ABB ACS580-01-293A-4+J400 Manuals

Manuals and User Guides for ABB ACS580-01-293A-4+J400. We have 1 ABB ACS580-01-293A-4+J400 manual available for free PDF download: Hardware Manual

ABB ACS580-01-293A-4+J400 Hardware Manual

ABB ACS580-01-293A-4+J400 Hardware Manual (468 pages)

GENERAL PURPOSE DRIVES

Brand: ABB | Category: DC Drives | Size: 77.57 MB

Table of Contents

Table of Contents
5
Table of Contents
7
Safety Instructions
21
Contents of this Chapter
21
Use of Warnings and Notes
21
General Safety in Installation, Start-Up and Maintenance
22
Electrical Safety in Installation, Start-Up and Maintenance
24
Electrical Safety Precautions
24
Additional Instructions and Notes
25
Printed Circuit Boards
25
Grounding
26
General Safety in Operation
27
Additional Instructions for Permanent Magnet Motor Drives
27
Safety in Installation, Start-Up, Maintenance
27
Safety in Operation
28
Introduction to the Manual
29
Contents of this Chapter
29
Applicability
29
Target Audience
29
Categorization by Frame Size
29
Quick Installation and Commissioning Flowchart
30
Terms and Abbreviations
31
Related Documents
33
Operation Principle and Hardware Description
35
Contents of this Chapter
35
Operation Principle
36
Layout
36
Overview of Power and Control Connections
48
External Control Connection Terminals, Frames R1
49
External Control Connection Terminals, Frames R6
50
Control Panel
51
Control Panel Door Mounting Kits
52
Type Designation Label
52
Locations of the Labels on the Drive
53
Type Designation Key
54
Option Codes
55
Manual Kit Ordering Codes
57
Mechanical Installation
59
Contents of this Chapter
59
Safety
59
Cabinet Installation (Option +P944)
60
Examining the Installation Site
60
Installation Alternatives
61
Necessary Tools
66
Moving the Drive
66
Unpacking and Examining Delivery, Frames R1 and R2
67
Frames R1 and R2 Cable Box (IP21, UL Type 1)
69
Unpacking and Examining Delivery, Frame R3
70
Unpacking and Examining Delivery, Frames R1
72
Unpacking and Examining Delivery, Frames R4
74
Unpacking and Examining Delivery, Frame R5 and R6
76
Frame R5 Cable Box (IP21, UL Type 1)
77
Frame R6 Cable Box (IP21, UL Type 1)
78
Unpacking and Examining Delivery, Frame R7
79
Frame R7 Cable Box (IP21, UL Type 1)
81
Unpacking and Examining Delivery, Frames R8 and R9
82
Frame R8 Cable Box (IP21, UL Type 1)
84
Frame R9 Cable Box (IP21, UL Type 1)
85
Installing the Drive
86
Installing the Drive Vertically, Frames R1
86
Installing the Cable Box, Frames R1
87
Installing the Drive Vertically, Frame R5
88
IP21 (UL Type 1)
89
IP21 (UL Type 1), IP55 (UL Type 12)
90
Installing the Drive Vertically, Frames R6
91
IP21 (UL Type 1)
92
IP55 (UL Type 12)
93
Installing the Drive Vertically Side by Side
93
Installing the Drive Horizontally, Frames R1
93
Flange Mounting
93
Strut Channel Installation (US Only)
94
Installation Instructions
94
Cabinet Installation (Options +P940 and +P944)
94
Guidelines for Planning the Electrical Installation
95
Contents of this Chapter
95
Limitation of Liability
95
North America
95
Selecting the Main Supply Disconnecting Device
95
Selecting the Main Contactor
96
Examining the Compatibility of the Motor and Drive
96
Protecting the Motor Insulation and Bearings
96
Requirements Tables
97
Requirements for ABB Motors, P
98
Requirements for ABB Motors, P
99
Requirements for Non-ABB Motors, P N < 100 Kw (134 Hp)
100
Requirements for Non-ABB Motors, P
