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ABB ACH580-01 Series, Hardware Manual

The ABB ACH580-01 Series is a highly-efficient motor drive designed for various industrial applications. This advanced product ensures seamless motor control and energy optimization. Get the most out of this powerful device with the comprehensive downloadable Instructions Manual available for free download from manualshive.com.

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Table of contents   5

Table of contents

1. Safety instructions

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  15
Use of warnings and notes in this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  15
General safety in installation, start-up and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  16
Electrical safety in installation, start-up and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . .  18

Precautions before electrical work   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  18
Additional instructions and notes   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  19
Grounding  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  20

Additional instructions for permanent magnet motor drives   . . . . . . . . . . . . . . . . . . . . . . . . . .  22

Safety in installation, start-up and maintenance  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  22

General safety in operation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  23

2. Introduction to the manual

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  25
Applicability  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  25
Target audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  25
Purpose of the manual   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  25
Contents of this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  26
Categorization by frame (size) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  27
Related documents  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  27
Quick installation and commissioning flowchart   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  29
Terms and abbreviations  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  31

3. Operation principle and hardware description

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  35
Operation principle   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  36
Layout  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  37
Overview of power and control connections  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  43

External control connection terminals, frames R1…R5   . . . . . . . . . . . . . . . . . . . . . . . . . .  44
External control connection terminals, frames R6…R9   . . . . . . . . . . . . . . . . . . . . . . . . . .  45

Control panel  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  46

Control panel door mounting kits   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  47

Type designation label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  47
Type designation key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  49

4. Mechanical installation

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  53
Safety   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  53
Checking the installation site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  54
Required tools  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  58
Moving the drive   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  58
Unpacking and examining delivery, frames R1 and R2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  59

Safety

Summary of Contents for ACH580-01 Series

Page 1: ...ABB DRIVES FOR HVAC ACH580 01 drives 0 75 to 250 kW 1 to 350 hp Hardware manual...

Page 2: ...Related documents are listed on page 27...

Page 3: ...50 kW 1 to 350 hp 3AXD50000044839 Rev B EN EFFECTIVE 2018 12 20 2018 ABB Oy All Rights Reserved 1 Safety instructions Table of contents 4 Mechanical installation 6 Electrical installation IEC 7 Electr...

Page 4: ......

Page 5: ...arget audience 25 Purpose of the manual 25 Contents of this manual 26 Categorization by frame size 27 Related documents 27 Quick installation and commissioning flowchart 29 Terms and abbreviations 31...

Page 6: ...1 Limitation of liability 81 Selecting the supply disconnecting device 81 European Union 82 North America 82 Other regions 82 Checking the compatibility of the motor and drive 83 Protecting the motor...

Page 7: ...ementing a motor temperature sensor connection 110 6 Electrical installation IEC Contents of this chapter 113 Warnings 113 Required tools 113 Checking the insulation of the assembly 114 Drive 114 Inpu...

Page 8: ...nstalling the drive to a TT system 172 Identifying different types of electrical power systems 173 Frames R1 R3 disconnecting EMC or varistor screws 174 Frames R4 R9 disconnecting EMC or varistor scre...

Page 9: ...cooling fan IP55 UL Type 12 frame R3 235 Replacing the auxiliary cooling fan IP55 UL Type 12 frame R4 236 Replacing the second auxiliary cooling fan IP55 UL Type 12 frames R8 R9 237 Capacitors 238 Re...

Page 10: ...ficiency 296 Degree of protection 296 Ambient conditions 296 Materials 298 Applicable standards 298 CE marking 300 Compliance with the European Low Voltage Directive 300 Compliance with the European E...

Page 11: ...UL Type 12 333 Frame R9 IP21 UL Type 1 334 Frame R9 IP55 UL Type 12 335 12 Resistor braking Contents of this chapter 337 Operation principle and hardware description 337 Resistor braking frames R1 R3...

Page 12: ...external 24 V AC DC and digital I O 370 Safety instructions 370 Hardware description 370 Mechanical installation 371 Electrical installation 372 Start up 374 Diagnostics 375 Technical data 376 CMOD 0...

Page 13: ...filters 391 Sine filters 392 Selecting a sine filter for the drive 392 Description installation and technical data 393 Further information Product and service inquiries 395 Product training 395 Provi...

Page 14: ...14 Table of contents...

Page 15: ...h or damage to the equipment They also tell you how to prevent the danger Notes draw attention to a particular condition or fact or give information on a subject The manual uses these warning symbols...

Page 16: ...hot for a while after disconnection of the electrical supply Keep the drive in its package or protect it otherwise from dust and burr from drilling and grinding until you install it Protect also the...

Page 17: ...mware manual 3AXD50000027537 English For the validation of other safety circuits see the instructions provided with them Note If you select an external source for start command and it is on and the st...

Page 18: ...harge before you continue 3 Protect any other energized parts in the work location against contact 4 Take special precautions when close to bare conductors 5 Measure that the installation is de energi...

Page 19: ...ve with the ground to phase varistor connected can be installed to a symmetrically grounded TN S system If you install the drive to another system check if you must disconnect the varistor See section...

Page 20: ...l installation including the grounding of the drive WARNING Obey these instructions If you ignore them injury or death or equipment malfunction can occur and electromagnetic interference can increase...

Page 21: ...er than 3 5 mA AC or 10 mA DC you must use a fixed protective earth PE connection In addition install a second protective earth conductor of the same cross sectional area as the original protective ea...

Page 22: ...not disconnect the motor make sure that the motor cannot rotate during work Make sure that no other system can rotate the motor directly or through any mechanical connection Measure that the installat...

Page 23: ...stop the drive use the control panel Hand Off and Auto keys or commands through the I O terminals of the drive Give a stop command to the drive before you reset a fault If you have an external source...

Page 24: ...24 Safety instructions...

Page 25: ...all applicable types in section Electrical ratings on page 244 Note The manual does not apply to R0 R3 frames with type codes ACH580 01 02A6 4 03A3 4 04A0 4 05A6 4 07A2 4 09A 4 12A6 4 017A 4 025A 4 0...

Page 26: ...y with other than symmetrically grounded TN S systems It then shows how to connect the power and control cables install optional modules and connect a PC Electrical installation North America page 167...

Page 27: ...kW 1 to 350 hp hardware manual 3AXD50000044839 ACH580 01 quick installation and start up guide for frames R1 to R5 3AXD50000044861 ACH580 01 quick installation and start up guide for frames R6 to R9...

Page 28: ...Flange mounting kit quick installation guide for ACx580 01 frames R1 to R3 3AXD50000119172 Flange mounting kit quick installation guide for ACx580 01 frames R4 to R5 3AXD50000287093 Flange mounting k...

Page 29: ...em than symmetrically grounded TN S system Check if you must disconnect the EMC filter or ground to phase varistor IEC Checking the compatibility with IT ungrounded corner grounded delta midpoint grou...

Page 30: ...nstallation IEC Connecting the control cables on page 142 North America Connecting the control cables on page 178 Check the installation Installation checklist on page 223 Commission the drive ACH580...

Page 31: ...on adapter module CHDI 01 Optional 115 230 V digital input extension module CMOD 01 Optional multifunction extension module external 24 V AC DC and digital I O extension CMOD 02 Optional multifunction...

Page 32: ...Input Output IGBT Insulated gate bipolar transistor Intermediate circuit See DC link Inverter Converts direct current and voltage to alternating current and voltage LONWORKS LONWORKS local operating...

Page 33: ...to materials that experience an increase in electrical resistance when their temperature is raised R1 R2 Frame size Rectifier Converts alternating current and voltage to direct current and voltage SIL...

Page 34: ...34 Introduction to the manual...

Page 35: ...on 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 gen...

Page 36: ...and inverter 3 Inverter Converts direct current and voltage to alternating current and voltage 4 Built in brake chopper R R in frames R1 R3 Conducts the surplus energy from the intermediate DC circuit...

Page 37: ...connection terminals frames R1 R5 on page 44 9 Varistor grounding screw VAR See Frames R1 R3 on page 120 IEC or Frames R1 R3 disconnecting EMC or varistor screws North America on page 174 6 7 8 11 8 1...

Page 38: ...e control panel visible UL Type 12 frames have a hood whose construction depends on the frame size R1 IP55 UL Type 12 1 Mounting points 4 pieces top points are under the hood which is installed last 2...

Page 39: ...tor screws North America on page 174 10 EMC filter grounding screw EMC DC See Frames R1 R3 on page 120 IEC or Frames R1 R3 disconnecting EMC or varistor screws North America on page 174 11 Input power...

Page 40: ...istor screws North America on page 176 10 Two EMC filter grounding screws 10a EMC DC and 10b EMC AC See Frames R4 R9 on page 121 IEC or Frames R4 R9 disconnecting EMC or varistor screws North America...

Page 41: ...ding screw VAR See Frames R4 R9 on page 121 IEC or Frames R4 R9 disconnecting EMC or varistor screws North America on page 176 11 Two EMC filter grounding screws 11a EMC DC and 11b EMC AC See Frames R...

Page 42: ...O cables 12 Clamps for I O cable mechanical support 13 Varistor grounding screw VAR under the control panel platform See Frames R4 R9 on page 121 IEC or Frames R4 R9 disconnecting EMC or varistor scre...

Page 43: ...onnections and control interfaces of the drive 1 Option slot 1 for optional fieldbus adapter modules 2 Option slot 2 for optional I O extension modules 3 Panel port 4 du dt or common mode filter optio...

Page 44: ...Programmable digital inputs X4 Safe torque off connection X5 Embedded fieldbus X6 Relay output 3 X7 Relay output 2 X8 Relay output 1 X10 Auxiliary fan connection IP55 X13 Option slot 1 fieldbus adapt...

Page 45: ...apter module X6 Relay output 3 X7 Relay output 2 X8 Relay output 1 X10 External 24 V AC DC input connection X12 Panel connection X13 Option slot 1 fieldbus adapter modules X14 Option slot 2 I O extens...

