safety function, validation is required. The final assembler of the machine must validate the function by performing an acceptance test. The acceptance test must be performed •...

  • Page 203: Acceptance Test Procedure

    Safe torque off function 203  Acceptance test procedure After wiring the Safe torque off function, validate its operation as follows. Action WARNING! Follow the Safety instructions, page 13. Ignoring the instructions can cause physical injury or death, or damage to the equipment.

  • Page 204: Use

    204 Safe torque off function 1. Open the activation switch, or activate the safety functionality that is wired to the STO connection. 2. STO inputs on the drive control board de-energize, and the drive control board cuts off the control voltage from the drive IGBTs. 3.

  • Page 205: Maintenance

    Safe torque off function 205 Maintenance After the operation of the circuit is validated at start-up, the STO function shall be maintained by periodic proof testing. In high demand mode of operation, the maximum proof test interval is 20 years. In low demand mode of operation, the maximum proof test interval is 2 years.

  • Page 206: Safety Data

    206 Safe torque off function Safety data The safety data for the Safe torque off function is given below. Note: The safety data is calculated for redundant use, and does not apply if both STO channels are not used. Frame IEC 61508 and IEC/EN 61800-5-2 size (1/h)
  • Page 207 Safe torque off function 207 • The STO is a type A safety component as defined in IEC 61508-2. • Relevant failure modes: • The STO trips spuriously (safe failure) • The STO does not activate when requested A fault exclusion on the failure mode “short circuit on printed circuit board” has been made (EN 13849-2, table D.5).

  • Page 208: Abbreviations

    208 Safe torque off function  Abbreviations Abbr. Reference Description EN ISO 13849-1 Common cause failure (%) EN ISO 13849-1 Diagnostic coverage IEC 61508 Failure in time: 1E-9 hours IEC 61508 Hardware fault tolerance MTTF EN ISO 13849-1 Mean time to dangerous failure: (The total number of life units) / (the number of dangerous, undetected failures) during a particular measurement interval under stated conditions...

  • Page 209: Optional I/O Extension Modules

    Optional I/O extension modules 209 Optional I/O extension modules What this chapter contains This chapter describes how to install and start up the optional CMOD-01 and CMOD-01 multifunction extension modules. The chapter also contains diagnostics and technical data. CMOD-01 multifunction extension module (external 24 V AC/DC and digital I/O) ...

  • Page 210: Mechanical Installation

    210 Optional I/O extension modules Note: In frames R5…R9, you do not need a CMOD-01 module to use external 24 V AC/DC supply. The external supply is connected directly to terminals 40 and 41 on the control board. WARNING! Do not connect the +24 V AC cable to the control board ground when the control board is powered using an external 24 V AC supply.

  • Page 211: Electrical Installation

    Optional I/O extension modules 211 Unpacking and checking the delivery 1. Open the option package. 2. Make sure that the package contains: • CMOD-01 multifunction extension module • mounting screw. 3. Make sure that there are no signs of damage. Installing the module See chapter Installing option modules...
  • Page 212 212 Optional I/O extension modules Transistor output Marking Description DO1 SRC Source input DO1 OUT Digital or frequency output DO1 SGND Ground (earth) potential External power supply The external power supply is needed only if you want to connect an external back-up power supply for the drive control board.

  • Page 213: Start-Up

    Optional I/O extension modules 213 Frequency output connection example DO1 SRC DO1 OUT DO1 SGND CMOD-01 An externally supplied frequency indicator which provides, for example: • a 40 mA / 12 V DC power supply for the sensor circuit (CMOD frequency output) •...

  • Page 214: Diagnostics

    214 Optional I/O extension modules 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 215: Technical Data

    Optional I/O extension modules 215  Technical data Dimension drawing: The dimensions are in millimeters and [inches]. Installation: Into an option slot on the drive control board Degree of protection: IP20 Ambient conditions: See the drive technical data. Package: Cardboard...
  • Page 216 216 Optional I/O extension modules Isolation areas: CMOD-01 Plugged to 24 V drive SLOT2 Symbol Description Reinforced insulation (IEC 61800-5-1:2007) Functional insulation (IEC 61800-5-1:2007) Relay outputs (50…52, 53…55): • Wire size max. 1.5 mm • Minimum contact rating: 12 V / 10 mA •...

  • Page 217: Cmod-02 Multifunction Extension Module (External 24 V Ac/Dc And Isolated Ptc Interface)

    Optional I/O extension modules 217 CMOD-02 multifunction extension module (external 24 V AC/DC and isolated PTC interface)  Safety instructions WARNING! Obey the safety instructions for the drive. If you ignore the safety instructions, injury or death can occur.  Hardware description Product overview The CMOD-02 multifunction extension module (external 24 V AC/DC and isolated...

  • Page 218: Mechanical Installation

    218 Optional I/O extension modules Layout Item Description Additional information Grounding screw Page Hole for mounting screw Page 2-pin terminal block for motor thermistor connection Page 2-pin terminal block for relay output Page 2-pin terminal block for external power supply Page Diagnostic LED Page...

  • Page 219: Electrical Installation

    Optional I/O extension modules 219 Unpacking and checking the delivery 1. Open the option package. 2. Make sure that the package contains: • CMOD-02 multifunction extension module • mounting screw 3. Make sure that there are no signs of damage. Installing the module See chapter Installing option modules...
  • Page 220 220 Optional I/O extension modules External power supply The external power supply is needed only if you want to connect an external back-up power supply for the drive control board. Note: Frames R0…R4 need CMOD-02 for connecting external power supply, frames R5…R9 have corresponding terminals 40 and 41 on the control board.

  • Page 221: Start-Up

    Optional I/O extension modules 221 Relay output connection example CMOD-02 RO PTC C PTC B OUT1 OUT2 SGND Power supply connection example 24V AC/DC + in 24V AC/DC - in CMOD-02 External power supply, 24 V AC/DC WARNING! Do not connect the +24 V AC cable to the control board ground when the control board is powered using an external 24 V AC supply.

  • Page 222: Diagnostics

    222 Optional I/O extension modules You can now see the parameters of the extension module in parameter group 15 I/O extension module.  Diagnostics Faults and warning messages Warning A7AB Extension I/O configuration failure. LEDs The extension module has one diagnostic LED. Color Description Green...

  • Page 223: Technical Data

    Optional I/O extension modules 223  Technical data Dimension drawing: The dimensions are in millimeters and [inches]. Installation: Into an option slot on the drive control board Degree of protection: IP20 Ambient conditions: See the drive technical data. Package: Cardboard...
  • Page 224 224 Optional I/O extension modules Isolation areas: CMOD-02 Plugged to 24 V RO PTC drive SLOT2 Symbol Description Reinforced insulation (IEC 61800-5-1:2007) Functional insulation (IEC 61800-5-1:2007) Motor thermistor connection (60…61): • Wire size max. 1.5 mm • Supported standards: DIN 44081 and DIN 44082 •...

  • Page 225: Further Information

    Product and service inquiries Address any inquiries about the product to your local ABB representative, quoting the type designation and serial number of the unit in question. A listing of ABB sales, support and service contacts can be found by navigating to www.abb.com/searchchannels.
  • Page 226 Contact us www.abb.com/drives www.abb.com/drivespartners AXD50000018826 Rev D (EN) 2015-11-02 3AXD50000018826D...

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