101
Abbreviations
102
Availability of D U /D T Filter and Common Mode Filter by Drive Type
102
Additional Requirements for Explosion-Safe (EX) Motors
102
Additional Requirements for ABB Motors of Types Other than M2_, M3_, M4_, HX_ and am
102
Additional Requirements for Braking Applications
102
Additional Requirements for the Regenerative and Low Harmonics Drives
102
Additional Requirements for ABB High-Output and IP23 Motors
103
Additional Requirements for Non-ABB High-Output and IP23 Motors
103
Additional Data for Calculating the Rise Time and the Peak Line-To-Line Voltage
104
Additional Note for Sine Filters
105
Selecting the Power Cables
106
General Guidelines
106
Typical Power Cable Sizes
106
Power Cable Types
107
Preferred Power Cable Types
107
Alternate Power Cable Types
108
Not Allowed Power Cable Types
109
Additional Guidelines - North America
109
Metal Conduit
110
Power Cable Shield
110
Grounding Requirements
111
Additional Grounding Requirements - IEC
112
Additional Grounding Requirements - UL (NEC)
113
Selecting the Control Cables
113
Shielding
113
Signals in Separate Cables
113
Signals that Can be Run in the same Cable
113
Relay Cable
114
Control Panel to Drive Cable
114
PC Tool Cable
114
FPBA-01 PROFIBUS DP Adapter Module Connectors
114
Routing the Cables
114
General Guidelines - IEC
114
General Guidelines - North America
115
Continuous Motor Cable Shield/Conduit and Metal Enclosure for Equipment on the Motor Cable
116
Separate Control Cable Ducts
117
Implementing Short-Circuit and Thermal Overload Protection
117
Protecting the Drive and the Input Power Cable in Short-Circuits
117
Protecting the Motor and Motor Cable in Short-Circuits
118
Protecting the Motor Cables against Thermal Overload
118
Protecting the Motor against Thermal Overload
118
Protecting the Motor against Overload Without Thermal Model or Temperature Sensors
119
Protecting the Drive against Ground Faults
119
Residual Current Device Compatibility
119
Implementing the Emergency Stop Function
120
Implementing the Safe Torque off Function
120
Using Power Factor Compensation Capacitors with the Drive
120
Controlling a Contactor between Drive and Motor
120
Implementing an ATEX-Certified Motor Thermal Protection
121
Implementing the Power Loss Ride-Through Function
121
Using a Safety Switch between the Drive and the Motor
122
Implementing a Bypass Connection
122
Example Bypass Connection
123
Switching the Motor Power Supply from Drive to Direct-On-Line
124
Switching the Motor Power Supply from Direct-On-Line to Drive
124
Protecting the Contacts of Relay Outputs
124
Limiting Relay Output Maximum Voltages at High Installation Altitudes
125
Implementing a Motor Temperature Sensor Connection
125
Connecting a Motor Temperature Sensor to the Drive through an Option Module
126
Electrical Installation - Global (IEC)
129
Contents of this Chapter
129
Warnings
129
Required Tools
129
Grounding the Motor Cable Shield at the Motor End
130
Measuring the Insulation
130
Measuring the Insulation Resistance of the Drive
130
Measuring the Insulation Resistance of the Input Power Cable
130
Measuring the Insulation Resistance of the Motor and Motor Cable
130
Brake Resistor Assembly for R1
131
Grounding System Compatibility Check
132
EMC Filter
132
Ground-To-Phase Varistors
132
When to Disconnect EMC Filter or Ground-To-Phase Varistor: TN-S, IT, Corner-Grounded Delta and Midpoint-Grounded Delta Systems