Page 46: ...e 1b To reinstall the control panel put the bottom of the container in position 1a press the retaining clip at the top 1b and push the control panel in at the top edge 1c For the use of the control pa...

Page 47: ...labels on the drive An example label is shown below No Description 1 Type designation see section Type designation key on page 49 2 Name and address of the manufacturer 3 Frame size 4 Type of the dri...

Page 48: ...48 Operation principle and hardware description Locations of the labels on the drive 1 2 3 Note Pn is not shown in UL NEC drive labels 1 2 3...

Page 49: ...bottom cable box or the conduit plate with cable entries quick installation and start up guide multilingual Size xxxx Refer to the rating table page 244 Voltage rating 4 2 200 240 V 4 380 480 V 6 575...

Page 50: ...odbus TCP K492 FPNO 21 Two port PROFINET IO Embedded fieldbus Embedded fieldbus EIA 485 as standard Construction B056 IP55 UL type 12 Factory option retro fit not possible C135 Flange mounting kit Fla...

Page 51: ...le Note These options are not available in North America You can find manuals in PDF format on the Internet See section Document library on the Internet on the inside of the back cover R700 English R7...

Page 52: ...52 Operation principle and hardware description...

Page 53: ...ck the installation site unpack check the delivery and install the drive mechanically Safety WARNING Frames R5 R9 Lift the drive with a lifting device Use the lifting eyes of the drive Do not tilt the...

Page 54: ...3 9 06 Hood height mm 72 230 Frame size Vertical installation Free space IP21 UL Type 1 IP55 UL Type 12 Above a 1 Below b 2 Beside c 3 Above a 1 Below b 2 Beside c 3 mm in mm in mm in mm in mm in mm i...

Page 55: ...wall Note The recommended free space above and below the drive is for installations where the drive is mounted on a wall indoors For ABB cabinet built drives which are thermally tested and approved f...

Page 56: ...nd R9 exceeds the requirement of free space above for these frames 2 Free space below is always measured from the drive frame not from the cable box 3 Free space between the drives Note The recommende...

Page 57: ...space IP21 IP20 IP55 UL Type 12 Above a Below b 1 Above a Below b 1 mm in mm in mm in mm in R1 150 5 91 86 3 39 137 5 39 116 4 57 R2 150 5 91 86 3 39 137 5 39 116 4 57 R3 200 7 87 53 2 09 200 7 87 53...

Page 58: ...ion Dimensions weights and free space requirements on page 270 The floor material below the installation is non flammable There is enough free space above and below the drive to enable cooling air flo...

Page 59: ...arate packages if they have been ordered with a plus code such as for example K490 FEIP 21 Two port EtherNet IP adapter module in the option box North America Options may be ordered as factory install...

Page 60: ...kage material according to local regulations Frames R1 and R2 cable box IP21 UL Type 1 This illustration shows the contents of the cable box package The package also includes an assembly drawing which...

Page 61: ...rol panel factory installed 9 Possible options in separate packages if they have been ordered with a plus code such as for example K490 FEIP 21 Two port EtherNet IP adapter module in the option box No...

Page 62: ...installation To unpack Cut the straps 6 Remove the upper tray 7a and option tray 2 Remove the cardboard box 4 Remove the plastic bag 5 Lift the drive 2 Recycle the package material according to local...

Page 63: ...odule in the option box North America Options may be ordered as factory installed 4 Cardboard box 5 Inner box with edge boards and cushions Mounting template in the inner box 6 Plastic bag Note Hood i...

Page 64: ...To unpack Cut the straps Open box 4 and remove top cushions and option tray 2 Lift out the inner box 5 Open the inner box 5 lift the drive 1 and remove plastic bag 7 Recycle the package material acco...

Page 65: ...led 10 Possible options in separate packages if they have been ordered with a plus code such as for example K490 FEIP 21 Two port EtherNet IP adapter module in the option box North America Options may...

Page 66: ...otecting film 6 Lift the drive 2 Recycle the package material according to local regulations Frame R5 cable box IP21 UL Type 1 This illustration shows the contents of the cable box package The package...

Page 67: ...t corrosion 6 Pallet 7 Stopper 8 Option tray 9 In the option tray Europe Multilingual quick installation and start up guide always and Hardware and firmware manuals if ordered with a plus code North A...

Page 68: ...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 53 Lift the drive with a hoist Recycle the pack...

Page 69: ...tallation 69 Frame R6 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 th...

Page 70: ...l installation 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...

Page 71: ...tallation 71 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 th...

Page 72: ...installation 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 th...

Page 73: ...mplate under the drive The drive dimensions and hole locations are also shown in the drawings in chapter Dimension drawings on page 309 2 Drill the mounting holes 3 Insert anchors or plugs into the ho...

Page 74: ...securely Install the cable box frames R1 R2 6 Remove the screw 6a and lift the cover off 6b from the separate cable box 7 Attach the cable box cover to the front cover 8 Install the cable box to the...

Page 75: ...ve The drive dimensions and hole locations are also shown in the drawings in chapter Dimension drawings on page 309 2 Drill the mounting holes 3 Insert fixing anchors or plugs into the holes Start the...

Page 76: ...s 4b and then to the top side 4c 5 Attach the cable box to the drive frame 6 Tighten the box nuts 7 Slide the box cover from the bottom 7a and tighten the retaining screws 7b 8 Put the tabs at the top...

Page 77: ...to the wall and place drive over the upper bolts 9b Lift the drive with another person or with a lifting device as it is heavy Tighten the bolts in the wall securely 9c 10 Tighten the two remaining b...

Page 78: ...attach the lower part of the drive 2 Drill the mounting holes 3 Insert fixing anchors or plugs into the holes and start the bolts into the anchors or plugs 4 Position the drive onto the bolts on the...

Page 79: ...front cover Remove the fastening screws a with a T20 Torx screwdriver move the cover to the top side b and then up c Note Install the hood for UL Type 12 drives after you have installed the drive ele...

Page 80: ...mounting Instructions for flange mounting are delivered with the flange mounting kit Flange mounting kit quick installation guide for ACX580 01 frames R1 to R3 3AXD50000119172 English Flange mounting...

Page 81: ...ed and made according to applicable local laws and regulations The manufacturer does not assume any liability whatsoever for any installation which breaches the local laws and or other regulations Fur...

Page 82: ...evices to break the load circuit before the opening of the main contacts of the disconnector EN 60947 3 circuit breaker suitable for isolation in accordance with EN 60947 2 North America Installations...

Page 83: ...the same size consider the following operation limits of the drive control program motor nominal voltage range 1 6 2 UN motor nominal current range 1 6 2 IN IEC or 1 6 2 ILD North America of the driv...

Page 84: ...system ABB du dt and common mode filters insulated N end motor bearings PN 100 kW and frame size IEC 315 100 kW PN 350 kW or IEC 315 frame size IEC 400 PN 134 hp and frame size NEMA 500 134 hp PN 469...

Page 85: ...00 V Standard LL 1300 V du dt du dt N or CMF or Reinforced LL 1600 V 0 2 microsecond rise time N or CMF Abbr Definition UN Nominal AC line voltage LL Peak line to line voltage at motor terminals which...

Page 86: ...time considering the actual cable length proceed as follows Peak line to line voltage Read the relative LL UN value from the appropriate diagram below and multiply it by the nominal supply voltage UN...

Page 87: ...l Motor cable length LL UN Relative peak line to line voltage du dt UN Relative du dt value Note LL and du dt values are approximately 20 higher with resistor braking LL UN l m du dt U N 1 s 1 0 2 0 5...

Page 88: ...ical installation Additional note for sine filters Sine filters protect the motor insulation system Therefore a du dt filter can be replaced with a sine filter The peak phase to phase voltage with the...

Page 89: ...90 To comply with the EMC requirements of the CE mark use one of the approved cable types in section Preferred power cable types IEC and North America on page 91 Symmetrical shielded cable reduces ele...

Page 90: ...al If this is not so the cross sectional area of the protective earthing conductor shall be determined in a manner which produces a conductance equivalent to that which results from the application of...

Page 91: ...mored cable with three phase conductors and concentric PE conductor as shield or armor Yes Yes Symmetrical shielded or armored cable with three phase conductors and symmetrically constructed PE conduc...

Page 92: ...commended to minimize radio frequency interference Four conductor cabling in PVC conduit or jacket three phase conductors and PE Yes Yes with phase conductor smaller than 10 mm2 8 AWG or motors up to...

Page 93: ...tate and local codes for the appropriate materials for your application Yes WARNING If you use unshielded high power input power cables in an IT network make sure that the non conductive outer sheath...

Page 94: ...uctors require separation from motor feed and other low voltage conductors Do not run outputs of multiple drives in parallel Bundle each cable together and use separator where possible Free air3 Notes...

Page 95: ...per tape or copper wire The better and tighter the shield the lower the emission level and bearing currents Conductor type Notes1 2 Copper Allowed All frames Aluminum UL installations Not allowed All...

Page 96: ...96 Guidelines for planning the electrical installation 2 Helix of copper tape or copper wire 3 Copper wire screen 4 Inner insulation 5 Cable core...

Page 97: ...1 3 1 5 1 5 12A0 2 R1 3 1 5 1 5 018A 2 R1 3 2 5 2 5 025A 2 R2 3 4 0 4 0 032A 2 R2 3 6 0 6 0 047A 2 R3 3 10 10 060A 2 R3 3 10 10 089A 2 R5 3 35 16 3 50 25 115A 2 R5 3 50 25 3 70 35 144A 2 R6 3 70 35 3...

Page 98: ...s laid on a cable ladder side by side ambient temperature 30 C PVC insulation surface temperature 70 C EN 60204 1 and IEC 60364 5 52 2001 For other conditions size the cables according to local safety...

Page 99: ...mbient temperature is other than 30 C 86 F See 310 15 B 3 a for more than three current carrying conductors For other conditions size the cables according to local safety regulations appropriate input...

Page 100: ...115 230 V AC signals in the same cable Signals allowed to be run in the same cable Relay controlled signals providing their voltage does not exceed 48 V can be run in the same cables as digital input...

