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ABB GENERAL PURPOSE DRIVES

ACS580-04 drive modules

Hardware manual

Summary of Contents for ACS580-04

Page 1: ... ABB GENERAL PURPOSE DRIVES ACS580 04 drive modules Hardware manual ...

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Page 3: ...0 04 drive modules Hardware manual Table of contents 1 Safety instructions 6 Mechanical installation 8 Electrical installation 14 Start up 3AXD50000015497 Rev F EN Original instructions EFFECTIVE 2022 09 26 ...

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Page 5: ...ation by frame size and option code 28 Terms and abbreviations 29 Quick installation commissioning and operating flowchart 30 Related documents 3 Operation principle and hardware description 31 Contents of this chapter 32 Product overview 33 Layout 33 Standard drive module configuration 34 Drive module configuration with option B051 36 Drive module with full power cabling panels option H381 37 Con...

Page 6: ...figuration 57 Drive module with option B051 58 Installation positions other than vertical 58 Free space requirements 58 Free space at the top of the drive module 58 Free space around the drive module 58 Free space below the drive module 6 Mechanical installation 61 Contents of this chapter 61 Examining the installation site 61 Moving and unpacking the unit 61 Moving the drive module 62 Unpacking t...

Page 7: ...for explosion safe EX motors 80 Additional requirements for ABB motors of types other than M2_ M3_ M4_ HX_ and AM_ 80 Additional requirements for braking applications 80 Additional requirements for ABB high output and IP23 motors 80 Additional requirements for non ABB high output and IP23 motors 81 Additional data for calculating the rise time and the peak line to line voltage 82 Additional note f...

Page 8: ... ATEX certified motor thermal protection 95 Controlling a contactor between drive and motor 96 Implementing a bypass connection 96 Example bypass connection 97 Switching the motor power supply from drive to direct on line 97 Switching the motor power supply from direct on line to drive 97 Protecting the contacts of relay outputs 98 Implementing a motor temperature sensor connection 98 Connecting a...

Page 9: ...ng the protective covering from the drive module air outlet 119 Miscellaneous 119 Input power cable entry from top 119 Attaching the drive module to a mounting plate or wall 10 Installation example with full cabling panels option H381 121 Contents of this chapter 121 Safety 122 Required parts 122 Required tools 123 Overall flowchart of the installation process 123 Installing the mechanical accesso...

Page 10: ...6 147 Contents of this chapter 147 Product overview 148 Layout 149 Cables 150 Unpacking the delivery 151 Installing the control unit 151 Installation procedure 155 Connecting the control unit to the drive module 158 Dimension drawing 13 Installation checklist 159 Contents of this chapter 159 Checklist 14 Start up 161 Contents of this chapter 161 Reforming the capacitors 161 Start up procedure 15 F...

Page 11: ... data and noise 187 Terminal and entry data for the power cables 187 Drive modules without output cable connection terminals 0H371 and with a common mode filter E208 187 Drive modules with optional cabling panels H381 188 Typical power cable sizes 189 Terminal data for the control cables 189 Electrical power network specification 190 Motor connection data 190 Brake resistor connection data 190 DC ...

Page 12: ...ons E208 H356 H381 P906 215 R11 Cabling panels H381 installed into a Rittal VX25 enclosure 216 Air baffles for the drive module with option B051 217 Air baffles for option H381 in Rittal VX25 400 mm wide enclosure installation 217 Material of the air baffles 218 Bottom plate for option H381 in Rittal VX25 400 mm wide enclosure installation 19 Example circuit diagram 219 Contents of this chapter 21...

Page 13: ... against thermal overload 243 EMC compliance of the complete installation 243 Placing the brake resistors 243 Protecting the system in fault situations 243 Selecting the default brake system components 243 Calculation example 244 Selecting a custom brake resistor 245 Mechanical installation of resistors 245 Electrical installation 245 Measuring the insulation of the brake resistor circuit 245 Conn...

Page 14: ...7 Necessary tools 257 Wiring 257 Start up 257 Setting the parameters 257 Parameter setting example for AI1 258 Diagnostics 258 LEDs 258 Technical data 259 Dimension drawing 24 CHDI 01 115 230 V digital input extension module 261 Contents of this chapter 261 Product overview 262 Layout and connection examples 263 Mechanical installation 263 Necessary tools 263 Unpacking and examining the delivery 2...

Page 15: ...ontents of this chapter 273 Product overview 274 Layout and example connections 274 Mechanical installation 274 Necessary tools 275 Unpacking and examining the delivery 275 Installing the module 275 Electrical installation 275 Necessary tools 275 Wiring 275 Start up 275 Setting the parameters 275 Diagnostics 275 Faults and warning messages 276 LEDs 276 Technical data 277 Dimension drawing 27 Filte...

Page 16: ...cal power network 286 When you can connect the EMC filter and ground to phase varistor TN S IT corner grounded delta and mid point grounded delta systems 287 Connecting EMC filter North America 287 Connecting ground to phase varistor North America Step by step drawings for an installation example of a drive module with the B051 option in a Rittal VX25 600 mm wide enclosure Step by step drawings fo...

Page 17: ...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 WARNING Electricity warning tells about hazards from electricity which can cause injury or death or damage to the equipment WARNING General warning tells about conditions other than those caused by electricity which can cause injury or death or...

Page 18: ...dition of lifting equipment and for training of personnel Incorrect lifting can cause danger or damage Attach the drive cabinet to the floor to prevent it from toppling over The cabinet has a high center of gravity When you pull out heavy components or power modules there is a risk of overturning Attach the cabinet also to the wall when necessary Do not use the module extraction installation ramp ...

Page 19: ...rably with help from another person Keep a constant pressure with one foot on the base of the module 2 to prevent the module from falling on its back 1 2 1 2 Beware of hot surfaces Some parts such as heatsinks of power semiconductors and brake resistors remain hot for a while after disconnection of the electrical supply Vacuum clean the area around the drive before the start up to prevent the driv...

Page 20: ...r These functions reset the drive automatically and continue operation after a fault or supply break If these functions are activated the installation must be clearly marked as defined in IEC EN UL 61800 5 1 subclause 6 5 3 for example THIS MACHINE STARTS AUTOMATICALLY The maximum number of drive power ups is five in ten minutes Too frequent power ups can damage the charging circuit of the DC capa...

Page 21: ... external voltages from the control circuits After you disconnect power from the drive always wait 5 minutes to let the intermediate circuit capacitors discharge 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 energized Use a quality voltage tester If the meas...

Page 22: ...n of such devices This can cause a health hazard Remove the code labels attached to mechanical parts such as busbars shrouds and sheet metal parts before installation They may cause bad electrical connections or after peeling off and collecting dust in time cause arcing or block the cooling air flow Note When the drive is connected to the input power the motor cable terminals and the DC bus are at...

Page 23: ...djoining equipment This is necessary for the personnel safety Make sure that the conductivity of the protective earth PE conductors is sufficient and that other requirements are met See the electrical planning instructions of the drive Obey the applicable national and local regulations When using shielded cables make a 360 grounding of the cable shields at the cable entries to reduce electromagnet...

Page 24: ...These functions reset the drive automatically and continue operation after a fault or supply break If these functions are activated the installation must be clearly marked as defined in IEC EN UL 61800 5 1 subclause 6 5 3 for example THIS MACHINE STARTS AUTOMATICALLY Note The maximum number of drive power ups is five in ten minutes Too frequent power ups can damage the charging circuit of the DC c...

Page 25: ...cal safety precautions page 21 Install temporary grounding to the drive output terminals T1 U T2 V T3 W Connect the output terminals together as well as to the PE During the start up Make sure that the motor cannot run overspeed for example driven by the load Motor overspeed causes overvoltage that can damage or destroy the capacitors in the intermediate circuit of the drive Safety in operation WA...

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Page 27: ... on the drive or create instructions for the end user of the drive concerning the installation and maintenance of the drive Read the manual before you work on the drive You are expected to know the fundamentals of electricity wiring electrical components and electrical schematic symbols Categorization by frame size and option code The frame size identifies information which concerns only a certain...