132
Guidelines for Installing the Drive to a TT System
134
Identifying the Grounding System of the Electrical Power Network
135
Disconnecting Internal EMC Filter or Ground-To-Phase Varistor - Frames R1
135
Disconnecting Internal EMC Filter or Ground-To-Phase Varistor - Frames R4
136
Connecting the Power Cables
139
Connection Diagram
139
Connection Procedure, Frames R1
140
Motor Cable
141
Input Power Cable
144
Grounding Shelf
146
Brake Resistor Cable (if Used)
146
Finalization
148
Connection Procedure, Frame R5
148
IP21 (UL Type 1)
148
IP55 (UL Type 12)
148
Connection Procedure, Frames R6
153
Motor Cable
154
Input Power Cable
155
Detaching and Reinstalling the Connectors
156
DC Connection
158
Connecting the Control Cables
159
Connection Diagram
159
Control Cable Connection Procedure R1
159
Installing Option Modules
164
Option Slot 2 (I/O Extension Modules)
165
Option Slot 1 (Fieldbus Adapter Modules)
166
Wiring the Optional Modules
166
Reinstalling Grommets
167
Reinstalling Covers
168
Reinstalling Cover, Frames R1
168
Reinstalling Covers, Frame R5
169
IP21 (UL Type 1)
169
IP55 (UL Type 12)
169
Reinstalling Side Plates and Covers, Frames R6
170
IP21 (UL Type 1)
170
IP55 (UL Type 12)
170
Installing IP66 (UL Type 4X) Sun Shield
171
Connecting a PC
171
Connecting a Remote Panel, or Chaining One Panel to Several Drives
172
Electrical Installation - North America
173
Contents of this Chapter
173
Warnings
173
Required Tools
174
Grounding the Motor Cable Shield at the Motor End
174
Measuring the Insulation
174
Measuring the Insulation Resistance of the Drive
174
Measuring the Insulation Resistance of the Input Power Cable
174
Measuring the Insulation Resistance of the Motor and Motor Cable
174
Brake Resistor Assembly for R1
175
Grounding System Compatibility Check
176
EMC Filter
176
Ground-To-Phase Varistors (VAR)
176
When to Connect EMC Filter or Disconnect Ground-To-Phase Varistor: TN-S, IT, Corner-Grounded Delta and Midpoint-Grounded Delta Systems
177
Guidelines for Installing the Drive to a TT System
178
Identifying the Grounding System of the Electrical Power Network
179
Disconnecting Internal EMC Filter or Ground-To-Phase Varistor - Frames R1
180
Disconnecting Internal EMC Filter or Ground-To-Phase Varistor - Frames R4
181
Connecting the Power Cables
184
Connection Diagram
184
Connection Procedure, Frames R1
186
Motor Cabling
187
Input Power Cabling
190
Brake Resistor Cabling (if Used)
192
Finalization
193
Connection Procedure, Frame R5
194
IP21 (UL Type 1)
194
IP55 (UL Type 12)
194
Connection Procedure, Frames R6
198
Motor Cabling
199
Input Power Cabling
200
Detaching and Reinstalling the Connectors
200
DC Connection
202
Connecting the Control Cables
202
Connection Diagram
202
Control Cable Connection Procedure R1
202
Installing Option Modules
208
Reinstalling Grommets
208
Reinstalling Covers
209
Reinstalling Cover, Frames R1
209
Reinstalling Covers, Frame R5
210
IP21 (UL Type 1)
210
IP55 (UL Type 12)
210
Reinstalling Side Plates and Covers, Frames R6
211
IP21 (UL Type 1)
211
IP55 (UL Type 12)
211
Installing UL Type 12 Hood
212
Installing IP66 (UL Type 4X) Sun Shield
212
Connecting a PC
212
Connecting a Remote Panel, or Chaining One Panel to Several Drives
213
Control Unit
215
Contents of this Chapter
215
Layout
216
Default I/O Connection Diagram
218
Additional Information on the Control Connections