Page 101: ...the cable is 3 m 9 8 ft FPBA 01 PROFIBUS DP adapter module connectors Frames R1 R3 The following connector types have been tested to fit in the tight space for option slot 1 Phoenix Contact SUBCON PL...

Page 102: ...voltage Where control cables must cross power cables make sure they are arranged at an angle as near to 90 degrees as possible Do not run extra cables through the drive The cable trays must have good...

Page 103: ...power and motor cabling in conduit Ensure the installation of your application is in accordance with national and local codes Do not run input power cable and motor cable in the same conduit Use sepa...

Page 104: ...grounding for the shields of both the incoming and outgoing cable or connect the shields of the cables otherwise together North America Install the equipment in a way that the conduit or motor cable...

Page 105: ...cteristics are known WARNING Due to the inherent operating principle and construction of circuit breakers independent of the manufacturer hot ionized gases can escape from the breaker enclosure in cas...

Page 106: ...r monitors a calculated temperature value based on a motor thermal model which in turn is based on the motor nominal current or an actual temperature indication given by motor temperature sensors The...

Page 107: ...torque off function For more information see CPTC 02 ATEX certified thermistor protection module Ex II 2 GD L537 Q971 user s manual 3AXD50000030058 English Using a safety switch between the drive and...

Page 108: ...the undervoltage control power loss ride through See ACH580 HVAC control program firmware manual 3AXD50000027537 English Protecting the contacts of relay outputs Inductive loads relays contactors moto...

Page 109: ...ation 109 Limiting relay output maximum voltages at high installation altitudes See sections Isolation areas R1 R5 on page 292 and Isolation areas R6 R9 on page 293 1 Relay outputs 2 Varistor 3 RC fil...

Page 110: ...ct and insulated with basic insulation from other low voltage circuits The insulation must be rated for the same voltage level as the drive main circuit Note that extra low voltage circuits such as 24...

Page 111: ...tension module Temperature sensor type Type Insulation PTC KTY Pt100 Pt1000 CMOD 02 Reinforced insulation between the motor thermistor connector and the other connectors of the module including drive...

Page 112: ...112 Guidelines for planning the electrical installation...

Page 113: ...d connect a PC Warnings WARNING Obey the instructions in chapter Safety instructions on page 15 If you ignore them injury or death or damage to the equipment can occur Make sure that the drive is disc...

Page 114: ...and motor cable Check the insulation of the motor and motor cable as follows 1 Check that the motor cable is disconnected from the drive output terminals T1 U T2 V and T3 W 2 Measure the insulation r...

Page 115: ...s connected to the resistor and disconnected from the drive output terminals R and R 2 At the drive end connect the R and R conductors of the resistor cable together Measure the insulation resistance...

Page 116: ...ter is not suitable for This can cause danger or damage the drive Note When the internal EMC filter is disconnected the EMC compatibility of the drive is considerably reduced See section EMC compatibi...

Page 117: ...B1 and midpoint grounded delta B2 systems IT systems ungrounded or high resistance grounded ohms C R1 R3 Do not disconnect EMC or VAR screws Disconnect EMC screw Do not disconnect VAR screw Disconnect...

Page 118: ...urrent will cause the residual current device to trip Note Because the EMC filter screws have been disconnected ABB does not guarantee the EMC category ABB does not guarantee the functioning of the gr...

Page 119: ...ltages in relation to the line to line voltage of the electrical power system types are shown below UL L UL1 G UL2 G UL3 G Electrical power system type X 0 58 X 0 58 X 0 58 X Symmetrically grounded TN...

Page 120: ...m the drive 2 Open the front cover if not already opened see page 124 3 To disconnect the internal EMC filter remove the EMC screw 3a and place it in the storage place 3b 4 To disconnect the ground to...

Page 121: ...Switch off the power from the drive 2 Open the cover if not already opened Frame R4 see page 124 frame R5 see page 131 frames R6 R9 see page 79 3 To disconnect the internal EMC filter remove the two E...

Page 122: ...122 Electrical installation IEC IEC R6 R9 Screw A EMC DC B EMC AC C VAR 3 B 3 A 4 C...

Page 123: ...brake resistor 6 Use a separate grounding cable if the shield does not meet the requirements of IEC 61439 1 see page 89 or there is no symmetrically constructed grounding conductor in the cable see pa...

Page 124: ...system than symmetrically grounded TN S system see section Checking the compatibility with IT ungrounded corner grounded delta midpoint grounded delta and TT systems on page 116 if you have to discon...

Page 125: ...al installation IEC 125 IEC 3 Remove the rubber grommets for the motor and input power cables as well as brake resistor cable if used Remove the grommets for the control cables when you are connecting...

Page 126: ...are markings on the drive frame near the power cable terminals helping you to strip the wires to the correct length of 8 mm Two different motor cable types are shown 6a 6b Note The bare shield will be...

Page 127: ...nal I O extension module installed in options slot 2 at this point 9 Prepare the ends of the cable as illustrated in the figure If you use aluminum cables put grease to the peeled aluminum cable befor...

Page 128: ...ctor see the note on page 20 in chapter Safety instructions of the cable 11c 20 Connect the phase conductors of the cable to the L1 L2 and L3 terminals Tighten the screws to the torque given in the ta...

Page 129: ...Frames R1 R2 R4 Install the grounding shelf included with the mounting screws in a plastic bag in the delivery Brake resistor cable if used Frames R1 R3 only 13 Repeat steps 4 6 for the brake resistor...

Page 130: ...at this point See section Installing option modules on page 159 15 Secure the cables outside the unit mechanically 16 Ground the motor cable shield at the motor end For minimum radio frequency interf...

Page 131: ...P55 UL Type 12 1 Remove the front cover Loosen the retaining screws with a T20 Torx screwdriver 1a and lift the cover from the bottom outwards 1b and then up 1c WARNING If you install the drive on any...

Page 132: ...EC 2 Attach the residual voltage warning sticker in the local language next to the control board 3 Remove the shroud on the power cable terminals by releasing the clips with a screwdriver 3a and pulli...

Page 133: ...e hole into the rubber grommet Slide the grommet onto the cable 5 Prepare the ends of the motor cable as illustrated in figures 5a and 5b two different motor cable types are shown If you use aluminum...

Page 134: ...the clamp of the power cable grounding shelf onto the stripped part of the cable 7a Connect the twisted shield of the cable to the grounding terminal 7b Connect the phase conductors of the cable to th...

Page 135: ...t the input power cable Use terminals L1 L2 and L3 Tighten the screws to the torque given in the table 10 Install the cable box plate Position the plate 10a and tighten the screw 10b 8b 8a PE PE PE 9...

Page 136: ...r counterparts on the drive frame 11a and then pressing the shroud in place 11b Finalization 12 Secure the cables outside the unit mechanically 13 Ground the motor cable shield at the motor end For mi...

Page 137: ...stor 1 Attach the residual voltage warning sticker in the local language next to the control board 2 Remove the side plates of the cable box Remove the retaining screws 2a and slide the walls out 2b 3...

Page 138: ...lide the cables through the holes in the cable entry and attach the grommets to the holes the motor cable to the right and the input power cable to the left 9 Connect the motor cable Ground the shield...

Page 139: ...hes the connector to its busbar Put the conductor under the connector pressure plate and pre tighten the conductor Put the connector back to its busbar Start the nut and turn it at least two rotations...

Page 140: ...nd turn it at least two rotations by hand WARNING Before using tools make sure that the nut screw is not cross threading Cross threading will damage the drive and cause danger Tighten the combi screw...

Page 141: ...ure 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 cable entry of...

Page 142: ...ontrol cables See section Default I O connection diagram HVAC default configuration on page 143 for the default I O connections of the HVAC default configuration Connect the cables as described under...

Page 143: ...quency speed selection3 16 DI4 Start interlock 1 1 allow start 17 DI5 Not configured 18 DI6 Not configured X6 X7 X8 Relay outputs 19 RO1C Damper control 250 V AC 30 V DC 2 A 20 RO1A 21 RO1B 22 RO2C Ru...

Page 144: ...ow start 17 DI5 Not configured 18 DI6 Not configured X6 X7 X8 Relay outputs 19 RO1C Damper control 250 V AC 30 V DC 2 A 20 RO1A 21 RO1B 22 RO2C Running 250 V AC 30 V DC 2 A 23 RO2A 24 RO2B 25 RO3C Fau...

Page 145: ...setting Start stop reference Constant speeds constant frequencies or parameter group 22 Speed reference selection 4 Connected with jumpers at the factory 5 Use shielded twisted pair cables for digital...

Page 146: ...to the terminated ON position when the drive is the first or last unit on the link Bus not terminated default Bus terminated S5 BIAS Activates on the biasing voltages to the bus One and only one devic...

Page 147: ...control board ground when the control board is powered using an external 24 V AC supply Internal 24 V power supply PNP connection source External 24 V power supply PNP connection source X2 X3 10 24V 1...

Page 148: ...AC cable to the control board ground when the control board is powered using an external 24 V AC supply Internal 24 V power supply NPN connection source External 24 V power supply NPN connection sourc...

Page 149: ...hm resistor or two 1 kohm resistors in parallel between the analog output 2 AO2 and analog common ground AGND Examples are shown in the figure below 8 AO2 Analog output 2 Default output 0 20 mA 9 AGND...

Page 150: ...the drive feeds the supply voltage 24 V DC Thus the output signal must be 4 20 mA not 0 20 mA 5 AI2 Process actual value measurement or reference 0 4 20 mA Rin 100 ohm 6 AGND 10 24V Auxiliary voltage...

Page 151: ...English DI6 as PTC input If DI6 is used as a PTC input see ACH580 HVAC control program firmware manual 3AXD50000027537 English for how to set parameters accordingly Note If DI6 is used as PTC input th...

Page 152: ...lfill the requirement the I O board terminals must be protected against contact and must not be connected to other equipment or the temperature sensor must be isolated from the I O terminals Safe torq...