Page 28: ...apter module FDNA 01 Optional EtherCAT adapter module FECA 01 Optional Ethernet adapter module for EtherNet IP FEIP 21 Optional Ethernet adapter module for EtherNet IP Modbus TCP and PROFINET IO protocols 2 port FENA 21 Optional Ethernet POWERLINK adapter module FEPL 02 Optional Ethernet adapter module for Modbus TCP protocol FMBT 21 Optional PROFIBUS DP adapter module FPBA 01 Optional PROFINET IO...

Page 29: ...e motor cable and brake assembly if present Measuring the insulation resistance of the motor and motor cable page 102 Measuring the insulation resistance of the brake resistor circuit page 102 Mechanical installation page 61 Install the additional components into the cabin et eg main disconnector main contactor main AC fuses etc Install the drive module into the cabinet Connect the motor cables to...

Page 30: ...ls and other product documents in PDF format on the Internet at www abb com drives documents The code and link below open an online listing of the manuals applicable to this product ACS580 04 related manuals 30 Introduction to the manual ...

Page 31: ...peration principle and hardware description Contents of this chapter This chapter describes the operating principle and construction of the drive module 3 Operation principle and hardware description 31 ...

Page 32: ...r Converts alternating current and voltage to direct current and voltage 2 DC link DC circuit between rectifier and inverter 3 Inverter Converts direct current and voltage to alternating current and voltage 4 Brake chopper option D150 Conducts the surplus energy from the intermediate circuit of the drive to the brake resistor when necessary The chopper operates when the DC link voltage exceeds a c...

Page 33: ...1 U2 T2 V2 T3 W2 attached and brake resistor connection busbars R and R with option D150 6 Control cable duct 7 Main cooling fans 8 Pedestal 9 Upper front cover 10 Lower front cover 11 Control panel Can also be mounted on the cabinet door as well with the door mounting platform kit 12 Handle for pulling the drive module out of the cabinet 13 Retractable support legs 14 Base fastening screws behind...

Page 34: ...B051 The drive module configuration with clear plastic shrouds option B051 mounted is shown below 2 1 4 5 3 Pedestal 4 Upper front cover 1 Control panel 5 Lower front cover 2 Clear plastic shrouds attached option B051 3 See the next page for the part descriptions 34 Operation principle and hardware description ...

Page 35: ...etallic shroud With option H370 the shroud includes a ground bar 10 Clear plastic shroud to be attached on top of the drive module lead through for top cabling with option B051 3 Control unit 11 Upper back clear plastic shroud with option B051 4 Pedestal guide plate 12 Lower back clear plastic shroud with option B051 5 Telescopic extraction installation ramp 13 Front clear plastic shroud with opti...

Page 36: ... panel to be attached to the drive cabinet 9 Side guides 2 Output power cabling panel to be attached to the drive cabinet 10 Output power cabling panel 3 Front cover 11 Top guide plate 4 External control unit option P906 12 Pedestal guide plate 5 Telescopic extraction installation ramp 6 Shim plates for Rittal VX25 enclosure 9 pcs 7 36 Operation principle and hardware description ...

Page 37: ...e control panel on the cabinet door 5 In the standard drive module configuration and with option B051 the control panel is mounted on the upper front cover of the drive module Note The standard delivery in the US market includes the external control unit option P906 and the DPMP 05 S control panel mounting platform For more information on the control panel refer to ACS AP I S W and ACH AP H W Assi...

Page 38: ... 3 2 1 4 5 t R R 7 Option slot 1 for optional fieldbus adapter modules 1 Option slot 2 for optional I O extension modules 2 Panel port 3 I O terminal blocks See chapter Control unit page 135 4 Control panel see section Connecting a PC page 110 5 du dt or sine filter optional see chapter Filters page 279 6 Brake resistor See chapter Resistor braking page 241 7 38 Operation principle and hardware de...

Page 39: ...ize 3 Cooling method 4 Degree of protection enclosure type 5 Losses according to IEC 61800 9 2 6 Short circuit withstand strength Refer to section Electrical power network specification page 189 7 Ratings Refer to section Electrical ratings page 177 8 Valid markings 9 S N Serial number of format MYYWWXXXXX where 10 M Manufacturing location YY Year of manufacture 19 20 21 for 2019 2020 2021 WW Week...

Page 40: ...ket the standard offering differs in that the door mounting kit is the DPMP 05 S the control unit is external P906 the DC connection busbars H356 are in cluded and the quick guide contains English language only Refer to section Option codes page 40 for options Size See the ratings table xxxxA Voltage range 380 480 V AC This is indicated in the type designation label as typical input voltage level ...

Page 41: ...rNet IP adapter module K490 FMBT 21 Modbus TCP adapter module K491 FPNO 21 PROFINET IO adapter module K492 CBAI 01 bipolar analog IO adapter module L500 CMOD 01 External 24 V AC DC and digital I O extension 2 RO and 1 DO L501 CHDI 01 115 230 V digital input module six digital inputs and two relay outputs L512 CMOD 02 External 24 V and isolated PTC interface L523 CPTC 02 ATEX certified thermistor p...

Page 42: ...y be included if a translation in the specified language is not available Ordering codes You can order IP20 shrouds for frame R10 with code 3AXD50000024563 and for R11 with code 3AXD50000024564 DPMP 05 control panel mounting platform with code 3AXD50000240319 42 Operation principle and hardware description ...

Page 43: ...t followed the drive may experience problems that the warranty does not cover Cabinet construction Basic requirements for the cabinet construction are listed below Make sure that the cabinet frame is sturdy enough to carry the weight of the components control circuitry and other equipment installed in it the cabinet protects the modules against contact and agrees with the requirements for dust and...

Page 44: ...abinet according to the principle above Busbar material and joints ABB recommends tin plated copper but bare copper and aluminum can also be used Before joining aluminum busbars remove the oxide layer and apply suitable anti oxidant joint compound Shrouds The installation of shrouds touch protection to fulfill applicable safety regulations is the responsibility of the drive system builder Ready ma...

Page 45: ...ooling Observe the minimum clearances given for each component For the module specific free space requirements see the applicable hardware manual Air cooled drive systems Air inlets and outlets Equip the air inlets and outlets with gratings that are large enough to allow sufficient air flow in and out of the cabinet critical for correct cooling of the module guide the air flow protect against cont...

Page 46: ... ventilated The internal cooling fans of the converter modules and filters are usually sufficient to keep the component temperatures low enough in IP20 and IP42 cabinets For higher degrees of protection or if the air outlet is in the cabinet door extra fans can be necessary If you install additional heat generating components to the cabinet make sure to upgrade the cooling system accordingly In IP...

Page 47: ...t Generally the fewer and smaller the holes in the cabinet the better the interference attenuation The maximum recommended diameter of a hole in galvanic metal contact in the covering cabinet structure is 100 mm 3 94 in Pay special attention to the cooling air inlet and outlet gratings The best galvanic connection between the steel panels is achieved by welding them together as no holes are necess...

Page 48: ...t the cable entries improves the EMC shielding of the cabinet ABB recommends 360 high frequency grounding of the motor cable shields at their entries The grounding can be implemented by a knitted wire mesh screening as shown below Cable 1 Cable tie 2 Strain relief 3 Bare cable shield 4 Knitted wire mesh 5 Cabinet entry plate 6 3 1 6 4 5 2 ABB recommends 360 high frequency grounding of the control ...

Page 49: ...the whole cabinet base is not supported from below the cabinet weight will lie on the sections that the floor carries Equip the cabinet with a sealed bottom plate and cable entries to ensure the degree of protection and to prevent the cooling air flow from the cable duct into the cabinet Cabinet side view with a bottom plate The supporting structure on a cable duct Cabinet heating elements Use a h...

Page 50: ...le as options from ABB For more information see Code English Manual 3AUA0000100140 DPMP 01 mounting platform for control panels installation guide 3AUA0000136205 DPMP 02 03 mounting platform for control panels installation guide 3AXD50000308484 DPMP 04 05 mounting platform for control panels installation guide DPMP 04 05 DPMP 02 DPMP 01 50 Generic cabinet planning instructions ...

