ABB ACH580-04 Manuals

Manuals and User Guides for ABB ACH580-04. We have 5 ABB ACH580-04 manuals available for free PDF download: Hardware Manual, Installation, Operation And Maintenance Manual, Quick Installation Manual, User Manual, Manual

ABB ACH580-04 Hardware Manual (242 pages)

Drive modules

Brand: ABB | Category: DC Drives | Size: 29.83 MB

Table of Contents
5
Table of Contents
7
Safety Instructions
15
Contents of this Chapter
15
Use of Warnings and Notes
15
General Safety in Installation, Start-Up and Maintenance
16
Electrical Safety in Installation, Start-Up and Maintenance
18
Electrical Safety Precautions
18
Additional Instructions and Notes
19
Optical Components
20
Printed Circuit Boards
20
Grounding
20
General Safety in Operation
21
Additional Instructions for Permanent Magnet Motor Drives
22
Safety in Installation, Start-Up, Maintenance
22
Safety in Operation
22
Introduction to the Manual
23
Contents of this Chapter
23
Applicability
23
Target Audience
23
Purpose of the Manual
23
Categorization by Frame Size and Option Code
23
Terms and Abbreviations
24
Quick Installation, Commissioning and Operating Flowchart
25
Related Documents
26
Operation Principle and Hardware Description
27
Contents of this Chapter
27
Product Overview
28
Layout
29
Standard Drive Module Configuration
29
Drive Module Configuration with Option +B051
30
Control Panel
32
Overview of Power and Control Connections
33
Type Designation Label
34
Type Designation Key
35
Basic Code
35
Option Codes
35
Ordering Codes
36
Generic Cabinet Planning Instructions
37
Contents of this Chapter
37
Limitation of Liability
37
Cabinet Construction
37
Disposition of the Devices
37
Grounding of Mounting Structures
38
Busbar Material and Joints
38
Shrouds
38
Tightening Torques
38
Electrical Connections
38
Mechanical Connections
38
Insulation Supports
39
Cable Lugs
39
Cooling and Degrees of Protection
39
Planning the Cooling
39
Air Inlets and Outlets
39
Preventing the Recirculation of Hot Air
40
EMC Requirements
41
Attaching the Cabinet
43
Cabinet Placement on a Cable Channel
43
Heaters
43
Mounting the Control Panel on the Cabinet Door
44
Guidelines for Planning the Mechanical Installation
45
Contents of this Chapter
45
Installation Positions of the Drive Module
45
Planning the Layout
46
Layout Example, Door Closed
46
Layout Example, Door Open (Standard Drive Module Configuration)
47
Layout Example, Door Open (Option +B051)
49
Planning the Cooling of the ACH580-04
50
Standard Drive Module Configuration
51
Drive Module with Option +B051
52
Other Installation Positions than Vertical
53
Free Space Requirements
53
Free Space at the Top of the Drive Module
53
Free Space Around the Drive Module
53
Mechanical Installation
55
Contents of this Chapter
55
Examining the Installation Site
55
Moving and Unpacking the Unit
56
Lifting the Drive Module
60
Examining the Delivery
60
Installation Alternatives
60
Input Power Cable Connection Terminals (Option +H370) and Ground Busbar Assembly
61
Drive Module Without Output Cable Connection Terminals (Option +0H371)
61
Drive Module Without Pedestal (Option +0H354)
61
Attaching the Drive Module to a Mounting Plate or Wall
61
Alternatives for Grounding the Drive Module
62
Installing the Bottom Grille for IP20 Degree Protection
63
Removing the Protective Covering from the Drive Module Air Outlet
64
Installing External Control Unit (Option +P906)
64
Guidelines for Planning the Electrical Installation
65
Contents of this Chapter
65
Limitation of Liability
65
Selecting the Main Supply Disconnecting Device
65
European Union
65
North America
66
Other Regions
66
Selecting the Main Contactor
66
Examining the Compatibility of the Motor and Drive
66
Protecting the Motor Insulation and Bearings
66
Requirements Table
67