223
Embedded EIA-485 Fieldbus Connection
223
Connecting Motor Temperature Sensors to the Drive
224
PNP Configuration for Digital Inputs (X2 & X3)
224
NPN Configuration for Digital Inputs (X2 & X3)
225
Connection for Obtaining 0
225
Connection Examples of Two-Wire and Three-Wire Sensors to Analog Input (AI2)
226
DI5 as Frequency Input
226
Safe Torque off (X4)
226
Technical Data
228
Installation Checklist
237
Contents of this Chapter
237
Checklist
237
Start-Up
241
Contents of this Chapter
241
Reforming the Capacitors
241
Start-Up Procedure
241
Maintenance
243
Contents of this Chapter
243
Maintenance Intervals
243
Description of Symbols
243
Recommended Maintenance Intervals after Start-Up
243
Cleaning the Exterior of the Drive, IP21 and IP55
246
UL Type 12)
246
Cleaning the Exterior of the Drive, IP66 (UL Type 4X)
247
Cleaning the Heatsink, IP21, IP55 (UL Type 1, 12)
248
Cleaning the Heatsink, IP 66 (UL Type 4X)
249
Fans
250
Replacing the Main Cooling Fan, IP21, IP55 and IP66 (UL Type 1, UL Type 12 and UL Type 4X) Frames R1
251
Replacing the Main Cooling Fan, IP21 and IP55 (UL Type 1 and UL Type 12) Frames R5
253
Replacing the Main Cooling Fans, IP21 and IP55 (UL Type 1 and UL Type 12) Frame R9
254
Replacing the Auxiliary Cooling Fan, IP21 and IP55 (UL Type 1 and UL Type 12) Frames R6
255
Replacing the Auxiliary Cooling Fan, IP55 (UL Type 12) Frames R1
256
Replacing the Auxiliary Cooling Fan, IP55 and IP66 (UL Type 12 and UL Type 4X) Frame R3
257
Replacing the Auxiliary Cooling Fan, IP55 (UL Type 12) Frame R4; IP21 and IP55 (UL Type 1 and UL Type 12) Frame R5
259
Replacing the Second Auxiliary Cooling Fan, IP55 (UL Type 12) Frames R8
260
Capacitors
261
Reforming the Capacitors
261
Control Panel
261
Leds
262
Drive Leds
262
Control Panel Leds
263
Functional Safety Components
264
Technical Data
265
Contents of this Chapter
265
Electrical Ratings
266
Iec
266
Definitions
270
Ul (Nec)
270
Definitions
274
UL Listed Multiple Ratings
275
Conversion Tables for IEC and North American Type Codes
275
Sizing
276
Deratings
277
Surrounding Air Temperature Derating, IP21 (UL Type 1)
279
Surrounding Air Temperature Derating, IP55 (UL Type 12)
280
Altitude Derating
282
Switching Frequency Derating by Derating Factor
283
Switching Frequency Derating with Actual Output Current Values
286
Output Frequency Derating
290
Fuses (IEC)
290
Gg Fuses
291
Ur and Ar Fuses
293
Calculating the Short-Circuit Current of the Installation
296
Calculation Example
296
Circuit Breakers (IEC)
298
Fuses (UL)
299
Circuit Breakers (UL)
303
Dimensions, Weights and Free Space Requirements
307
Dimensions with Flange
313
Losses, Cooling Data and Noise
318
Cooling Air Flow, Heat Dissipation and Noise for Stand-Alone Drives
318
IEC - IP21 and IP55 (UL Type 1 and 12)
318
IEC - IP66 (UL Type 4X)
320
UL (NEC) - IP21 and IP55 (UL Type 1 and 12)
321
UL (NEC) - IP66 (UL Type 4X)
324
Cooling Air Flow and Heat Dissipation for Flange Mounting (Option +C135)
325
IEC - IP21 and IP55 (UL Type 1 and 12)
325
IEC - IP66 (UL Type 4X)
326
UL (NEC) - IP21 and IP55 (UL Type 1 and 12)
327
UL (NEC) - IP66 (UL Type 4X)
328
Terminal and Entry Data for the Power Cables
330
Iec
330
Ul (Nec)
333
Power Cables
337
Typical Power Cables, IEC
337
Typical Power Cables UL (NEC)
338
Terminal and Entry Data for the Control Cables
341
Iec
341
Ul (Nec)
342
Electrical Power Network Specification
342