Page 51: ... cabinet layout examples and free space requirements around the module for cooling These drive specific guidelines are essential for the safe and trouble free use of the drive system Installation positions of the drive module You can install the drive module in a bookshelf or flat position or on its back in a cabinet On its back Flat Bookshelf 5 Guidelines for planning the mechanical installation ...

Page 52: ...quipment 2b Air outlet for the drive module and other equip ment on the cabinet roof An exhaust fan if needed ABB recommends this alternative instead of 2a 2c Drive control panel with DPMP 03 mounting platform The control panel is connected to the drive module control unit inside the cabinet 3 Contactor control switch and emergency stop switch connected to the contactor control circuit inside the ...

Page 53: ...hot air 2 Note With the integrated control unit the upper door air inlet is critical for the cooling of the control unit External control cables 10 Optional air baffle that is needed when there is no fan on the lower part of the cabinet door 1b in section Layout example door closed page 52 2e Grounding screws 11 Cabinet grounding busbar PE 3 Alternative to grounding screws 11 12 Input power cable ...

Page 54: ...e module 8 Vertical 2a and horizontal 2b air baffles with leak proof cable entries The air baffles separ ate the cool and hot areas and prevent recircu lation of hot air 2a 2b External drive module control unit option P906 9 Optional air baffle that is needed when there is no fan on the lower part of the cabinet door 1b in section Layout example door closed page 52 2c Note With the integrated cont...

Page 55: ... of the ACS580 04 The drawing below shows two typical cabinet cooling solutions The air inlet is at the bottom of the cabinet and the outlet is at the top on the upper part of the door or on the roof ABB recommends that the air outlet is on the cabinet roof If the air outlet is on the cabinet door use an extra exhaust fan 1 2 Air flow inside the drive module Air inlets and outlets of the cabinet a...

Page 56: ...y 2e D D x y 2c 2d 2b 2b 2c 2d 2a 2b 2c 2d 2b 2b 1b 8 7 Drive module 3 Air flow to the drive module max 40 C 104 F 1a Disconnector and fuses 4 Air inlet to the drive module circuit boards and DC output busbars 1b Contactor 5 Vertical air baffle that separates the cool and hot areas in the cabinet 2a External drive module control unit P906 6 Vertical air baffle 2b 56 Guidelines for planning the mec...

Page 57: ... and fuses 4 Air flow to the drive module max 40 C 104 F 1a Contactor 5 Air inlet to the drive module circuit boards and DC output busbars 1b External drive module control unit P906 6 Vertical air baffle that separates the cool and hot areas in the cabinet 2a Air flow out 7 Horizontal air baffle see Air baffles for the drive module with option B051 page 216 2b Cabinet grounding busbar 8 Optional a...

Page 58: ...let in the upper part of the cabinet door Air outlet on the cabinet roof 290 mm 11 42 in 1 2 1 270 mm 10 63 in 1 2 1 Air inlet 1 Air outlet 2 Free space around the drive module Bookshelf installation 10 mm 0 39 in free space around the drive module is required from the cabinet back panel and front door No free space for cooling is required on the left and right hand sides of the module The module ...

Page 59: ...or cooling is required below the drive module when the module is installed in a cabinet 200 mm 7 87 in free space is required below the drive module when the module is installed on a wall Guidelines for planning the mechanical installation 59 ...

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Page 61: ...ations See the technical data The material behind above and below the drive is non flammable There is sufficient free space around the drive for cooling maintenance and operation See the free space specifications for the drive Make sure that there are no sources of strong magnetic fields such as high current single core conductors or contactor coils near the drive A strong magnetic field can cause...

Page 62: ...e configuration Output cable connection terminals 2 With option H381 Output cabling panel parts See below for the box contents Plywood support 3 Drive module with factory installed options and multilingual residual voltage warning sticker top guide plate pedestal guide plate telescopic ramp package fastening screws in a plastic bag control unit options delivery documents printed multilingual insta...

Page 63: ...18 16 14 12 2 Paper fill 1 Clear plastic shroud for output power cabling 2 Mounting bracket for bottom grille 3 Cardboard box bottom 4 Cardboard box cover 5 Bottom grille 6 Support 7 Straps 8 Screws in a plastic bag 9 Back clear plastic shroud lower 10 Back clear plastic shroud upper 11 Front clear plastic shroud 12 Clear plastic shroud for input power cabling 13 Top clear plastic shroud 14 Entry ...

Page 64: ...ay 5 Top cardboard cover 6 Rubber grommet 7 Support 8 Bands 9 Plastic bag 10 Input power cabling panel 11 Top guide 12 Box B2 contains this box 3AXD5000009515 2 6 7 5 4 3 1 Paper fill 1 Output cable connection terminal T3 W2 2 Output cable connection terminal T2 V2 3 Output cable connection terminal T1 U2 4 Grounding terminal 5 Cardboard box 6 Screws and insulators in a plastic bag 7 64 Mechanical...

Page 65: ... bag 7 Accessory box contents Assembly kit 3AXD50000453900 1 3AXD50000453894 3 4 5 2 Screw package includes also spacers for FSO module installation 1 Rubber grommets for control unit cable entry holes in the middle front cover of the drive module 2 Fastener for Rittal VX25 enclosure 3 Bracket for attaching the drive module from top 3AUA0000096082 The bracket brings a gap for cooling air flow and ...

Page 66: ...dule also with chains Do not tilt the module It is heavy and its center of gravity is high The module overturns from a sideways tilt of 5 degrees Do not leave the module unattended on a sloping floor 1 2 3 3AUA0000086323 Examining the delivery Examine that all the items are present and there are no signs of damage Read the data on the type designation label of the drive module to make sure that th...

Page 67: ...e module with full cabling panels option H381 into a Rittal VX25 enclosure including power cable connection procedure see Installation example with full cabling panels option H381 page 121 Note This installation alternative is not possible without pedestal with option 0H354 Input power cable connection terminals option H370 and ground busbar assembly Connect the input power cable connection termin...

Page 68: ...ng plate and frame are strong enough to carry the weight of the drive module Attaching the drive module to a mounting plate or wall Use the support bracket 3AUA0000096082 included in the assembly kit 3AXD50000453900 if you attach the drive module directly to a mounting plate or wall The support bracket prevents the drive module screws from chafing against the plate M4 12 Torx Alternatives for grou...

Page 69: ...2 1 Tapping screw M6 12 Torx T30 Hex 9 N m 6 6 lbf ft Mechanical installation 69 10 ...

Page 70: ... Installing the bottom grille for IP20 degree protection option B051 If IP20 degree of protection is needed from the bottom side install the bottom grille as shown below 70 Mechanical installation ...

Page 71: ...ing from the top of the drive module after the installation If the covering is not removed the cooling air cannot flow freely through the module and the drive will overheat Installing external control unit option P906 See chapter External control unit option P906 page 147 Mechanical installation 71 10 ...

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Page 73: ...atsoever for any installation which breaches the local laws and or other regulations Furthermore if the recommendations given by ABB are not followed the drive may experience problems that the warranty does not cover Selecting the main supply disconnecting device You must equip the drive with a main supply disconnecting device which meets the local safety regulations You must be able to lock the d...

Page 74: ...he drive Also consider the environmental conditions such as surrounding air temperature IEC devices only Select contactor with utilization category AC 1 number of operations under load according to IEC 60947 4 Consider the application life time requirements North America Installations must be compliant with NFPA 70 NEC 1 and or Canadian Electrical Code CE along with state and local codes for your ...

Page 75: ...cause additional stress on the motor and motor cable insulation Modern variable speed drives with their fast rising voltage pulses and high switching frequencies can generate current pulses that flow through the motor bearings This can gradually erode the bearing races and rolling elements du dt filters protect motor insulation system and reduce bearing currents Common mode filters mainly reduce b...