Page 153: ...minals of the control board as possible Frames R5 R9 Secure the cables mechanically at the clamps below the control board Ground also the pair cable shields and grounding wire at the SCR terminal 5 Ro...

Page 154: ...cable tie mounts Note Leave the other ends of the control cable shields unconnected or ground them indirectly via a high frequency capacitor with a few nanofarads eg 3 3 nF 630 V The shield can also b...

Page 155: ...5 IEC MOTOR T1 U T2 V T3 W INPUT L1 L2 L3 BRAKE RES R R UDC PE BRAKE RES INPUT PE MOTOR R R UDC L1 L2 L3 T1 U T2 V T3 W R3 3 4 11 11 5 5 7 8 7 8 6 6 9 9 10 10 R1 R2 0 5 0 6 N m 0 4 lbf ft R3 0 5 0 6 N...

Page 156: ...156 Electrical installation IEC IEC R4 0 5 0 6 N m 0 4 lbf ft 7 4 3 8 11 5 9 11 6 10 8 4...

Page 157: ...Electrical installation IEC 157 IEC R5 4 6 11 11 10 4 3 5 7 8 9 0 5 0 6 N m 0 4 lbf ft 4 8...

Page 158: ...158 Electrical installation IEC IEC R6 R9 0 5 0 6 N m 0 5 0 6 N m 0 4 lbf ft M4 20 4 6 10 3 4 4 5 7 8 9 8 11 11...

Page 159: ...Remove the front cover s if not already removed See page 124 R1 R4 page 131 R5 or page 79 R6 R9 The figures for frames R1 R5 page 160 and R6 R9 page 161 show an example of installing option modules Op...

Page 160: ...160 Electrical installation IEC IEC R3 R5 R1 R2 3 2 3 4 6 6 7 7 4 5 5...

Page 161: ...ptional I O extension modules CHDI 01 CMOD 01 and CMOD 02 see chapter Optional I O extension modules on page 363 for specific installation and wiring instructions For other option modules for example...

Page 162: ...162 Electrical installation IEC IEC Reinstalling grommets UL Type 12 To maintain UL Type 12 reinstall grommets top of the grommets downwards to all cable entry holes without conduits...

Page 163: ...he 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 T20 Torx screwdriver 1b 2 x 2 2 1a 1b IP21...

Page 164: ...ng screws 1b with a T20 Torx screwdriver 2 Reinstall the module cover Press the cover at the bottom 2a and tighten the retaining screws 2b IP55 UL Type 12 1 Reinstall the front cover Press the cover a...

Page 165: ...T20 Torx screwdriver 2 Slide the cover of the cable box on the module from below until the cover snaps into place 3 Reinstall the module cover Tighten the two retaining screws with a screwdriver IP55...

Page 166: ...rom bottom upwards 2 Put the USB cable Mini B plug in the control panel USB connector 3 Put the USB cable A plug in the USB connector of the PC 3a The panel displays text USB connected 3b Note Panel k...

Page 167: ...l modules and connect a PC Warnings WARNING Obey the instructions in chapter Safety instructions on page 15 If you ignore them injury or death or damage to the equipment can occur Make sure that the d...

Page 168: ...ons before connecting it to the drive Motor and motor cable Check the insulation of the motor and motor cable as follows 1 Check that the motor cable is disconnected from the drive output terminals T1...

Page 169: ...cable is connected to the resistor and disconnected from the drive output terminals R and R 2 At the drive end connect the R and R conductors of the resistor cable together Measure the insulation resi...

Page 170: ...r is not suitable for This can cause danger or damage the drive Note When the internal EMC filter is disconnected the EMC compatibility of the drive is considerably reduced See section EMC compatibili...

Page 171: ...rial Symmetrically grounded TN systems TN S systems ie center grounded wye A Corner grounded delta B1 and midpoint grounded B2 delta systems IT systems ungrounded or high resistance grounded 30 ohms C...

Page 172: ...ve can be installed to a TT system under these conditions 1 Residual current device has been installed in the supply system 2 EMC filter screws have been disconnected they are plastic screws or there...

Page 173: ...ge line 1 to ground UL1 G 3 input voltage line 2 to ground UL2 G 4 input voltage line 3 to ground UL3 G The line to ground voltages in relation to the line to line voltage of the electrical power syst...

Page 174: ...page 170 do as follows 1 Switch off the power from the drive 2 Open the front cover if not already opened see page 180 3 The internal DC EMC filter is disconnected by default with a plastic screw 3a...

Page 175: ...Electrical installation North America 175 UL NEC R3 Screw Default material A EMC DC Plastic B VAR Metal 3a 4a 4b 3b A B...

Page 176: ...e 2 Open the cover if not already opened Frame R4 see page 180 frame R5 see page 185 frames R6 R9 see page 79 3 To disconnect the internal EMC filters The DC EMC filter is disconnected by default with...

Page 177: ...nstallation North America 177 UL NEC R5 3a 3b 4 A B Screw Default material A EMC DC Plastic B EMC AC Plastic C VAR Metal C R6 R9 3b 3a 4 B A Screw Default material A EMC DC Plastic B EMC AC Plastic C...

Page 178: ...21 3 With the conduit Make sure of a proper grounding of the conduit at the cable entry Ground the other end of the conduit and PE conductor if used at the distribution board With a shielded cable Do...

Page 179: ...requirements for the PE conductor see page 89 or there is no symmetrically constructed grounding conductor in the cable see page 93 7 du dt or common mode filter optional see page 389 Note With a shie...

Page 180: ...other system than symmetrically grounded TN S system see section Checking the compatibility with IT ungrounded corner grounded delta midpoint grounded delta and TT systems on page 170 if you have to...

Page 181: ...er grommets if present for the motor and input power cabling as well as brake resistor cabling if used Remove the grommets for the control cabling when you are connecting them 4 Attach the cable condu...

Page 182: ...phase conductors to the T1 U T2 V and T3 W terminals Tighten the screws to the torque given in the table 7b Conduit 5 R3 MOTOR T1 U T2 V T3 W INPUT L1 L2 L3 BRAKE RES R R UDC BRAKE RES INPUT PE MOTOR...

Page 183: ...phase conductors to the L1 L2 and L3 terminals Tighten the screws to the torque given in the table 10b MOTOR T1 U T2 V T3 W INPUT L1 L2 L3 BRAKE RES R R UDC BRAKE RES INPUT PE MOTOR R R UDC L1 L2 L3 T...

Page 184: ...ten the screws to the torque given in the table Finalization Note Frame R1 You have to install any optional I O extension module if used in options slot 2 at this point See section Installing option m...

Page 185: ...s 1e IP55 UL Type 12 1 Remove the front cover Loosen the retaining screws with a T20 Torx screwdriver 1a and lift the cover from the bottom outwards 1b and then up 1c WARNING If you install the drive...

Page 186: ...oud on the power cable terminals by releasing the clips with a screwdriver 3a and pulling the shroud out 3b 4 Remove the rubber grommets if present for the motor and input power cabling Remove the gro...

Page 187: ...through the conduit 8 Connect the conductors Connect the grounding conductor to the grounding terminal 8a Connect the phase conductors to the T1 U T2 V and T3 W terminals 8b Tighten the screws to the...

Page 188: ...rews to the torque given in the table 11 Install the cable box plate Position the plate 11a and tighten the screw 11b 12 Reinstall the shroud on the power terminals by putting the tabs at the top of t...

Page 189: ...Electrical installation North America 189 UL NEC Finalization 13 Secure the conduits outside the unit mechanically...

Page 190: ...the local language next to the control board 2 Remove the side plates of the cable box Remove the retaining screws 2a and slide the walls out 2b 3 Remove the shroud on the power cable terminals by rel...

Page 191: ...Electrical installation North America 191 UL NEC 7 Attach the cable conduits for the motor and input cabling to the cable entry holes 7...

Page 192: ...conductor to the connector ABB recommends that you put it under the upper pressure plate If you use parallel power cabling put the first conductor under the lower pressure plate and the second under t...

Page 193: ...make sure that the nut screw is not cross threading Cross threading will damage the drive and cause danger Tighten the nut to a torque of 30 N m 22 lbf ft Tighten the conductor s to 40 N m 30 lbf ft f...

Page 194: ...the combi screw to a torque of 30 N m 22 lbf ft Tighten the conductor s to 40 N m 30 lbf ft for frame R8 or to 70 N m 52 lbf ft for frame R9 12 Frames R8 R9 Connect the parallel motor 11a and input po...

Page 195: ...Electrical installation North America 195 UL NEC DC connection The UDC and UDC terminals as standard in frames R4 R9 are for using external brake chopper units...

Page 196: ...the control cables See section Default I O connection diagram HVAC default configuration on page 197 for the default I O connections of the HVAC default configuration Connect the cables as described...

Page 197: ...stant frequency speed selection3 16 DI4 Start interlock 1 1 allow start 17 DI5 Not configured 18 DI6 Not configured X6 X7 X8 Relay outputs 19 RO1C Damper control 250 V AC 30 V DC 2 A 20 RO1A 21 RO1B 2...

Page 198: ...1 1 allow start 17 DI5 Not configured 18 DI6 Not configured X6 X7 X8 Relay outputs 19 RO1C Damper control 250 V AC 30 V DC 2 A 20 RO1A 21 RO1B 22 RO2C Running 250 V AC 30 V DC 2 A 23 RO2A 24 RO2B 25...

Page 199: ...hain In vector control See Menu Primary setting Start stop reference Constant speeds constant frequencies or parameter group 22 Speed reference selection 4 Connected with jumpers at the factory 5 Use...

Page 200: ...be set to the terminated ON position when the drive is the first or last unit on the link Bus not terminated default Bus terminated S5 BIAS Activates on the biasing voltages to the bus One and only on...

Page 201: ...o the control board ground when the control board is powered using an external 24 V AC supply Internal 24 V power supply PNP connection source External 24 V power supply PNP connection source X2 X3 10...

Page 202: ...24 V AC cable to the control board ground when the control board is powered using an external 24 V AC supply Internal 24 V power supply NPN connection source External 24 V power supply NPN connection...