Availability of Du/Dt Filter and Common Mode Filter by Drive Type
69
Additional Requirements for Explosion-Safe (EX) Motors
69
And am
69
Additional Requirements for ABB High-Output and IP23 Motors
69
Additional Requirements for Non-ABB High-Output and IP23 Motors
69
Additional Data for Calculating the Rise Time and the Peak Line-To-Line Voltage
70
Selecting the Power Cables
71
General Guidelines
71
Typical Power Cable Sizes
72
Power Cable Types
72
Preferred Power Cable Types
72
Alternate Power Cable Types
73
Not Allowed Power Cable Types
74
Additional Guidelines, North America
74
Metal Conduit
75
Power Cable Shield
75
Selecting the Control Cables
75
Shielding
75
Signals in Separate Cables
76
Signals that Can be Run in the same Cable
76
Relay Cable
76
Control Panel to Drive Cable
76
PC Tool Cable
76
Routing the Cables
76
General Guidelines - IEC
76
General Guidelines - North America
77
Continuous Motor Cable Shield/Conduit or Enclosure for Equipment on the Motor Cable
78
Separate Control Cable Ducts
78
Implementing Motor and Motor Cable Short-Circuit and Thermal Overload Protection
79
Protecting the Motor and Motor Cable in Short-Circuits
79
Protecting the Motor Cables against Thermal Overload
79
Protecting the Motor against Thermal Overload
79
Protecting the Motor against Overload Without Thermal Model or Temperature Sensors
79
Protecting the Drive and Input Power Cable in Short-Circuits
80
Circuit Breakers
80
Tested Circuit Breakers
80
Protecting the Drive against Ground Faults
80
Residual Current Device Compatibility
80
Implementing the Emergency Stop Function
81
Implementing the Safe Torque off Function
81
Implementing the Undervoltage Control (Power-Loss Ride-Through)
81
Using Power Factor Compensation Capacitors with the Drive
81
Using a Safety Switch between the Drive and the Motor
82
Implementing an ATEX-Certified Motor Thermal Protection
82
Controlling a Contactor between Drive and Motor
82
Implementing a Bypass Connection
83
Example Bypass Connection
84
Switching the Motor Power Supply from Drive to Direct-On-Line
85
Switching the Motor Power Supply from Direct-On-Line to Drive
85
Protecting the Contacts of Relay Outputs
85
Implementing a Motor Temperature Sensor Connection
86
Connecting Motor Temperature Sensor to the Drive Via an Option Module
86
Electrical Installation
89
Contents of this Chapter
89
Safety
89
Grounding the Motor Cable Shield at the Motor End
89
Measuring the Insulation
90
Measuring the Insulation of the Drive
90
Measuring the Insulation of the Input Power Cable
90
Measuring the Insulation of the Motor and Motor Cable
90
Measuring the Insulation of the Brake Resistor Circuit
90
Grounding System Compatibility Check - IEC, Not North America
91
EMC Filter Compatibility
91
Ground-To-Phase Varistor Compatibility
91
Grounding System Compatibility Check - North America
92
EMC Filter Compatibility
92
Ground-To-Phase Varistor Compatibility
92
Connecting the Power Cables
93
Power Cable Connection Diagram
93
Preparing the Cable Ends - Symmetrical Shielded Cables
94
Power Cable Connection Process
94
DC Connection
95
Connecting the Control Cables
95
Connecting a Control Panel
96
Connecting a PC
97
Connecting a Remote Panel, or Chaining One Panel to Several Drives
97
Installing Option Modules
97
Option Slot 2 (I/O Extension Modules)
98
Option Slot 1 (Fieldbus Adapter Modules)
99
Wiring the Optional Modules
99
Installation Example of Drive Module with IP20 Shrouds (Option +B051)
101
Contents of this Chapter
101
Safety
101
Required Parts
102
Required Tools
102
Overall Flowchart of the Installation Process
103
Installing the Drive Module into a Cabinet
103
Connecting the Power Cables and Installing the Shrouds
104
Installing the Roof and Door (Rittal Parts)
105
Miscellaneous
106
Input Power Cable Entry from Top
106