Page 76: ...ed 600 V Un 690 V cable length 150 m Reinforced 600 V Un 690 V cable length 150 m N A Standard 380 V Un 690 V Form wound HX_ and AM_ N du dt with voltages over 500 V CMF Check with the motor manufac turer 380 V Un 690 V Old1 form wound HX_ and modular N CMF Enamelled wire with fiber glass taping 0 V Un 500 V Random woundHX_ and AM_ 2 N du dt CMF 500 V Un 690 V Consult the motor manufacturer HDP 1 ...

Page 77: ...CMF N Reinforced N du dt CMF N du dt Reinforced 600 V Un 690 V cable length 150 m N CMF N Reinforced 600 V Un 690 V cable length 150 m Pn 500 kW N CMF N CMF Standard 380 V Un 690 V Form wound HX_ and AM_ Pn 500 kW N du dt CMF N du dt with voltages over 500 V CMF Check with the motor manufac turer 380 V Un 690 V Old1 form wound HX_ and modular N CMF Enamelled wire with fiber glass taping 0 V Un 500...

Page 78: ...V Random woundand form wound du dt Standard ÛLL 1300 V 420 V Un 500 V Reinforced ÛLL 1600 V 0 2 µs rise time du dt Reinforced ÛLL 1600 V 500 V Un 600 V Reinforced ÛLL 1800 V du dt Reinforced ÛLL 1800 V 600 V Un 690 V Reinforced ÛLL 2000 V 0 3 µs rise time1 1 If the intermediate DC circuit voltage of the drive is increased from the nominal level due to long term resistor braking cycles check with t...

Page 79: ... V Un 600 V N CMF N or CMF Reinforced ÛLL 1800 V N du dt CMF du dt N Reinforced ÛLL 1800 V 600 V Un 690 V N CMF N CMF Reinforced ÛLL 2000 V 0 3 µs rise time1 1 If the intermediate DC circuit voltage of the drive is increased from the nominal level due to long term resistor braking cycles check with the motor manufacturer if additional output filters are needed Abbreviations Definition Abbr Nominal...

Page 80: ...AC line voltage application must be selected as if the drive were supplied with 480 V Additional requirements for ABB high output and IP23 motors The rated output power of high output motors is higher than what is stated for the particular frame size in EN 50347 2001 This table shows the requirements for protecting the motor insulation and bearings in drive systems for ABB random wound motor serie...

Page 81: ...800 V 600 V Un 690 V N CMF N CMF Reinforced ÛLL 2000 V 0 3 microsecond rise time1 1 If the intermediate DC circuit voltage of the drive is increased from the nominal level due to long term resistor braking cycles check with the motor manufacturer if additional output filters are needed Additional data for calculating the rise time and the peak line to line voltage The diagrams below show the relat...

Page 82: ...nt temperature affect the cable current carrying capacity Obey local regulations and laws Temperature For an IEC installation select a cable rated for at least 70 C 158 F maximum permissible temperature of conductor in continuous use For North America select a cable rated for at least 75 C 167 F Important For certain product types or option configurations higher temperature rating may be required ...

Page 83: ... PE Symmetrical shielded or ar mored cable with three phase conductors and a shield or ar mor and separate PE conduct or cable1 1 A separate PE conductor is required if the conductivity of the shield or armor is not sufficient for the PE use Alternate power cable types Use as motor cabling and as brake resistor cabling Use as input power cabling Cable type Yes with phase conductor smaller than 10 ...

Page 84: ...e at least 1 10 of the phase conductor conductivity The effectiveness of the shield can be evaluated based on the shield inductance which must be low and only slightly dependent on frequency The requirements are easily met with a copper or aluminum shield armor The cross section of a steel shield must be ample and the shield helix must have a low gradient A galvanized steel shield has a better hig...

Page 85: ...es for your application 3 Non metallic conduit use underground is allowed however these installations inherently have an increased chance for nuisance problems due to the potential for water moisture in the conduit Water moisture in the conduit increases the likelihood of VFD faults or warnings Proper installation is required to make sure there is no intrusion of water moisture Metal conduit Coupl...

Page 86: ...f the protective earth conductor related to the phase conductor size according to IEC UL 61800 5 1 when the phase conductor s and the protective earth conductor are made of the same metal If this is not so the cross sectional area of the protective earth conductor must be determined in a manner which produces a conductance equivalent to that which results from the application of this table Minimum...

Page 87: ... mm2 as part of a multi conductor power cable Sufficient strain relief must be provided If the protective earth conductor is routed through a plug and socket or similar means of disconnection it must not be possible to disconnect it unless power is simultaneously removed Note You can use power cable shields as grounding conductors only when their conductivity is sufficient Additional grounding req...

Page 88: ...ool cable Connect the Drive Composer PC tool to the drive through the USB port of the control panel Use a USB Type A PC Type Mini B control panel cable The maximum length of the cable is 3 m 9 8 ft Routing the cables General guidelines IEC Route the motor cable away from other cables Motor cables of several drives can be run in parallel installed next to each other Install the motor cable input po...

Page 89: ...able 1 Input power cable 2 Control cable 3 Brake resistor or chopper cable if any 4 General guidelines North America Make sure that the installation is in accordance with national and local codes Obey these general guidelines Use separate conduits for the input power motor brake resistor optional and control cabling Use separate conduit for each motor cabling The following figure illustrates the c...

Page 90: ...trical shielded cable or install the cabling in a metal conduit Make sure that there is a good and continuous galvanic connection in the shield conduit between drive and motor Connect the shield conduit to the protective ground terminal of the drive and the motor Separate control cable ducts Put 24 V DC and 230 V AC 120 V AC control cables in separate ducts unless the 24 V DC cable is insulated fo...

Page 91: ...or The drive overload protection is tuned for the total motor load It may not detect an overload in one motor circuit only North America The local code NEC requires an overload protection and a short circuit protection for each motor circuit Use for example manual motor protector circuit breaker contactor and overload relay or fuses contactor and overload relay Protecting the motor against thermal...

Page 92: ...ven in the technical data The fuses for the drive protection will restrict drive damage and prevent damage to adjoining equipment in case of a short circuit inside the drive Note If the fuses for the drive protection are placed at the distribution board and the input cable is dimensioned according to the nominal input current of the drive given in the technical data the fuses protect also the inpu...

Page 93: ... against ground faults in the motor and motor cable This function is not a personnel safety or a fire protection feature See the firmware manual for more information Residual current device compatibility The drive is suitable for use with residual current devices of Type B Note As standard the drive contains capacitors connected between the main circuit and the frame These capacitors and long moto...

Page 94: ...will not cause any danger If you are in doubt do not implement the power loss ride through function Using power factor compensation capacitors with the drive Power factor compensation is not needed with AC drives However if a drive is to be connected in a system with compensation capacitors installed note the following restrictions WARNING Do not connect power factor compensation capacitors or har...

Page 95: ...trolling a contactor between drive and motor The control of the output contactor depends on how you use the drive that is which motor control mode and which motor stop mode you select If you have the vector control mode and motor ramp stop selected open the contactor as follows 1 Give a stop command to the drive 2 Wait until the drive decelerates the motor to zero speed 3 Open the contactor If you...

Page 96: ...HIS MACHINE STARTS AUTOMATICALLY WARNING Never connect the drive output to the electrical power network The connection may damage the drive Example bypass connection An example bypass connection is shown below Drive main switch Q1 Bypass circuit breaker Q4 Drive main contactor K1 Bypass contactor K4 Drive output contactor K5 Drive main contactor on off control S11 Motor power supply selection driv...

Page 97: ...the motor power supply from direct on line to the drive with S40 3 Close the main contactor of the drive with switch S11 turn to position ST for two seconds and leave to position 1 4 Start the drive and the motor with the drive control panel start key drive in the local control mode or the external start signal drive in the remote control mode Protecting the contacts of relay outputs Inductive loa...

Page 98: ...ive control unit See Connecting a motor temperature sensor to the drive through an option module page 98 Make sure that the voltage does not exceed the maximum allowed voltage over the sensor 3 If there is basic insulation between the sensor and the live parts of the motor or if the insulation type is not known You can connect a sensor to a digital input of the drive via an external relay The sens...