Page 203: ...a 500 ohm resistor or two 1 kohm resistors in parallel between the analog output 2 AO2 and analog common ground AGND Examples are shown in the figure below 8 AO2 Analog output 2 Default output 0 20 mA...

Page 204: ...ut and the drive feeds the supply voltage 24 V DC Thus the output signal must be 4 20 mA not 0 20 mA 5 AI2 Process actual value measurement or reference 0 4 20 mA Rin 100 ohm 6 AGND 10 24V Auxiliary v...

Page 205: ...027537 English DI6 as PTC input If DI6 is used as a PTC input see ACH580 HVAC control program firmware manual 3AXD50000027537 English for how to set parameters accordingly Note If DI6 is used as PTC i...

Page 206: ...not fulfill the requirement the I O board terminals must be protected against contact and must not be connected to other equipment or the temperature sensor must be isolated from the I O terminals Sa...

Page 207: ...he control board Ground the pair cable shields and grounding wire at the SCR terminal or either you may ground the shield at the source of the signal but do not ground it at both the source of the sig...

Page 208: ...s of the control cable shields unconnected or ground them indirectly via a high frequency capacitor with a few nanofarads eg 3 3 nF 630 V The shield can also be grounded directly at both ends if they...

Page 209: ...on North America 209 UL NEC BRAKE RES INPUT PE MOTOR R R UDC L1 L2 L3 T1 U T2 V T3 W MOTOR T1 U T2 V T3 W INPUT L1 L2 L3 BRAKE RES R R UDC R3 3 11 11 5 5 7 7 6 6 9 9 10 10 R1 R2 0 4 lbf ft R3 0 4 lbf...

Page 210: ...210 Electrical installation North America UL NEC R4 4 lbf ft 7 4 3 11 5 9 11 6 10...

Page 211: ...Electrical installation North America 211 UL NEC 8 R5 4 6 11 11 10 3 5 7 9 0 4 lbf ft 4...

Page 212: ...212 Electrical installation North America UL NEC R6 R9 0 4 lbf ft 0 4 lbf ft 6 10 3 4 4 5 7 8 9 11 11...

Page 213: ...cal work on page 18 before you start the work 1 Remove the front cover s if not already removed See page 180 R1 R4 page 185 R5 or page 79 R6 R9 The figures for frames R1 R5 page 214 and R6 R9 page 215...

Page 214: ...214 Electrical installation North America UL NEC R3 R5 R1 R2 3 2 3 4 6 6 7 7 4 5 5...

Page 215: ...For the optional I O extension modules CHDI 01 CMOD 01 and CMOD 02 see chapter Optional I O extension modules on page 363 for specific installation and wiring instructions For other option module for...

Page 216: ...216 Electrical installation North America UL NEC Reinstalling grommets UL Type 12 To maintain UL Type 12 reinstall grommets top of the grommets downwards to all cable entry holes without conduits...

Page 217: ...stall 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 T20 Torx screwdriver 1b 2 x 2 2 1a 1...

Page 218: ...etaining screws 1b with a T20 Torx screwdriver 2 Reinstall the module cover Press the cover at the bottom 2a and tighten the retaining screws 2b IP55 UL Type 12 1 Reinstall the front cover Press the c...

Page 219: ...Torx screwdriver 1b 2 Slide the cover of the cable box on the module from below until the cover snaps into place 3 Reinstall the module cover Tighten the two retaining screws with a screwdriver IP55...

Page 220: ...tallation North America UL NEC Installing UL Type 12 hood See UL Type 12 hood quick installation guide for ACS580 01 ACH580 01 and ACQ580 01 frames R1 to R9 3AXD50000196067 English which is included i...

Page 221: ...cover from bottom upwards 2 Put the USB cable Mini B plug in the control panel USB connector 3 Put the USB cable A plug in the USB connector of the PC 3a The panel displays text USB connected 3b Note...

Page 222: ...222 Electrical installation North America UL NEC...

Page 223: ...re you start the work Go through the checklist together with another person Check that The ambient operating conditions meet the specification in section Ambient conditions on page 296 If the drive wi...

Page 224: ...el The input power cable has been connected to appropriate terminals the phase order is correct and the terminals have been properly tightened Pull conductors to check Appropriate supply fuses and dis...

Page 225: ...or more information consult your local ABB Service representative www abb com searchchannels Maintenance and component replacement intervals are based on the assumption that the equipment is operated...

Page 226: ...ink cleaning page 227 Component Years from start up 3 6 9 12 15 18 21 Cooling Fans IP21 UL Type 1 frames R1 to R9 Main cooling fan R1 R4 page 229 R5 page 231 R R R Main cooling fan R6 R8 page 231 R9 p...

Page 227: ...atic hose and nozzle Using a normal vacuum cleaner creates static discharges which can damage circuit boards 1 Stop the drive and disconnect it from the power line Wait for 5 minutes and then make sur...

Page 228: ...s This increases the life span of the fan Main fans are speed controlled When the drive is stopped the main fan is kept running at low speed to cool the control board IP21 UL Type 1 frames R5 R9 and a...

Page 229: ...e is no voltage See section Precautions before electrical work on page 18 before you start the work R1 R3 2 Lever the fan assembly off the drive frame with for example a screwdriver 2a and pull out th...

Page 230: ...Maintenance and hardware diagnostics R4 2 Lever the fan assembly off the drive frame with for example a screwdriver 2a and pull out the fan assembly 2b 3 Install the fan assembly in reverse order R4...

Page 231: ...isconnect 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 18 before you start the work 2 Remov...

Page 232: ...e 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 18 before you start the...

Page 233: ...amage 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 See section Precautions before electrical work...

Page 234: ...pen the cover 2b Press the retaining clip of the control panel at the top 2c and pull it forward from the top edge 2d 3 Remove the front cover Loosen the retaining screws with a screwdriver 3a and lif...

Page 235: ...ork 2 Remove the control panel Press the retaining clip of the IP55 panel cover 2a and open the cover 2b Press the retaining clip of the control panel at the top 2c and pull it forward from the top ed...

Page 236: ...rical work on page 18 before you start the work 2 Remove the control panel Press the retaining clip of the IP55 panel cover 2a and open the cover 2b Press the retaining clip of the control panel at th...

Page 237: ...at there is no voltage See section Precautions before electrical work on page 18 before you start the work 2 Remove the front cover Loosen the retaining screws 14 pieces with a screwdriver 2a and lift...

Page 238: ...manufacturer if capacitor failure is suspected Replacements are available from the manufacturer Do not use other than specified spare parts Reforming the capacitors The capacitors must be reformed if...

Page 239: ...rating in memory during power interruptions The expected life for the battery is greater than ten years Note The battery is NOT required for any control panel or drive functions except the clock 1 Rem...

Page 240: ...ttached to the drive switch to remote control otherwise a fault will be generated and then remove the panel to be able to see the LEDs LEDs off LED lit and steady LED blinking No power Green POWER Pow...

Page 241: ...rive may be incompatible Check the control panel display Green Blinking Active warning in the drive Flickering Data transferred between the PC tool and drive through the USB connection of the control...

Page 242: ...242 Maintenance and hardware diagnostics...

Page 243: ...ta Contents of this chapter This chapter contains the technical specifications of the drive for example ratings sizes and technical requirements as well as provisions for fulfilling the requirements f...

Page 244: ...0 15 430 179 R3 089A 2 89 135 89 22 619 139 R5 115A 2 115 158 115 30 835 139 R5 144A 2 144 205 144 37 1035 435 R6 171A 2 171 257 171 45 1251 450 R7 213A 2 213 304 213 55 1521 450 R7 276A 2 276 380 276...

Page 245: ...Technical data 245 See definitions and notes on page 247...

Page 246: ...3 R1 12A7 4 12 6 15 3 12 6 5 5 174 43 R1 018A 4 17 0 22 7 17 0 7 5 228 101 R2 026A 4 25 0 30 6 25 0 11 0 322 101 R2 033A 4 32 0 44 3 32 0 15 0 430 179 R3 039A 4 38 0 56 9 38 0 18 5 525 179 R3 046A 4 4...

Page 247: ...5 1976 450 R7 206A 4 180 287 180 150 2346 450 R7 246A 4 240 350 240 200 3336 550 R8 293A 4 260 418 260 200 3936 550 R8 363A 4 361 542 361 300 4836 1150 R9 430A 4 414 542 414 350 6036 1150 R9 3AXD00000...

Page 248: ...load allowed for one minute every ten minutes 1 Maximum current with 30 overload allowed for one minute every ten minutes 2 Maximum current with 25 overload allowed for one minute every ten minutes PH...

Page 249: ...2 7 5 11 9 7 5 2 0 224 66 25 R1 10A6 2 10 6 14 3 10 6 3 0 288 84 25 R1 017A 2 16 7 22 6 16 7 5 0 454 133 25 R1 024A 2 24 32 7 24 2 7 5 593 174 59 R2 031A 2 31 43 6 30 8 10 777 228 59 R2 046A 2 46 62...

Page 250: ...5 593 174 25 R1 014A 4 14 0 21 6 14 0 10 0 777 228 59 R2 023A 4 23 0 30 5 23 0 15 0 1100 322 59 R2 027A 4 27 0 41 4 27 0 20 0 1469 430 105 R3 034A 4 34 0 48 6 34 0 25 0 1791 525 105 R3 044A 4 44 0 61...

Page 251: ...2 50 3497 1024 82 R5 062A 6 62 94 62 60 4235 1240 82 R5 077A 6 77 112 77 75 5157 1510 82 R5 099A 6 99 139 99 100 7039 2061 265 R7 125A 6 125 178 125 125 8422 2466 265 R7 144A 6 144 225 144 150 10266 3...

Page 252: ...088A 2 R5 115A 2 114A 2 R5 144A 2 143A 2 R6 171A 2 169A 2 R7 213A 2 211A 2 R7 276A 2 273A 2 R8 346A 2 343A 2 R9 400A 2 396A 2 R9 3AXD00000586715 xls L IEC type ACH580 01 North American type ACH580 01...