Attaching the Drive Module to a Mounting Plate
106
Control Unit
107
Contents of this Chapter
107
Layout
108
Default I/O Connection Diagram
109
Switches
110
Additional Information on I/O Connections
110
PNP Configuration for Digital Inputs (X2 & X3)
110
NPN Configuration for Digital Inputs (X2 & X3)
111
Connection for Obtaining 0
111
Connection Examples of Two-Wire and Three-Wire Sensors to Analog Input (AI2)
112
DI5 as Frequency Input
112
DI6 as PTC Input
112
AI1 and AI2 as Pt100, Pt1000, Ni1000, KTY83 and KTY84 Sensor Inputs (X1)
113
Safe Torque off (X4)
113
Technical Data
114
Installation Checklist
119
Contents of this Chapter
119
Checklist
119
Start-Up
121
Contents of this Chapter
121
Start-Up Procedure
121
Fault Tracing
123
Contents of this Chapter
123
Leds
123
Warning and Fault Messages
123
Maintenance
125
Contents of this Chapter
125
Maintenance Intervals
125
Cabinet
126
Cleaning the Interior of the Cabinet
126
Heatsink
127
Cleaning the Interior of the Heatsink
127
Fans
129
Replacing the Circuit Board Compartment Cooling Fans
129
Replacing the Main Cooling Fans
130
Replacing the Drive Module
131
Capacitors
133
Reforming the Capacitors
133
Control Panel
133
Technical Data
135
Contents of this Chapter
135
Electrical Ratings
136
IEC Ratings
136
UL (NEC) Ratings
136
Definitions
137
Output Derating
137
When Is Derating Necessary
137
Surrounding Air Temperature Derating
138
Altitude Derating
139
Switching Frequency Derating
139
Fuses (IEC)
140
Fuses (UL)
141
Circuit Breakers (IEC)
142
Dimensions, Weights and Free Space Requirements
142
Losses, Cooling Data and Noise
144
Terminal and Entry Data for the Power Cables
144
Drive Modules Without Output Cable Connection Terminals (+0H371) and with a Common Mode Filter (+E208)
144
Typical Power Cable Sizes
145
Terminal Data for the Control Cables
146
Electrical Power Network Specification
146
Motor Connection Data
146
Brake Resistor Connection Data
147
DC Connection Data
147
Control Panel Type
147
Control Unit Data
147
Efficiency
147
Protection Classes
147
Ambient Conditions
148
Materials
148
Applicable Standards
149
Markings
149
EMC Compliance (IEC/EN 61800-3:2004 + A2012)
150
Definitions
150
Category C3
151
Category C4
152
Compliance with the European Machinery Directive
152
UL and CSA Checklist
153
Design Lifetime Expectancy
153
Disclaimers
154
Generic Disclaimer
154
Cybersecurity Disclaimer
154
Dimension Drawings
155
Contents of this Chapter
155
R10 Standard Configuration
156
R10 with +E208+0H354+H356+H370+0H371
157
R10 with Option +B051
158
R10 with Option +E208 +H356 +P906
159
R10 with Option +E208+0H371+H356+0H354+H370+P906
160
R10 with Option +B051 +P906
161
R11 Standard Configuration
162
R11 with Option +E208+0H371+H356+0H354+H370
163
R11 with Option +B051
164
R11 with Option +E208 +H356 +P906
165
R11 with Option +E208+0H371+H356+0H354+H370+P906
166
R11 with Option +B051 +P906
167
Air Baffles for the Drive Module with Option +B051
168
Example Circuit Diagram
169
Contents of this Chapter
169
The Safe Torque off Function
171
Contents of this Chapter
171
Description
171
Compliance with the European Machinery Directive
172
Wiring
173
Connection Principle
173
Single ACH580-04 Drive, Internal Power Supply
173
Single ACH580-04 Drive, External Power Supply
173
Wiring Examples
174
Single ACH580-04 Drive, Internal Power Supply
174
Single ACH580-04 Drive, External Power Supply
174
Multiple ACH580-04 Drives, Internal Power Supply
175
Multiple ACH580-04 Drives, External Power Supply
176
Activation Switch
176
Cable Types and Lengths
177
Grounding of Protective Shields
177
Operation Principle
178
Start-Up Including Acceptance Test
179
Competence
179
Acceptance Test Reports
179
Acceptance Test Procedure
179
Use
181
Maintenance
182
Competence
182
Fault Tracing
183
Safety Data
184
Abbreviations
184
TÜV Certificate