Page 99: ...l requirement x Reinforced insulation between the sensor connector and other connect ors including drive control unit connector The drive control unit is PELV com patible also when the module and a thermistor protection circuit are in stalled CMOD 02 No special requirement x CPTC 02 Guidelines for planning the electrical installation 99 ...

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Page 101: ...ve configuration Safety WARNING If you are not a qualified electrical professional do not do installation or maintenance work Obey the safety instructions of the drive If you ignore them injury or death or damage to the equipment can occur Grounding the motor cable shield at the motor end For minimum radio frequency interference ground the cable shield 360 degrees at the cable entry of the motor t...

Page 102: ...ioning or maintenance work 1 Do the steps in section Electrical safety precautions page 21 before you start the work 2 Make sure that the motor cable is disconnected from the drive output terminals 3 Measure the insulation resistance between each phase conductor and the protective earth conductor Use a measuring voltage of 1000 V DC The insulation resistance of an ABB motor must be more than 100 M...

Page 103: ...nnected Connected R10 R11 EMC filter compatibility The drive has an internal EMC filter E210 as standard You can install the drive with the EMC filter connected to a symmetrically grounded TN S system IT system corner grounded delta mid point grounded delta and TT system Note If you disconnect the EMC filter the electromagnetic compatibility of the drive decreases Ground to phase varistor compatib...

Page 104: ...can installations If you are concerned with EMC issues and install the drive to a symmetrically grounded TN S system IT system corner grounded delta or mid point grounded delta system you can connect the internal EMC filter See section Connecting EMC filter North America page 287 Note When the internal EMC filter is disconnected the electromagnetic compatibility of the drive is reduced Ground to p...

Page 105: ...ded cable is used Ground the other end of the input cable shield or PE conductor at the distribution board 3 ABB recommends 360 degree grounding at the cabinet entry 4 Use a separate grounding cable if the conductivity of the shield does not meet the requirements of IEC 61800 5 1 see section General guidelines page 82 and there is no symmetrically constructed grounding conductor in the cable 5 If ...

Page 106: ...ng the cable ends Symmetrical shielded cables 1 Peel off 3 5 cm 1 2 in of the outer insulation of the cables at the cable entries with the conductive sleeves for the 360 high frequency grounding 2 Prepare the ends of the cables PE PE WARNING Apply grease to stripped aluminum conductors before attaching them to non coated aluminum cable lugs Obey the grease manufacturer s instructions Aluminum alum...

Page 107: ...the motoring mode For more information contact your local ABB representative Connecting the control cables Integrated control unit This procedure applies to the standard drive module with integrated control unit 2 Combi screw M4 8 Torx T20 2 N m 1 5 3 1 5 lbf ft 1 Remove the middle front cover of the drive module 2 Attach the option modules if not attached already See section Installing option mod...

Page 108: ...rews to secure the connection 7 Connect the conductors to the appropriate detachable terminals of the control unit See chapter Control unit page 135 for the default I O connections of the drive module Use shrink tubing or insulating tape to contain any stray strands Tighten the screws to secure the connection Keep any signal wire pairs twisted as close to the terminals as possible Twisting the wir...

Page 109: ...Note When a PC is connected to the control panel the control panel keypad is disabled In this case the control panel acts as a USB RS485 adapter Electrical installation 109 11 ...

Page 110: ...el will display an indication whenever the connection is active 5 See the documentation of the PC tool for setup instructions Start Stop Loc Rem Start Stop Loc Rem USB connected 3a 4 3b 2 2 Connecting a remote panel or chaining one panel to several drives You can connect a drive control panel remotely to the drive or chain the control panel or a PC to several drives on a panel bus with a CDPI 01 c...

Page 111: ...position on the control unit 2 Tighten the mounting screw 3 Tighten the grounding screw CHASSIS to 0 8 N m 7 lbf in The screw grounds the module This is necessary for fulfilling the EMC requirements and for correct operation of the module 1 2 3 Electrical installation 111 11 ...

Page 112: ...HASSIS to 0 8 N m 7 lbf in The screw tightens the connections and grounds the module This is necessary for fulfilling the EMC requirements and for correct operation of the module 1 2 Wiring the optional modules See the appropriate option module manual or for I O options the appropriate chapter in this manual 112 Electrical installation ...

Page 113: ... Safety WARNING If you are not a qualified electrical professional do not do installation or maintenance work Obey the safety instructions of the drive If you ignore them injury or death or damage to the equipment can occur Required parts Drive module standard parts Drive module Fastening bracket Pedestal guide plate Telescopic extraction installation ramp Fastening screws and insulators in a plas...

Page 114: ...e 55 Step by step drawings for an installation example of a drive module with the B051 option in a Rittal VX25 600 mm wide enclos ure page 289 Connecting the power cables and installing the shrouds page 115 Install the auxiliary components such as mounting plates air baffles switches busbars etc 2 Attach the drive module to the enclosure Connect the power cables and install the clear plastic shrou...

Page 115: ...closure back Note The fastening bracket grounds the drive module to the cabinet frame Install the air baffles For option B051 refer to chapter Step by step drawings for an installation example of a drive module with the B051 option in a Rittal VX25 600 mm wide enclosure and section Air baffles for the drive module with option B051 page216 Forthestandarddrivemoduleconfiguration seesectionStandard d...

Page 116: ...gh the drilled holes in the clear plastic shroud 4 For drive modules without option H370 Connect the input cable conductors to the drive module L1 U1 L2 V1 and L3 W1 connection busbars Go to step 12 5 For option H370 Perform steps 6 to 11 Screw in and tighten the insulators to the drive module by hand Install the L1 U1 connection terminal to the insulators 6 WARNING Do not use longer screws or a l...

Page 117: ...rs on top of the cabinet as shown below This layout has been tested by ABB Rittal 7967 000 3AUA0000145776 2 1 592 23 31 1978 77 85 Rittal 3243 200 Door 1 Install these gratings as close to each other as possible Remove the filter mats 2 Installation example of drive module with IP20 shrouds option B051 117 ...

Page 118: ...ilters and roof This drawing shows a layout tested by ABB 3AXD50000016652 ABB 3AUA0000125202 IP20 ABB 3AUA0000114971 IP42 ABB 3AUA0000117003 IP20 ABB 3AUA0000117008 IP42 118 Installation example of drive module with IP20 shrouds option B051 ...

Page 119: ...able entry from top If you run the input cables from top to the drive module drill the entry holes to the top clear plastic shroud Attaching the drive module to a mounting plate or wall Use the support bracket 3AUA0000096082 included in the assembly kit 3AXD50000453900 if you attach the drive module directly to a mounting plate or wall The support bracket prevents the drive module screws from chaf...

Page 120: ...120 ...

Page 121: ...re bottom with its front facing the enclosure door Space for the additional components can be made by connecting two or more VX25 enclosures together Available alternative ABB parts are also given Safety WARNING Obey the safety instructions of the drive If you ignore them injury or death or damage to the equipment can occur If you are not a qualified electrical professional do not do installation ...

Page 122: ... horizontal 3 VX 8617 010 Air filter 323 mm 323 mm Remove the filter mat according to the manufacturer s instructions 4 2 SK 3243 200 ABB 3AUA0000117002 IP20 ABB 3AUA0000117007 IP42 Support rail alternative to a customer made bottom plate 3 TS 4396 500 Customer made parts not ABB or Rittal products Description Qty pcs Dimension drawing code Air baffles See section Air baffles for option H381 in Ri...

Page 123: ...step drawings for installing full cabling panels option H381 in a Rittal VX25 400 mm wide enclosure page 293 If you do not use Rittal support rails on the bottom of the enclosure but use a custom bottom plate instead see the dimension drawings for the correct dimensions of the bottom plate If the thickness of the bottom plate is not 2 5 mm 0 1 in adjust the dimensions accordingly Connecting the po...