Page 253: ...The DriveSize dimensioning PC tool available from ABB http new abb com drives software tools drivesize is recommended for selecting the drive motor and gear combination 206A 4 180A 4 R7 246A 4 240A 4...

Page 254: ...altitude and at 50 C ambient temperature as follows 1 Switching frequency derating page 260 No derating needed for 4 kHz 2 Altitude derating page 258 The derating factor for 1500 m is 1 1 10 000 m 150...

Page 255: ...from page 246 drive type ACH580 01 026A 4 exceeds the IN requirement of 19 43 A Example 2 UL NEC How to calculate the required drive If your application requires continuous maximum current with 10 ov...

Page 256: ...8 F The output current can be calculated by multiplying the current given in the rating table by the derating factor k in the diagram below IP21 UL Type 1 drive type 302A 4 302A 4 In the temperature...

Page 257: ...for every added 1 C 1 8 F In the temperature range 45 50 C 113 122 F the rated output current is derated by 2 for every added 1 C 1 8 F The output current can be calculated by multiplying the current...

Page 258: ...for every 100 m 330 ft Note There are special considerations in corner grounded installations above 2000 m Contact your local ABB representative for further information The output current is calculate...

Page 259: ...educe the output current by 35 instead of 40 at 4000 meter above the see level Note Check the supply network compatibility restrictions above 2000 m 6562 ft see Installation site altitude on page 296...

Page 260: ...minimum switching frequencies 1 kHz 2 kHz 4kHz 8 kHz 12 kHz 3 phase UN 230 V R1 04A7 2 018A 2 1 1 1 0 89 0 80 R2 025A 2 032A 2 1 1 1 0 86 0 74 R3 047A 2 060A 2 1 1 1 0 85 0 72 R5 089A 2 115A 2 1 1 1 0...

Page 261: ...0 74 R5 088A 2 114A 2 1 1 1 0 89 0 79 R6 143A 2 1 1 1 R7 169A 2 211A 2 1 1 1 R8 273A 2 1 1 1 3 phase U1 440 480 V Pn at UN 460 V 60 Hz R1 02A1 4 012A 4 1 1 1 0 67 0 5 R2 014A 4 024A 4 1 1 1 0 65 0 48...

Page 262: ...put current gG IEC 60269 Nominal current I2 t Voltage rating ABB type IEC 60269 size A A A A2 s V 3 phase UN 230 V 04A7 2 200 4 7 25 0 2500 0 500 OFAF000H25 000 06A7 2 200 6 7 25 0 2500 0 500 OFAF000H...

Page 263: ...500 OFAF000H100 000 106A 4 1300 106 125 103000 500 OFAF00H125 00 145A 4 1700 145 160 185000 500 OFAF00H160 00 169A 4 3300 169 250 600000 500 OFAF0H250 0 206A 4 5500 206 315 710000 500 OFAF1H315 1 246...

Page 264: ...2 2050 276 0 630 220000 690 170M6810 3 3 phase UN 400 or 480 V 02A7 4 65 2 6 25 130 690 170M1561 000 03A4 4 65 3 3 25 130 690 170M1561 000 04A1 4 65 4 0 25 130 690 170M1561 000 05A7 4 65 5 6 25 130 69...

Page 265: ...170M1313 000 026A 4 120 25 0 40 460 690 170M1313 000 033A 4 170 32 0 63 1450 690 170M1315 000 039A 4 170 38 0 63 1450 690 170M1315 000 046A 4 280 45 0 80 2550 690 170M1316 000 062A 4 380 62 100 4650 6...

Page 266: ...ever for the correct function and protection with circuit breakers not listed below Furthermore if the recommendations given by ABB are not obeyed the drive can experience problems that the warranty d...

Page 267: ...LS I In 400 3p F F 65 T5 400 400 1SDA054365R1 293A 4 T5 L 630 PR221DS LS I In 630 3p F F 65 T5 630 630 1SDA054420R1 363A 4 T5 L 630 PR221DS LS I In 630 3p F F 65 T5 630 630 1SDA054420R1 430A 4 T5 L 6...

Page 268: ...ng Bussmann type UL class A A V 3 phase U1 200 240 V Pn at UN 208 230 V 60 Hz 04A6 2 4 6 15 600 KTK R 15 or JJS 15 CC or T 06A6 2 6 6 15 600 KTK R 15 or JJS 15 CC or T 07A5 2 7 5 15 600 KTK R 15 or JJ...

Page 269: ...600 KTK R 15 or JJS 15 CC or T 09A0 6 9 0 15 600 KTK R 15 or JJS 15 CC or T 11A0 6 11 0 15 600 KTK R 15 or JJS 15 CC or T 17A0 6 17 0 30 600 KTK R 30 or JJS 30 CC or T 022A 6 22 0 40 600 JJS 40 T 027...

Page 270: ...61 62 4 R6 548 549 727 589 252 369 42 4 21 57 21 63 28 62 23 20 9 92 14 53 93 5 R7 600 601 880 641 284 370 54 23 62 23 67 34 65 25 25 11 18 14 57 119 1 R8 680 677 965 721 300 393 69 26 77 23 67 37 99...

Page 271: ...06 237 13 0 17 95 19 29 20 93 8 11 9 33 28 67 2 52 8 16 R4 600 636 203 265 20 0 23 62 25 04 27 03 7 99 10 43 44 10 2 83 8 59 R5 732 633 203 320 29 0 28 82 24 90 32 01 7 99 12 60 63 95 3 15 8 58 R6 727...

Page 272: ...1 R2 2 and R5 R9 Height back with cable conduit box H5 Height with hood UL Type 12 only W Width D Depth HH Hood height HW Hood width 2 See H3 and H4 location for R1 R2 in the figure on 270 W D H4 H3 I...

Page 273: ...7 87 53 2 09 150 5 91 200 7 87 200 7 87 0 0 R4 53 2 09 200 7 87 150 5 91 200 7 87 200 7 87 0 0 R5 100 3 94 200 7 87 150 5 91 200 7 87 200 7 87 0 0 R6 155 6 10 300 11 81 150 5 91 200 7 87 300 11 81 0...

Page 274: ...87 150 5 91 200 7 87 200 7 87 0 0 R5 100 3 94 200 7 87 150 5 91 200 7 87 200 7 87 0 0 R6 155 6 10 300 11 81 150 5 91 200 7 87 300 11 81 0 0 R7 155 6 10 300 11 81 150 5 91 200 7 87 300 11 81 0 0 R8 15...

Page 275: ...phase UN 230 V 04A7 2 23 3 5 25 0 45 43 25 59 R1 06A7 2 30 3 5 25 0 55 43 25 59 R1 07A6 2 41 3 5 25 0 66 43 25 59 R1 012A 2 81 3 5 25 0 106 43 25 59 R1 018A 2 108 3 5 25 0 133 43 25 59 R1 025A 2 149...

Page 276: ...976 450 265 67 R7 206A 4 2310 4 1 36 2346 450 265 67 R7 246A 4 3300 4 1 36 3336 550 324 65 R8 293A 4 3900 4 1 36 3936 550 324 65 R8 363A 4 4800 4 1 36 4836 1150 677 68 R9 430A 4 6000 4 1 36 6036 1150...

Page 277: ...1A 2 1485 4 1 36 1521 5194 450 265 67 R7 273A 2 2025 4 1 36 2061 7039 550 324 65 R8 3 phase U1 440 480 V Pn at UN 460 V 60 Hz 02A1 4 20 3 5 25 45 155 43 25 59 R1 03A0 4 30 3 5 25 55 187 43 25 59 R1 03...

Page 278: ...835 2852 139 82 63 R5 052A 6 999 3 5 25 1024 3497 139 82 63 R5 062A 6 1215 3 5 25 1240 4235 139 82 63 R5 077A 6 1485 3 5 25 1510 5157 139 82 63 R6 099A 6 2025 4 1 36 2061 7039 450 265 67 R7 125A 6 24...

Page 279: ...44 R7 246A 4 2925 375 550 324 120 71 R8 293A 4 3465 435 550 324 120 71 R8 363A 4 4275 525 1150 677 170 100 R9 430A 4 5355 645 1150 677 170 100 R9 3AXD00000586715 xls L Type ACH580 01 Heat dissipation...

Page 280: ...400 or 480 V R1 1 30 0 20 0 25 6 4 1 0 16 16 1 5 R2 1 30 0 5 0 5 16 16 1 5 16 16 1 5 R3 1 30 0 5 0 5 35 25 3 5 35 35 1 5 R4 1 45 0 5 0 5 50 4 0 35 35 1 5 R5 1 45 6 70 5 6 35 352 2 9 R6 1 45 25 150 30...

Page 281: ...2 1 5 R3 1 23 0 5 0 5 35 25 2 3 5 R4 1 39 0 5 0 5 50 2 4 0 R5 1 39 6 70 M5 5 6 R6 1 45 25 150 M8 30 R7 1 54 95 240 M10 30 R8 2 45 2 50 2 150 M10 40 R9 2 54 2 95 2 240 M12 70 3AXD00000586715 xls L 1 Ma...

Page 282: ...5 1 1 77 10 2 0 4 1 2 2 1 6 R6 1 1 77 4 300 MCM 22 1 2 2 7 2 R7 1 2 13 3 0 500 MCM 29 5 2 2 7 2 R8 2 1 77 2 1 0 2 300 MCM 29 5 2 2 7 2 R9 2 2 13 2 3 0 2 500 MCM 51 6 2 2 7 2 3 phase U1 500 600 V Pn at...

Page 283: ...M8 22 1 R7 1 2 13 3 0 500 MCM M10 29 5 R8 2 1 77 2 1 0 2 300 MCM M10 29 5 R9 2 2 13 2 3 0 2 500 MCM M12 51 6 3 phase U1 500 600 V Pn at UN 575 V 60 Hz R2 1 0 906 20 6 2 1 1 R3 1 1 18 20 2 2 2 6 R5 1 1...