Motor Connection Data
345
Brake Resistor Connection Data for Frames R1
348
Auxiliary Circuit Power Consumption
348
Efficiency
348
Energy Efficiency Data (Ecodesign)
349
Protection Classes for Module
349
Ambient Conditions
350
Storage Conditions
351
Colors
352
Materials
352
Drive
352
Package Materials for Small Wall-Mounted Drives and Converter Modules
352
Package Materials for Large Wall-Mounted Drives and Converter Modules
352
Package Materials for Options, Accessories and Spare Parts
352
Materials of Manuals
353
Disposal
353
Applicable Standards
353
Markings
354
CE Marking
356
Compliance with the European Low Voltage Directive
356
Compliance with the European EMC Directive
356
Compliance with the European ROHS II Directive 2011/65/EU
356
Compliance with the European WEEE Directive 2002/96/EC
356
Compliance with the European Machinery Directive 2006/42/EC 2Nd Edition - June 2010
356
Validating the Operation of the Safe Torque off Function
357
Compliance with the en 61800-3:2004 + A1:2012
357
Definitions
357
Category C1
357
Category C2
358
Category C3
358
Category C4
359
UL Checklist
360
Design Lifetime Expectancy
361
Disclaimers
361
Generic Disclaimer
361
Cyber Security Disclaimer
361
Dimension Drawings
363
Contents of this Chapter
363
Frame R1, IP21 (UL Type 1)
364
Frame R1, IP55 (UL Type 12)
365
Frame R1, IP55+F278 (UL Type 12)
366
Frame R1, IP66 (UL Type 4X) +B066
367
Frame R1, IP66 (UL Type 4X) +B063
368
Frame R1, IP66 (UL Type 4X) +C193
369
Frame R2, IP21 (UL Type 1)
370
Frame R2, IP55 (UL Type 12)
371
Frame R2, IP55+F278 (UL Type 12)
372
Frame R2, IP66 (UL Type 4X) +B066
373
Frame R2, IP66 (UL Type 4X) +B063
374
Frame R2, IP66 (UL Type 4X) +C193
375
Frame R3, IP21 (UL Type 1)
376
Frame R3, IP55 (UL Type 12)
377
Frame R3, IP55+E223 (UL Type 12)
378
Frame R3, IP55+F278/F316 (UL Type 12)
379
Frame R3, IP66 (UL Type 4X) +B066
380
Frame R3, IP66 (UL Type 4X) +B063
381
Frame R3, IP66 (UL Type 4X) +C193
382
Frame R4, IP21 (UL Type 1)
383
Frame R4, IP55 (UL Type 12)
384
Frame R4, IP55+E223 (UL Type 12)
385
Frame R4, IP55+F278/F316 (UL Type 12)
386
Frame R5, IP21 (UL Type 1)
387
Frame R5, IP55 (UL Type 12)
388
Frame R5, IP55+E223 (UL Type 12)
389
Frame R5, IP55+F278/F316 (UL Type 12)
390
Frame R6, IP21 (UL Type 1)
391
Frame R6, IP55 (UL Type 12)
392
Frame R7, IP21 (UL Type 1)
393
Frame R7, IP55 (UL Type 12)
394
Frame R8, IP21 (UL Type 1)
395
Frame R8, IP55 (UL Type 12)
396
Frame R9, IP21 (UL Type 1)
397
Frame R9, IP55 (UL Type 12)
398
Resistor Braking
399
Contents of this Chapter
399
Operation Principle and Hardware Description
399
Resistor Braking, Frames R1
399
Planning the Braking System
399
Selecting the Brake Resistor
399
Selecting and Routing the Brake Resistor Cables
403
Placing the Brake Resistor
403
Protecting the System in Brake Circuit Fault Situations
404
Mechanical Installation
405
Electrical Installation
405
Start-Up
405
Resistor Braking, Frames R4
406
Planning the Braking System
406
Iec
406
Ul (Nec)
407
Parameter Settings for External Braking Chopper and Resistor
408
The Safe Torque off Function
409
Contents of this Chapter
409
Description
409
Compliance with the European Machinery Directive and the UK Supply of Machinery (Safety) Regulations
410
Wiring
411
Connection Principle
411
Single ACS580-01 Drive, Internal Power Supply
411
Single ACS580-01 Drive, External Power Supply
412
Wiring Examples
412