Page 124: ... them and any separate ground conductors or cables to grounding busbar of the input cabling panel 8 Connect the phase conductors of the input cables to terminals L1 U1 L2 V1 and L3 W1 of the drive module For the tightening torques see the technical data C A A B C D 102 mm 4 in L1 U1 L2 V1 L3 W1 T1 U2 T2 V2 T3 W2 E E View without cabinet side plate in place 360 degree grounding at the entry plate f...

Page 125: ... Make sure that the module does not fall down when moving it on the floor and during installation and maintenance work To open the support legs press each leg a little down and turn it aside 1 2 When possible also secure the module with chains from top Do not tilt the drive module A It is heavy and its center of gravity is high The module will overturn from a sideways tilt of 5 degrees Do not leav...

Page 126: ...chains 5 Push the drive module carefully into to the enclosure preferably with the help from another person 6 Attach the grounding busbar that has been previously attached to the input cabling panel to the drive module Note The design of the grounding busbar can be different from what is shown in the figure 7 Connect the busbars of the drive module to the busbars of the cabling panels M12 combi sc...

Page 127: ...acers and the side panels see Assembly drawing of installing the roof and door page 131 10 Remove the filter mats from the air filters according to Rittal s instructions Install the filters to the cabinet door see Assembly drawing of installing the roof and door page 131 11 Drive modules with an external control unit option P906 Put back the removed front covers of the drive module on the power ca...

Page 128: ...2 7a 7b 5 3 3 7a 7b 8a 8b 8b 4 128 Installation example with full cabling panels option H381 ...

Page 129: ...Assembly drawing of installing the drive module to the enclosure frame R10 3AXD50000439317 Installation example with full cabling panels option H381 129 ...

Page 130: ...Assembly drawing of installing the drive module to the enclosure frame R11 3AXD50000438938 130 Installation example with full cabling panels option H381 ...

Page 131: ...rawing shows a layout tested by ABB Rittal 7967 000 3AUA0000145776 2 1 Rittal 3326 200 R10 1552 61 10 R11 Door 1 Install these gratings as close to each other as possible Remove the filter mats 2 Installation example with full cabling panels option H381 131 ...

Page 132: ...connected the lower side plate of the output cabling panel must be removed and the resistor cables lead from side to the terminals of the output cabling panel Installing the rubber grommet To get IP20 degree of protection for the drive module install the input power cables through the rubber grommet Install the grommet as follows 1 Cut adequate holes into the grommet for the input power cables 2 P...

Page 133: ...Installation example with full cabling panels option H381 133 ...

Page 134: ...134 ...

Page 135: ...Control unit Contents of this chapter This chapter contains the default I O connection diagram descriptions of the terminals and technical data for the drive control unit CCU 24 11 Control unit 135 ...

Page 136: ...2 DIGITAL IN Digital inputs 13 18 STO Safe torque off connection 34 38 Internal air temperature NTC sensor connection AIR IN TEMP Internal fan 2 connection FAN2 Internal fan 1 connection FAN1 Panel port control panel connec tion wired at the factory to the control panel X12 Reserved to internal use X15 EFB EIA RS 485 fieldbus connector Bias resistor switch BIAS End termination switch TERM Connecti...

Page 137: ...inputs Aux voltage output 24 V DC max 250 mA 2 24V 10 10 11 12 13 14 15 16 17 18 6 7 Aux voltage output common DGND 11 Digital input common for all DCOM 12 Stop 0 Start 1 DI1 13 Forward 0 Reverse 1 DI2 14 Constant frequency selection 4 DI3 15 Constant frequency selection 4 DI4 16 Ramp set 1 0 Ramp set 2 1 5 DI5 17 Not configured DI6 18 X6 X7 X8 Relay outputs Ready run RO1C 19 19 20 21 22 23 24 25 ...

Page 138: ... used as a speed reference if vector control is selected 3 In scalar control default See Menu Primary settings Start stop reference Constant fre quencies or parameter group 28 Frequency reference chain 4 In vector control See Menu Primary settings Start stop reference Constant speeds or parameter group 22 Speed reference selection Operation Parameter DI4 DI3 Vector control Scalar control default S...

Page 139: ...minated TERM ON Bias off default BIAS ON Switches on the biasing voltages to the bus One and only one device preferably at the end of the bus must have the bias on BIAS S5 Bias on BIAS ON Additional information on I O connections PNP configuration for digital inputs X2 X3 Internal and external 24 V power supply connections for PNP configuration are shown in the figure below External 24 V power sup...

Page 140: ...d when the control unit is powered from an external 24 V AC supply Connection for obtaining 0 10 V from analog output 2 AO2 To obtain 0 10 V from analog output AO2 connect a 500 ohm resistor or two 1 kohm resistors in parallel between analog output AO2 and analog common ground AGND X1 8 AO2 9 AGND 500 ohm X1 8 AO2 9 AGND 1 kohm 1 kohm 0 10 V 0 10 V Connection examples of two wire and three wire se...

Page 141: ...r need to be double isolated Otherwise the CMOD 02 I O extension module must be used 1 24V DI6 t t t t t t One to six PTC thermistors connected in series 1 AI1 and AI2 as Pt100 Pt1000 Ni1000 KTY83 and KTY84 sensor inputs X1 Sensors for motor temperature measurement can be connected between an analog input and output An example connection is shown below Leave the other end of the shield unconnected...

Page 142: ...or the temperature sensor must be isolated from the I O terminals Safe torque off X4 For the drive to start both connections 24 V DC to IN1 and 24 V DC to IN2 must be closed By default the terminal block has jumpers to close the circuit Remove the jumpers before connecting an external Safe torque off circuitry to the drive See also chapter The Safe torque off function page 221 Note Only 24 V DC ca...

Page 143: ...as page 144 Current voltage input mode selected with a parameter see AI1 and AI2 as Pt100 Pt1000 Ni1000 KTY83 and KTY84 sensor inputs X1 page 141 Current input 0 4 20 mA Rin 100 ohm Voltage input 0 2 10 V Rin 200 kohm Terminal size 0 14 2 5 mm2 26 14 AWG Analog inputs AI1 and AI2 Term 2 and 5 Inaccuracy typical 1 max 1 5 of full scale Inaccuracy for Pt100 sensors 10 C 50 F Current voltage output m...

Page 144: ...bottom of the control unit 2 Reinforced insulation IEC EN 61800 5 1 2007 UL 61800 5 1 First edition Functional insulation IEC EN 61800 5 1 2007 UL 61800 5 1 First edition The terminals on the control unit fulfill the Protective Extra Low Voltage PELV requirements EN 50178 There is reinforced insulation between the user terminals which only accept ELV voltages and terminals that accept higher volta...

Page 145: ...4V 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 SGND 37 IN1 38 IN2 X10 40 24VAC DC in 41 24VAC DC in Slot 1 Slot 2 Jumper installed at factory Control unit 145 ...

Page 146: ...146 ...

Page 147: ...awing is included Product overview Option P906 allows the drive control unit CCU 24 to be installed separately from the main drive module for example in a separate compartment The external control unit makes the drive module removal easier as the customer control cabling can stay in place while the module is removed 12 External control unit option P906 147 ...

Page 148: ...from drive module to be con nected to the ZBIB board at the back of the control unit 2 Connectors For descriptions see chapter Control unit page 135 3 Cables for connecting the external control unit to the drive module 148 External control unit option P906 ...

Page 149: ...ft 2560 mm 8 4 ft CAT 5e ZBIB BGDR X7 STO1 X8 STO2 ZPOW BGDR X3 SOIA ZINT V10 V20 A B 1 2 3 4 V1 V2 DPMP 03 X12 Drive module B CCU 24 control unit A 1 pair of optical cables for all major converter power stack communication 3 1 24 V power supply cable with a ground connection 1 CAT 5e cable must be ordered separately 4 2 Safe Torque Off STO cables 2 External control unit option P906 149 ...

Page 150: ...ntains a mounting pattern for a CCU 24 control unit on one side and a mounting pattern for a ZCU 14 control unit on the other side The control cables that will connect the external control unit to the drive module are connected to the drive module for safe transit ABB recommends that you disconnect them before you install the drive module 1 Remove the middle front cover of the drive module 2 Disco...