185
Declaration of Conformity
186
Resistor Braking
187
Contents of this Chapter
187
When Is Resistor Braking Necessary
187
Operation Principle and Hardware Description
187
Planning the Braking System
187
Generic Guidelines
187
Resistor Cables
188
Resistor Thermal Switch
188
Protecting the System against Thermal Overload
188
EMC Compliance of the Complete Installation
188
Placing the Brake Resistor
189
Protecting the System in Fault Situations
189
Selecting the Default Brake System Components
189
Calculation Example
189
Selecting a Custom Brake Resistor
190
Mechanical Installation of Resistors
191
Electrical Installation
191
Measuring the Insulation of the Brake Resistor Circuit
191
Connection Diagram
191
Connection Procedure
192
Start-Up
192
Parameter Settings
192
Technical Data
193
Ratings
193
SAFUR Resistors
193
Dimensions, Weights and Ordering Codes
194
Terminals and Cable Entry Data
194
External Control Unit (Option +P906)
195
Contents of this Chapter
195
Product Overview
195
Layout
196
Cables
196
Unpacking the Delivery
197
Installing the Control Unit
198
Installation Procedure
198
Optical Components
198
Connecting the Control Unit to the Drive Module
203
Maintenance
205
Dimension Drawing
206
CHDI-01 115/230 V Digital Input Extension Module
207
Contents of this Chapter
207
Product Overview
207
Layout and Connection Examples
208
Mechanical Installation
209
Necessary Tools
209
Unpacking and Examining the Delivery
209
Installing the Module
209
Electrical Installation
209
Wiring
209
Start-Up
209
Setting the Parameters
209
Parameter Setting Example for Relay Output
210
Fault and Warning Messages
210
Technical Data
210
Dimension Drawing
211
CMOD-01 Multifunction Extension Module (External 24 V AC/DC and Digital I/O)
213
Contents of this Chapter
213
Product Overview
213
Layout and Example Connections
214
Mechanical Installation
215
Necessary Tools
215
Unpacking and Examining the Delivery
215
Installing the Module
215
Electrical Installation
215
Wiring
215
Start-Up
216
Setting the Parameters
216
Diagnostics
217
Faults and Warning Messages
217
Leds
217
Technical Data
217
Dimension Drawing
218
CMOD-02 Multifunction Extension Module (External 24 V AC/DC and Isolated PTC Interface)
219
Contents of this Chapter
219
Product Overview
219
Layout and Example Connections
220
Mechanical Installation
220
Necessary Tools
220
Unpacking and Examining the Delivery
221
Installing the Module
221
Electrical Installation
221
Necessary Tools and Instructions
221
Wiring
221
Start-Up
221
Setting the Parameters
221
Diagnostics
222
Faults and Warning Messages
222
Leds
222
Technical Data
222
Dimension Drawing
223
Filters
225
Contents of this Chapter
225
When Is a Du/Dt Filter Necessary
225
Selection Table
225
Ordering Codes
225
Description, Installation and Technical Data of the FOCH Filters
225
Ground-To-Phase Varistor Disconnecting Instructions - IEC, Not North America
227
Contents of this Chapter
227
Identifying the Grounding System of the Electrical Power Network
227
When to Disconnect Ground-To-Phase Varistor: TN-S, IT, Corner-Grounded Delta and MID-Point-Grounded Delta Systems
228
Guidelines for Installing the Drive to a TT System
230
Disconnecting Instruction - IEC, Not North America
230
Connecting EMC Filter and Ground-To-Phase Varistor - North America
231
Contents of this Chapter
231
Identifying the Grounding System of the Electrical Power Network
231
When You Can Connect the EMC Filter and Ground-To-Phase Varistor: TN-S, IT, Corner-Grounded Delta and MID-Point-Grounded Delta Systems
232
Connecting EMC Filter - North America
233
Connecting Ground-To-Phase Varistor - North America
233
Step-By-Step Drawings for an Installation Example of a Drive Module with the +B051 Option in a Rittal VX25 600 MM Wide Enclosure
235
Further Information
241