Single ACS580-01 Drive, Internal Power Supply
412
Single ACS580-01 Drive, External Power Supply
413
Multiple ACS580-01 Drives, Internal Power Supply
414
Multiple ACS580-01 Drives, External Power Supply
415
Activation Switch
416
Cable Types and Lengths
416
Grounding of Protective Shields
416
Operation Principle
417
Start-Up Including Validation Test
418
Competence
418
Validation Test Reports
418
Validation Test Procedure
418
Use
420
Maintenance
422
Competence
422
Fault Tracing
423
Safety Data
424
Terms and Abbreviations
427
TÜV Certificate
428
Declarations of Conformity
429
Optional I/O Extension and Adapter Modules
431
Contents of this Chapter
431
CAIO-01 Bipolar Analog I/O Adapter Module
431
Product Overview
431
Layout
432
Mechanical Installation
433
Necessary Tools
433
Unpacking and Examining the Delivery
433
Installing the Module
433
Electrical Installation
433
Wiring
433
Start-Up
434
Setting the Parameters
434
Diagnostics
435
Leds
435
Technical Data
435
Isolation Areas
436
Dimension Drawings
437
CBAI-01 Bipolar Analog IO Adapter Module
438
Contents of this Chapter
438
Product Overview
438
Layout
438
Mechanical Installation
439
Necessary Tools
439
Unpacking and Examining the Delivery
439
Installing the Module
439
Electrical Installation
439
Wiring
439
Start-Up
440
Setting the Parameters
440
Diagnostics
441
Leds
441
Technical Data
441
Dimension Drawing
442
CHDI-01 115/230 V Digital Input Extension Module
443
Contents of this Chapter
443
Product Overview
443
Layout and Connection Examples
444
Mechanical Installation
445
Necessary Tools
445
Unpacking and Examining the Delivery
445
Installing the Module
445
Electrical Installation
445
Wiring
445
Start-Up
445
Setting the Parameters
445
Fault and Warning Messages
446
Technical Data
446
Dimension Drawing
447
CMOD-01 Multifunction Extension Module (External 24 V AC/DC and Digital I/O)
448
Contents of this Chapter
448
Product Overview
448
Layout and Example Connections
448
Mechanical Installation
449
Necessary Tools
449
Unpacking and Examining the Delivery
449
Installing the Module
450
Electrical Installation
450
Necessary Tools
450
Wiring
450
Start-Up
450
Setting the Parameters
450
Diagnostics
451
Technical Data
452
Dimension Drawing
453
CMOD-02 Multifunction Extension Module (External 24 V AC/DC and Isolated PTC Interface)
454
Contents of this Chapter
454
Product Overview
454
Layout and Example Connections
455
Mechanical Installation
456
Necessary Tools
456
Unpacking and Examining the Delivery
456
Installing the Module
456
Electrical Installation
456
Wiring
456
Start-Up
456
Setting the Parameters
456
Diagnostics
457
Faults and Warning Messages
457
Leds
457
Technical Data
457
Dimension Drawing
458
Common Mode, D U /D T and Sine Filters
461
Content of this Chapter
461
Common Mode Filters
461
When Is a Common Mode Filter Needed
461
Common Mode Filter Types
461
IEC Ratings at U N = 400 V and 480 V, UL (NEC) Ratings at U N = 480 V
461
Du/Dt Filters
462
When Is a D U /D T Filter Needed
462
D U /D T Filter Types
462
IEC Ratings at U = 208/230 V
462
= 230 V, UL (NEC) Ratings at U
462
Description, Installation and Technical Data of the FOCH Filters
464
Description, Installation and Technical Data of the noch Filters
465
Sine Filters
465
IEC Ratings at U N = 400 V, UL (NEC) Ratings at U N = 480 V
465
Description, Installation and Technical Data
466

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