Page 151: ...nddamage to the fiber optic cables can occur Handle the fiber optic cables with care When you unplug the cables always hold the connector not the cable itself Do not touch the ends of the fibers with bare hands as the ends are extremely sensitive to dirt Do not bend the fiber optic cables too tightly The minimum allowed bend radius is 35 mm 1 4 in 1 Remove the control unit from the anti static bag...

Page 152: ... it outside of the assembly Make sure that the cables are not against sharp edges or bare live parts 4 Connect the cables to their connectors on the ZBIB board Cables from drive mod ule ZBIB connectors View of ZBIB board ZPOW X3 1 X3 1 X3 2 X3 2 BGDR X7 STO 1 X7 STO 1 X8 STO 2 X8 STO 2 SOIA V10 black V1 gray V20 grey V2 black 152 External control unit option P906 ...

Page 153: ...all bracket a first then the full clamp plate b a b 7 Use the mounting template and a pen to make marks on the installation surface Then drill the holes and install the mounting screws Make sure that debris from drilling does not go into the drive or control unit External control unit option P906 153 ...

Page 154: ...he clamp presses on the bare shield The shield especially in case of multiple shields can also be terminated with a lug and fastened with a screw at the clamp plate Leave the other end of the shield unconnected or ground it indirectly via a few nanofarads high frequency capacitor eg 3 3 nF 630 V The shield can also be grounded directly at both ends if they are in the same ground line with no signi...

Page 155: ...ling Connecting the control unit to the drive module 1 Remove the middle front cover of the the drive module A view of drive module with optional clear plastic shrouds is shown below 2 Remove the cover plate from the control cable entry and put the rubber grommet in its place Put the control cables through the grommet Combi screw M4 8 Torx T20 2 N m 18 lbf in 1 2 2 3 Connect the control cables to ...

Page 156: ...elf Do not touch the ends of the fibers with bare hands as the ends are extremely sensitive to dirt Do not bend the fiber optic cables too tightly The minimum allowed bend radius is 35 mm 1 4 in ZBIB Drive module M4 8 Torx T20 2 N m 18 lbf in ZPOW BGDR SOIA ZPOW X3 1 X3 1 X3 2 X3 2 BGDR X7 STO1 X7 STO1 X8 STO2 X8 STO2 SOIA V1 V10 V2 V20 4 Connect the ground connection at the drive module end 156 E...

Page 157: ...External control unit option P906 157 ...

Page 158: ...Dimension drawing The dimensions are in millimeters and inches 158 External control unit option P906 ...

Page 159: ...stallation commissioning or maintenance work WARNING Stop the drive and do the steps in section Electrical safety precautions page 21 before you start the work Make sure that The ambient operating conditions meet the drive ambient conditions specification and enclosure rating IP code The supply voltage matches the nominal input voltage of the drive See the type designation label The insulation res...

Page 160: ...ened to the correct torque Grounding has also been measured according to the regulations The motor cable is connected to the correct terminals the phase order is correct and the terminals are tightened to the correct torque The motor cable is routed away from other cables No power factor compensation capacitors are connected to the motor cable If an external brake resistor is connected to the driv...

Page 161: ...e drive module has been checked according to the checklist in chapter Installation checklist page 159 and that the motor and driven equipment are ready for start 2 Perform the start up tasks instructed by the cabinet installer of the drive module 3 Run setup of the drive control program according to the start up instructions given in the quick start up guide or firmware manual 4 For drives with op...

Page 162: ...162 ...

Page 163: ...Control unit is powered and 15 V is supplied to the control panel Green POWER Control panel mounting plat form Drive in fault state Red FAULT Warning and fault messages See the quick installation and start up guide or the firmware manual for the descriptions causes and remedies of the control program warning and fault messages 15 Fault tracing 163 ...

Page 164: ...164 ...

Page 165: ...e information consult your local ABB Service representative www abb com searchchannels Description of symbols Description Action Inspection visual inspection and maintenance action if needed I Performance of on off site work commissioning tests measurements or other work P Replacement R Recommended annual actions by the user Connections and environment P Quality of supply voltage Spare parts I Spa...

Page 166: ... 20 years Safety component expiry Mission time TM Maintenance and component replacement intervals are based on the assumption that the equipment is operated within the specified ratings and ambient conditions ABB recommends annual drive inspections to ensure the highest reliability and optimum performance Note Long term operation near the specified maximum ratings or ambient conditions may require...

Page 167: ...stband Using a normal vacuum cleaner creates static discharges which can damage circuit boards 1 Stop the drive and do the steps in section Electrical safety precautions page 21 before you start the work 2 Open the cabinet door 3 Clean the interior of the cabinet Use a vacuum cleaner and a soft brush 4 Clean the air inlets of the fans and air outlets of the modules top 5 Clean the air inlet gratin...

Page 168: ... and nozzle and wear a grounding wristband Using a normal vacuum cleaner creates static discharges which can damage circuit boards 1 Stop the drive and do the steps in section Electrical safety precautions page 21 before you start the work 2 Remove the attaching screws of the handle plate of the drive module 3 Remove the handle plate 4 Vacuum the interior of the heatsink from the opening 5 Careful...

Page 169: ...board compartment cooling fans WARNING Obey the safety instructions of the drive If you ignore them injury or death or damage to the equipment can occur 1 Stop the drive and do the steps in section Electrical safety precautions page 21 before you start the work 2 Remove the drive module out of the cabinet as described in module replacement instructions 3 Undo the fastening screw of the fan enclosu...

Page 170: ...ribed in module replacement instructions 3 Open the support legs of the pedestal 4 Remove the two screws that fasten the fan assembly plate 5 Tilt the fan assembly plate down 6 Disconnect the power supply wires of the fans 7 Remove the fan assembly from the drive module 8 Remove the fastening screws of the fan s and remove the fan s from the assembly plate 9 Install the new fan s in reverse order ...

Page 171: ...dule only by the lifting lugs Make sure that the module does not topple over when you move it on the floor Open the support legs by pressing each leg a little down 1 2 and turning it aside Whenever possible attach the module also with chains Do not tilt the drive module It is heavy and its center of gravity is high The module overturns from a sideways tilt of 5 degrees Do not leave the module unat...

Page 172: ...trol unit and wind them on the top of the drive module Remove the middle front cover of the drive module to be able to disconnect the cables 2 combi screws M4 8 T20 2 N m 18 lbf in 6 Remove the screws that attach the drive module to the cabinet at the top and behind the front support legs 7 6 7 Attach the extraction installation ramp to the cabinet base with two screws 8 To prevent the drive modul...

Page 173: ...Handle the drive module carefully Use safety shoes with a metal toe cap to prevent foot injury Lift the drive module only by the lifting lugs Make sure that the module does not topple over when you move it on the floor To open the support legs press each leg a little down and turn it aside 1 2 When possible secure the module also with chains Do not tilt the drive module It is heavy and its center ...

Page 174: ... to the cabinet at the top a and behind the front support legs b 6 Remove the front air baffle 7 Attach the extraction installation ramp to the cabinet base with two screws 8 Disconnect the power supply cables STO cables and the fiber optic cables from the external control unit and wind them on the top of the drive module Remove the middle front cover of the drive module to be able to disconnect t...

Page 175: ...f electronic components remain constant This applies to the components of the standard Safe torque off circuit as well as any modules relays and typically any other components that are part of functional safety circuits The expiry of mission time terminates the certification and SIL PL classification of the safety function The following options exist Maintenance 175 ...

Page 176: ...electrolytic capacitors Operating time load and surrounding air temperature have an effect on the life of the capacitors Capacitor life can be extended by decreasing the surrounding air temperature Capacitor failure is usually followed by damage to the unit and an input cable fuse failure or a fault trip If you think that any capacitors in the drive have failed contact ABB Reforming the capacitors...