ABB ACH580-04 Installation, Operation And Maintenance Manual (157 pages)

Brand: ABB | Category: DC Drives | Size: 27.27 MB

Safety Instructions
2
General Safety in Installation, Start-Up and Maintenance
2
Use of Warnings and Notes in this Manual
2
Electrical Safety in Installation, Start-Up and Maintenance
3
Precautions before Electrical Work
3
Additional Instructions and Notes
4
Grounding
4
Additional Instructions for Permanent Magnet Motor Drives
5
Additional Instructions for Safety Functions
5
Safety in Installation, Start-Up and Maintenance
5
General Safety in Operation
6
Cybersecurity Disclaimer
6
Start-Up and Operation
6
Contents
7
ACH580-01 Installation
8
Vertically Alone
8
Vertically Side by Side
9
Prepare for Installation
9
Unpack the Drive
9
Tools Required
10
Flange Mounting
10
Install the Drive
11
Install the Cable Box, Frames R1…R2
11
Installing the Drive Vertically, Frame R5
12
Installing the Drive Vertically, Frames R6…R9
14
Installing the Drive Vertically Side by Side
15
Install Wiring
16
Checking the Insulation of the Assembly
16
Ground Connections
16
Checking Compatibility with IT and Corner-Grounded TN Systems
17
Ground-To-Phase Varistor
18
Power Cable Terminal and Lead-Through Data
19
Maximum Recommended Motor Cable Length
20
Operational Functionality and Motor Cable Length
20
Control Cable Terminal and Lead-Through Data
21
Fuses
24
208…240 Volt, Fuse Requirements
24
380…480 Volt, Fuse Requirements
25
500…600 Volt, Fuse Recommendations
26
External Control Connection Terminals
27
External Control Connection Terminals, Frames R6
28
Wiring R1…R2
29
Power Wiring Torque Table
30
Wiring R3
31
Wiring R4
33
Wiring R5
35
Wiring R6…R9
37
Communications
41
Switches
41
Check Installation
42
Re-Install Cover
43
Frame R5 Cover Installations
43
Before Start-Up
44
Motor Data
44
Default Configurations
44
Operation
45
Control Panel Features
45
Left Softkey
45
Right Softkey
45
Control Panel Display
46
For Initial Start-Up, Follow Steps 1 through 4 below
47
Make First Start Assistant-Guided Settings: Language, Motor Nominal Values, and Date and Time
47
Complete Commissioning
50
Default Configurations — HVAC and PID Control
50
Other Ways to Complete Commissioning
51
Make Additional Settings in the Primary Settings Menu – I/O Menu
52
Check Setup with the Diagnostics Menu
53
How to Control the Drive through the I/O Interface
54
Preliminary Settings
54
Starting and Controlling the Speed of the Motor
54
Stopping the Motor
54
Diagnostics
57
Warning Messages
57
Fault Messages
68
Maintenance Schedule
81
Description of Symbols
81
Recommended Annual Actions by the User
81
Heatsink
82
Main Cooling Fan Replacement
82
Frame Size R1...R3
82
To Replace the Fan
82
Frame Size R4
83
Frame Sizes R5…R8
83
Frame Size R9
84
Auxiliary Cooling Fan Replacement
84
IP55/UL (NEMA) Type 12 Frame Size R4
87
Second Auxiliary Cooling Fan Replacement