Page 284: ...14 1 5 0 5 0 6 R3 3 17 0 2 2 5 0 5 0 6 0 14 1 5 0 5 0 6 R5 3 17 0 2 2 5 0 5 0 6 0 14 1 5 0 5 0 6 R6 4 17 0 14 2 5 0 5 0 6 0 14 1 5 0 5 0 6 R7 4 17 0 14 2 5 0 5 0 6 0 14 1 5 0 5 0 6 R8 4 17 0 14 2 5 0...

Page 285: ...4 R5 3 0 67 24 14 0 4 26 16 0 4 R6 4 0 67 26 14 0 4 26 16 0 4 R7 4 0 67 26 14 0 4 26 16 0 4 R8 4 0 67 26 14 0 4 26 16 0 4 3 phase U1 440 480 V Pn at UN 460 V 60 Hz R1 3 0 67 24 14 0 4 26 16 0 4 R2 3 0...

Page 286: ...n page 117 and Guidelines for installing the drive to a TT system on page 118 North America When to connect EMC filter or disconnect ground to phase varistor TN S IT corner grounded delta and midpoint...

Page 287: ...660 ft for frame R3 Note 1 In multimotor systems the calculated sum of all motor cable lengths must not exceed the maximum motor cable length given in the table Note 2 Longer motor cables cause a mot...

Page 288: ...t applicable to 600 V ratings Note 4 Radiated and conducted emissions are according to category C3 with an internal EMC filter The internal EMC filter must be connected Frame size Maximum motor cable...

Page 289: ...5 mm2 26 14 AWG 24 V DC output Term 10 Total load capacity of this outputs is 6 0 W 250 mA 24 V minus the power taken by the option modules installed on the board Terminal size Frames R1 R5 0 2 2 5 mm...

Page 290: ...1 max 1 5 of full scale Analog outputs AO1 and AO2 Term 7 and 8 Current voltage input mode selected with a parameter Current output 0 20 mA Rload 500 ohm Voltage output 0 10 V Rload 100 kohm AO1 only...

Page 291: ...connection panel bus EIA 485 male RJ 45 connector unshielded or shielded twisted pair cable type CAT 5e or better max total cable length of the panel bus 100 m in single or multiple cables Control pa...

Page 292: ...ctional insulation IEC EN 61800 5 1 2007 Below altitudes 4000 m 13123 ft The terminals on the control board fulfill the Protective Extra Low Voltage PELV requirements EN 50178 There is adequate insula...

Page 293: ...oltage 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 Note There is functio...

Page 294: ...GND 7 AO1 8 AO2 9 AGND X2 X3 10 24V 11 DGND 12 DCOM 13 DI1 14 DI2 15 DI3 16 DI4 17 DI5 18 DI6 X6 X7 X8 19 RO1C 20 RO1A 21 RO1B 22 RO2C 23 RO2A 24 RO2B 25 RO3C 26 RO3A 27 RO3B X5 29 B 30 A 31 DGND X4 3...

Page 295: ...AGND X2 X3 10 24V 11 DGND 12 DCOM 13 DI1 14 DI2 15 DI3 16 DI4 17 DI5 18 DI6 X6 X7 X8 19 RO1C 20 RO1A 21 RO1B 22 RO2C 23 RO2A 24 RO2B 25 RO3C 26 RO3A 27 RO3B X5 29 B 30 A 31 DGND X4 34 OUT1 35 OUT2 36...

Page 296: ...508C 61800 5 1 UL Type 1 UL Type 12 Overvoltage category IEC 60664 1 III Protective classes IEC EN 61800 5 1 I Ambient conditions Environmental limits for the drive are given below The drive is to be...

Page 297: ...and their severities Stationary use of weather protected locations IEC 60721 3 1 1997 IEC 60721 3 2 1997 Chemical gases Class 3C2 Class 1C2 Class 2C2 Solid particles Class 3S2 No conductive dust allo...

Page 298: ...and molded pulp Foam cushions PE PP E bands PP Disposal The main parts of the drive can be recycled to preserve natural resources and energy Product parts and materials should be dismantled and separa...

Page 299: ...nected to public low voltage systems with input current The standard is met with a Rsce transformer short circuit ratio of 350 or higher IEC EN 61800 3 2004 A1 2012 Adjustable speed electrical power d...

Page 300: ...f conformity 3AXD10000437232 is available on the Internet See section Document library on the Internet on the inside of the back cover Compliance with the European ROHS II Directive 2011 65 EU The RoH...

Page 301: ...s a person or organization having necessary skills in installing and or starting up power drive systems including their EMC aspects Drive of category C3 drive of rated voltage less than 1000 V intende...

Page 302: ...tor is not suitable for If you do the varistor circuit can be damaged If you install the drive to any other system than symmetrically grounded TN S system you may need to disconnect the EMC filter or...

Page 303: ...enting disturbances is drawn up for the installation A template is available from the local ABB representative 3 The motor and control cables are selected as specified in this manual 4 The drive is in...

Page 304: ...rom corrosive materials and electrically conductive dust The maximum surrounding air temperature is 40 C 104 F at rated current for all UL Type 1 and UL Type 12 frames The current is derated for 40 to...

Page 305: ...ive provides motor overload protection For the adjustments see the firmware manual For drive overvoltage category see page 296 For pollution degree see page 297 To maintain the environmental integrity...

Page 306: ...3 EMC product standard including specific test methods mandated by the Trans Tasman Electromagnetic Compatibility Scheme For fulfilling the requirements of the standard see section Compliance with IE...

Page 307: ...in any appropriate measures such as but not limited to the installation of firewalls application of authentication measures encryption of data installation of anti virus programs etc to protect the pr...

Page 308: ...308 Technical data...

Page 309: ...Dimension drawings 309 11 Dimension drawings Contents of this chapter This chapter shows the dimension drawings of the ACH580 01 Note The dimensions are given in millimeters and inches...

Page 310: ...310 Dimension drawings Frame R1 IP21 UL Type 1 3AXD10000601652...

Page 311: ...Dimension drawings 311 Frame R1 IP55 UL Type 12 3AXD10000601699...

Page 312: ...312 Dimension drawings Frame R1 IP55 F278 UL Type 12 3AXD10000649451...

Page 313: ...Dimension drawings 313 Frame R2 IP21 UL Type 1 3AXD10000602398...

Page 314: ...314 Dimension drawings Frame R2 IP55 UL Type 12 3AXD10000602401...

Page 315: ...Dimension drawings 315 Frame R2 IP55 F278 UL Type 12 3AXD10000649654...

Page 316: ...316 Dimension drawings Frame R3 IP21 UL Type 1 3AXD10000602466...

Page 317: ...Dimension drawings 317 Frame R3 IP55 UL Type 12 3AXD10000602519...

Page 318: ...318 Dimension drawings Frame R3 IP55 E223 UL Type 12 3AXD10000649130...

Page 319: ...Dimension drawings 319 Frame R3 IP55 F278 F316 UL Type 12 3AXD10000649130...

Page 320: ...320 Dimension drawings Frame R4 IP21 UL Type 1 3AXD10000332430...

Page 321: ...Dimension drawings 321 Frame R4 IP55 UL Type 12 3AXD10000427933...

Page 322: ...322 Dimension drawings Frame R4 IP55 E223 UL Type 12 3AXD10000649283...

Page 323: ...Dimension drawings 323 Frame R4 IP55 F278 F316 UL Type 12 3AXD10000649283...

Page 324: ...324 Dimension drawings Frame R5 IP21 UL Type 1 3AXD10000412280...

Page 325: ...Dimension drawings 325 Frame R5 IP55 UL Type 12 3AXD10000415964...

Page 326: ...326 Dimension drawings Frame R5 IP55 E223 UL Type 12 3AXD10000687928...

Page 327: ...Dimension drawings 327 Frame R5 IP55 F278 F316 UL Type 12 3AXD10000687928...

Page 328: ...328 Dimension drawings Frame R6 IP21 UL Type 1 3AXD10000258705...

Page 329: ...Dimension drawings 329 Frame R6 IP55 UL Type 12 3AXD10000330667...

Page 330: ...330 Dimension drawings Frame R7 IP21 UL Type 1 3AXD10000258995...

Page 331: ...Dimension drawings 331 Frame R7 IP55 UL Type 12 3AXD10000330932...

Page 332: ...332 Dimension drawings Frame R8 IP21 UL Type 1 3AXD10000287670...

Page 333: ...Dimension drawings 333 Frame R8 IP55 UL Type 12 3AXD10000332446...

Page 334: ...334 Dimension drawings Frame R9 IP21 UL Type 1 3AXD10000287428...

Page 335: ...Dimension drawings 335 Frame R9 IP55 UL Type 12 3AXD10000334310...

Page 336: ...336 Dimension drawings...

Page 337: ...r 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 contr...

Page 338: ...g conditions are met The rated power of the resistor must be greater than or equal to PRmax Resistance R must be between Rmin and Rmax given in the table for the used drive type The resistor must be a...

Page 339: ...04A1 4 52 392 1 4 1 9 CBH 360 C T 406 210R 05A7 4 52 279 2 0 2 7 CBH 360 C T 406 210R 07A3 4 52 191 2 9 3 9 CBR V 330 D T 406 78R UL 09A5 4 52 140 3 9 5 2 CBR V 330 D T 406 78R UL 12A7 4 52 104 5 3 7...

Page 340: ...parallel cabling separation distance should be 0 3 meters Cross the other cables at right angles Keep the cable as short as possible in order to minimize the radiated emissions and stress on chopper...

Page 341: ...ensure that the material withstands high temperatures Protect the resistor against physical contact Protecting the system in brake circuit fault situations Protecting the system in cable and brake res...

Page 342: ...given in section Brake resistor assembly for R1 R3 on page 115 IEC or Brake resistor assembly for R1 R3 on page 169 North America Connection diagram See section Connection diagram page 123 IEC or Conn...

Page 343: ...rnal event 1 type to Fault 4 Enable the brake chopper by parameter 43 06 Brake chopper enable If Enabled with thermal model is selected set also the brake resistor overload protection parameters 43 08...