87
Capacitors
88
Reforming the Capacitors
88
Control Panel
88
Battery
88
ACH580 E-Clipse Bypass
89
Installation – Drive
89
Installation - Bypass
90
Connection Diagrams – Vertical E-Clipse Bypass
91
Connection Diagrams – Box E-Clipse Bypass
93
Power Connections – Box E-Clipse Bypass Configurations
98
Line Input Connections
98
Power Connections - Standard E-Clipse Bypass Configurations (Wall Mounted)
98
Install the Control Wiring
99
Basic Connections
99
Drive’s Power Connection Terminals
100
Branch Circuit Protection
104
208/230 Volt Fuses for Vertical Enclosures
104
460 Volt Fuses for Vertical Enclosures
105
575 Volt Fuses for Vertical Enclosures
105
208/230 Volt Fuses for Box Enclosures
106
460 Volt Fuses for Box Enclosures
106
575 Volt Fuses for Box Enclosures
107
Basic Control Connections for E-Clipse HVAC Default
108
Parameters Changed Relative to E-Clipse HVAC Default
108
Check Installation – Bypass
109
Control Panel Settings and Checks
109
Drive Link Recovery Procedure
109
System Check: Motor Connected to ACH580 with E-Clipse Bypass
110
System Check: Motor Disconnected from the ACH580 with E-Clipse Bypass
112
Check Jumpers and Switches
114
Jumper and Switch Locations
114
DIP Switch Settings
114
E-Clipse Bypass Configurations
115
Operation
115
Bypass Control
118
Ready (Power On) Indication
118
Enabled LED
118
Motor Run LED
118
Drive Selected LED
119
Bypass Selected LED
119
Drive Faulted LED
119
Automatic Transfer
119
Auto Key
120
Hand Key
120
Bypass Control Panel Modes
120
Start-Up by Changing the Parameters from the Start-Up List
121
Start-Up by Changing the Parameters Individually from Parameter List
121
Fault Listing
123
Warning Listing
129
Bypass Status Listing
133
Error Messages
134
Maintenance
134
Ach580-Pcr/Pdr
135
Connection Diagrams – Vertical Packaged Drive with Input Disconnect
136
Connection Diagrams – Box Packaged Drive with Input Disconnect
138
Power Connection Terminals
142
208 Volt Fuses for Packaged Drive
145
460 Volt Fuses for Packaged Drive
146
575 Volt Fuses for Packaged Drive
146
Input Disconnect Configuration
148
Maintenance Intervals
150
Filter Material
150
Enclosure Air Filter Replacement B3 - UL (NEMA) Type 12 Hinged Door Wall Mount Enclosures
150
Complete ACH580 Drive Parameter List
151

ABB ACH580-04 Quick Installation Manual (102 pages)

Brand: ABB | Category: Control Unit | Size: 5.21 MB

ABB ACH580-04 User Manual (22 pages)

ABB LV AC DRIVE PIHF Harmonic Filters

Brand: ABB | Category: DC Drives | Size: 0.92 MB

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

ABB ACH580-04 Manual (16 pages)

Converter modules with electrolytic DC capacitors in the DC link

Brand: ABB | Category: Control Unit | Size: 0.42 MB

Table of Contents
3
1 Introduction

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

9
Further Information

15

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