Page 344: ...h the brake chopper 088A 4 ACS BRK D 7 8 10 7 51 68 4 Built in with the brake chopper 106A 4 NBRA 658 1 3 8 7 63 84 5 SAFUR125F500 145A 4 NBRA 658 1 3 7 1 77 103 2 SAFUR125F500 169A 4 NBRA 658 1 3 5 2...

Page 345: ...erations like cleaning or work on non electrical parts of the machinery without switching off the power supply to the drive When activated the Safe torque off function disables the control voltage of...

Page 346: ...requirements for safety related systems and for equipment intended to perform safety related functions functional safety General industrial applications IEC 61508 1 2010 Functional safety of electric...

Page 347: ...ff function 347 Connection principle Connection with internal 24 V DC power supply 1 Drive 2 Control board 3 Control logic OUT2 OUT1 24 V DC IN1 IN2 T1 U T2 V T3 W SGND 24 V DC STO UDC UDC A 34 35 36...

Page 348: ...Otherwise no SIL PL classification is given Pay special attention to avoiding any potential failure modes for the wiring For example use shielded cable For measures for fault exclusion of wiring see e...

Page 349: ...off wiring with internal 24 V DC power supply is shown below 1 Drive 2 Control board 3 Control logic 1 Drive 2 Safety PLC 3 Safety relay OUT2 OUT1 IN1 IN2 T1 U T2 V T3 W SGND 24 V DC STO UDC UDC A 34...

Page 350: ...inputs must be switched on off within 200 ms of each other A CPTC 02 thermistor protection module can also be used For more information see the module documentation Cable types and lengths Double shi...

Page 351: ...n this occurs Note This parameter does not affect the operation of the STO function itself The STO function will operate regardless of the setting of this parameter a running drive will stop upon remo...

Page 352: ...IEC 61508 1 clause 6 The test procedures and report must be documented and signed by this person Acceptance test reports Signed acceptance test reports must be stored in the logbook of the machine The...

Page 353: ...drive operates as follows Open the STO circuit The drive generates an indication if one is defined for the stopped state in parameter 31 22 see the firmware manual Give a start command to verify that...

Page 354: ...out after isolating the drive from the supply Test the operation of the failure detection of the drive The motor can be stopped or running Open the 1st channel of the STO circuit wire coming to IN1 I...

Page 355: ...oltage and the motor will coast to a stop If this causes danger or is not otherwise acceptable stop the drive and machinery using the appropriate stop mode before activating the Safe torque off functi...

Page 356: ...practice to check the operation of the function when other maintenance procedures are carried out on the machinery Include the Safe torque off operation test described above in the routine maintenance...

Page 357: ...irmware manual for the indications generated by the drive and for details on directing fault and warning indications to an output on the control board for external diagnostics Any failures of the Safe...

Page 358: ...964 90 3 3 1 80 20 R6 3 e 99 8 26E 10 7 52E 06 1 83E 05 8046 90 3 3 1 80 20 R7 3 e 99 8 26E 10 7 52E 06 1 83E 05 8046 90 3 3 1 80 20 R8 3 e 99 8 26E 10 7 52E 06 1 83E 05 8046 90 3 3 1 80 20 UN 400 V R...

Page 359: ...has been made EN 13849 2 table D 5 The analysis is based on an assumption that one failure occurs at one time No accumulated failures have been analyzed STO reaction time shortest detectable break 1...

Page 360: ...perform the specified safety function when a demand occurs PFH IEC 61508 Average frequency of dangerous failures per hour that is average frequency of a dangerous failure of a safety related system to...

Page 361: ...library on the Internet on the inside of the back cover You can also find the T V certificate in ACH580 01 quick installation and start up guide for frames R1 to R5 3AXD50000044861 English or ACH580 0...

Page 362: ...362 Safe torque off function...

Page 363: ...lso contains diagnostics and technical data CHDI 01 115 230 V digital input extension module Safety instructions WARNING Obey the safety instructions for the drive If you ignore the safety instruction...

Page 364: ...tion package 2 Make sure that the package contains CHDI 01 high voltage digital extension module mounting screw 3 Make sure that there are no signs of damage Item Description Additional information 1...

Page 365: ...essional do not do electrical work Make sure that the drive is disconnected from the input power during installation If the drive is already connected to the input power wait for 5 minutes after disco...

Page 366: ...the cables 360 degrees under a grounding clamp on the grounding shelf of the control cables Relay output connection example Digital input connection example 73 HDI9 115 230 V input 3 74 HDI10 115 230...

Page 367: ...can now see the parameters of the extension module in parameter group 15 I O extension module 3 Set the parameters of the extension module to applicable values Parameter setting example for relay out...

Page 368: ...es 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...

Page 369: ...t rating 250 V AC 30 V DC 2 A Maximum breaking capacity 1500 VA 115 230 V inputs 70 78 Wire size max 1 5 mm2 Input voltage 115 to 230 V AC 10 Maximum current leakage in digital off state 2 mA Symbol D...

Page 370: ...h can function as a digital or frequency output In addition the extension module has an external power supply interface which can be used to power up the drive control board in case the drive power su...

Page 371: ...package contains CMOD 01 multifunction extension module mounting screw 3 Make sure that there are no signs of damage Item Description Additional information 1 Grounding screw Page 371 2 Hole for mount...

Page 372: ...o not do electrical work Make sure that the drive is disconnected from the input power during installation If the drive is already connected to the input power wait for 5 minutes after disconnecting t...

Page 373: ...y the instructions given in chapter Guidelines for planning the electrical installation on page 81 Wiring Connect the external control cables to the applicable module terminals Ground the outer shield...

Page 374: ...ing A7AB Extension I O configuration failure is shown make sure that the value of parameter 15 02 Detected extension module is CMOD 01 set parameter 15 01 Extension module type to CMOD 01 You can now...

Page 375: ...ut DO1 of the extension module indicate the motor speed 0 1500 rpm with a frequency range of 0 10000 Hz Diagnostics Faults and warning messages Warning A7AB Extension I O configuration failure LEDs Th...

Page 376: ...es 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...

Page 377: ...0 VA6 Transistor output 42 44 Wire size max 1 5 mm2 Type Transistor output PNP Maximum load 4 kohm Maximum switching voltage 30 V DC Maximum switching current 100 mA 30 V DC short circuit protected Fr...

Page 378: ...378 Optional I O extension modules External power supply 40 41 Wire size max 1 5 mm2 24 V AC V DC 10 GND user potential Maximum current consumption 25 W 1 04 A at 24 V DC...

Page 379: ...off input In addition the extension module has an external power supply interface which can be used to power up the drive control board in case the drive power supply fails If you do not need the bac...

Page 380: ...suitable bits Item Description Additional information 1 Grounding screw Page 380 2 Hole for mounting screw Page 380 3 2 pin terminal block for motor thermistor connection Page 381 4 2 pin terminal blo...

Page 381: ...ings WARNING Obey the instructions in chapter Safety instructions on page 15 If you ignore them injury or death or damage to the equipment can occur If you are not a qualified electrical professional...

Page 382: ...ter shield of the cables 360 degrees under a grounding clamp on the grounding shelf of the control cables Motor thermistor connection example The PTC input is reinforced double insulated If the motor...

Page 383: ...warning is shown make sure that the value of both parameter 15 02 Detected extension module and parameter 15 01 Extension module type is CMOD 02 If warning A7AB Extension I O configuration failure is...

Page 384: ...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 diagnosti...

Page 385: ...85 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...

Page 386: ...hreshold 3 6 kohm 10 Recovery threshold 1 6 kohm 10 PTC terminal voltage 5 0 V PTC terminal current 1 mA Short circuit detection 50 ohm 10 Relay output 62 63 Wire size max 1 5 mm2 Maximum contact rati...

Page 387: ...External power supply 40 41 Wire size max 1 5 mm2 24 V AC V DC 10 GND user potential Maximum current consumption 25 W 1 04 A at 24 V DC Installing option modules on page 159 IEC or Installing option...

Page 388: ...388 Optional I O extension modules...

Page 389: ...See section Checking the compatibility of the motor and drive page 60 Common mode filter kits are available from ABB see the table on page 390 A kit includes three wound cores For installation instruc...

Page 390: ...ves Frame size North American type ACH580 01 062A 4 64315811 R4 052A 4 073A 4 64315811 R4 065A 4 088A 4 64315811 R5 078A 41 106A 4 64315811 R5 096A 4 145A 4 3AXD50000017269 R6 124A 4 169A 4 3AXD500000...

Page 391: ...A4 4 NOCH0016 6x R1 03A0 4 04A1 4 NOCH0016 6x R1 03A5 4 05A7 4 NOCH0016 6x R1 04A8 4 07A3 4 NOCH0016 6x R1 06A0 4 09A5 4 NOCH0016 6x R1 07A6 4 12A7 4 NOCH0016 6x R1 012A 4 018A 4 NOCH0016 6x or NOCH00...

Page 392: ...43V0012R231 B84143V0016R229 B84143Q0006R229 R1 012A 4 018A 4 B84143V0016R229 B84143V0016R229 B84143Q0006R229 R2 014A 4 026A 4 B84143V0038R231 B84143V0025R229 B84143Q0008R229 R2 023A 4 033A 4 B84143V00...

Page 393: ...V0230S229 B84143Q0016R229 R8 240A 4 293A 4 B84143V0249R231 B84143V0390S229 B84143Q0018R229 R8 260A 41 363A 4 B84143V0390S229 B84143V0390S229 B84143Q0018R229 R9 361A 4 430A 4 B84143V0390S229 B84143V039...

Page 394: ...394 Common mode du dt and sine filters...

Page 395: ...contacts can be found by navigating to abb com searchchannels Product training For information on ABB product training navigate to new abb com service training Providing feedback on ABB Drives manual...

Page 396: ...abb com drives Copyright 2018 ABB All rights reserved Specifications subject to change without notice 3AXD50000044839 Rev B EN 2018 12 20...

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