Page 177: ... ratings Output ratings Max cur rent Input current Frame size ACS580 04 Heavy duty use Light duty use Nominal use PHd IHd PLd ILd Pn I2 Imax I1 kW A kW A kW A A A Un 400 V 200 361 250 485 250 505 560 505 R10 505A 4 250 429 315 575 315 585 730 585 R10 585A 4 250 477 355 634 355 650 730 650 R10 650A 4 315 566 400 715 400 725 1020 725 R11 725A 4 355 625 450 810 450 820 1020 820 R11 820A 4 400 725 500...

Page 178: ...t voltage range see section Electrical power network specification page 189 50 Hz for IEC ratings and 60 Hz for UL NEC ratings Un Nominal rms input current at 40 C 104 F Continuous rms input current for dimension ing the cables and fuses I1 Maximum output current Available for 10 seconds at start otherwise as long as allowed by drive temperature Imax Continuous rms output current Available continu...

Page 179: ...late the derated current The IP00 drive type is ACS580 04 725A 4 which has drive output current of 725 A Calculate the derated drive output current I2 at 4 kHz switching frequency at 1500 m altitude and at 50 C surrounding air temperature as follows 1 Switching frequency derating page 181 The derating factor for 4 kHz switching frequency is 0 78 The derated drive output current then becomes I2 0 7...

Page 180: ...r 35 C surrounding air temperature From the table in section IEC ratings page 177 drive type ACS580 04 820A 4 exceeds the I2 requirement of 750 A Surrounding air temperature derating In the temperature range 40 55 C 104 F 131 F the rated output current is derated by 1 for every added 1 C 1 8 F as follows Calculate the output current by multiplying the current given in the rating table by the derat...

Page 181: ...m 6562 ft 2500 m 8202 ft 3000 m 9842 ft 3500 m 11429 ft 4000 m 13123 ft 1 00 0 95 0 85 0 90 0 80 Derating factor 1 00 Derating factor 0 95 Derating factor 0 90 Derating factor 0 85 Derating factor 0 80 For a more accurate derating use the DriveSize PC tool Switching frequency derating Switching frequencies other than 1 5 kHz can require output current derating If you change the minimum switching f...

Page 182: ... 945000 1000 623 6500 650A 4 170M6016 690 1950000 1250 705 9100 725A 4 170M6269 690 3900000 1600 807 13000 820A 4 170M6269 690 3900000 1600 807 13000 880A 4 1 Minimum permitted short circuit current of the electrical power network Ultrarapid aR fuses type DIN 43620 blade style Input current Min short circuit current1 ACS580 04 Fuse Voltage rating I2t Nominal current Bussmann V A2s A A A Un 400 V 1...

Page 183: ...alue given in the fuse table The short circuit current of the installation can be calculated as follows Ik2 ph 2 Rc 2 Zk Xc 2 U where Short circuit current in symmetrical two phase short circuit Ik2 ph Network line to line voltage V U Cable resistance ohm Rc Zk zk Un 2 Sn transformer impedance ohm Zk Transformer impedance zk Transformer rated voltage V Un Nominal apparent power of the transformer ...

Page 184: ... Circuit breakers listed in section Circuit breakers UL are also acceptable as branch circuit protection 4 The recommended size or smaller UL listed 248 fast acting time delay or high speed fuses must be used to maintain the UL listing of the drive Additional protection can be used Refer to local codes and regulations 5 A fuse of a different class can be used at the high fault rating where the Ipe...

Page 185: ... case circuit breaker Tmax Frame size ACS580 04 Product ID Type Un 480 V 30 1SDA054412R1 R10 505A 4 T5H 630 PR221DS LS I In 630 3p F F 30 1SDA054412R1 R10 585A 4 T5H 630 PR221DS LS I In 630 3p F F 50 1SDA062770R1 R10 650A 4 T7H 1000 PR231 P LS I In 1000A 3p F F 50 1SDA062770R1 R11 725A 4 T7H 1000 PR231 P LS I In 1000A 3p F F 50 1SDA062770R1 R11 820A 4 T7H 1000 PR231 P LS I In 1000A 3p F F 50 1SDA0...

Page 186: ... 20 08 12 01 57 55 R10 429 20 08 12 01 65 43 R11 Weight of optional selections H381 H370 0H371 H356 E208 0H354 Frame size kg kg kg kg kg kg 30 2 9 2 9 2 3 7 R10 30 2 9 2 9 2 3 7 R11 Weight of optional selections H381 H370 0H371 H356 E208 0H354 Frame size lb lb lb lb lb lb 66 6 6 4 7 15 R10 66 6 6 4 7 15 R11 Height of drive module without pedestal option H354 mm Frame size 100 R10 R11 Height of dri...

Page 187: ... mm2 or 4 3 500 MCM Screw size for connecting busbars to the drive module input and output busbars M12 tightening torque 50 75 N m 37 55 lbf ft Drive modules without output cable connection terminals 0H371 and with a common mode filter E208 It is possible to use the maximum cable size 4 3 240 mm2 or 4 3 500 MCM only with special cable lugs and additional insulation For more information contact you...

Page 188: ...0 3 3 240 820A 4 4 3 240 3 3 240 880A 4 Un 480 V 3 3 150 3 3 95 505A 4 3 3 150 3 3 95 585A 4 3 3 185 3 3 120 650A 4 3 3 240 3 3 150 725A 4 4 3 185 3 3 185 820A 4 4 3 240 3 3 240 880A 4 1 The cable sizing is based on max 9 cables laid on a cable ladder side by side three ladder type trays one on top of the other ambient temperature 30 C PVC insulation surface temperature 70 C EN 60204 1 and IEC 603...

Page 189: ...nit page 135 Electrical power network specification ACS580 04 xxxx 4 drive modules 380 480 V AC 3 phase 10 This is indic ated in the type designation label as typical input voltage levels 3 400 480 V AC Voltage U1 TN grounded and IT ungrounded systems Network type Maximum permitted prospective short circuit current is 65 kA when protected by the fuses given in the fuse table Rated conditional shor...

Page 190: ...00 m 328 ft may not fulfill the EMC Directive requirements of Category C3 Note Long cables cause a motor voltage decrease which limits the available motor power The decrease depends on the motor cable length and character istics Contact ABB for more information Note that a sine filter optional at the drive output also causes a voltage decrease Brake resistor connection data See chapter Resistor br...

Page 191: ...rotective class IEC EN 61800 5 1 Ambient conditions Environmental limits for the drive are given below The drive is to be used in a heated indoor controlled environment Transportation Storage Operation in the protective package in the protective package For TN and TT neutral grounded network sys tems and IT non corner grounded network sys tems 0 4000 m 13123 ft above sea level Installation site al...

Page 192: ...usoidal Max 1 mm 0 04 in 5 13 2 Hz max 7 m s2 23 ft s2 13 2 100 Hz sinusoidal Max 0 1 mm 0 004 in 10 57 Hz max 10 m s2 33 ft s2 57 150 Hz si nusoidal Vibration IEC 60068 2 6 2007 EN 60068 2 6 2008 With packing max 100 m s2 330 ft s2 11 ms With packing max 100 m s2 330 ft s2 11 ms Not permitted Shock IEC 60068 2 27 2008 EN 60068 2 27 2009 100 mm 4 in for weight over 100 kg 220 lb 100 mm 4 in for we...

Page 193: ...board and other packaging material can be used in energy recovery Printed circuit boards and large electrolytic capacitors need selective treatment according to IEC 62635 guidelines To aid recycling plastic parts are marked with an appropriate identification code Contact your local ABB distributor for further information on environmental aspects and recycling instructions for professional recycler...

Page 194: ... and Scotland EAC Eurasian Conformity mark Product complies with the technical regulations of the Eurasian Customs Union EAC mark is required in Russia Belarus and Kazakhstan RCM mark Product complies with Australian and New Zealand requirements specific to EMC telecom munications and electrical safety For fulfilling the EMC requirements see the additional in formation concerning the drive EMC com...

Page 195: ...e first environment Note A professional is 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 and intended for use in the second environment and not intended for use in the first environment Drive of category C4 drive of rated voltage equal to or above 1000 V ...

Page 196: ...chnical guide No 3 EMC compliant installation and configuration for a power drive system 3AFE61348280 English 3 The motor and control cables are selected and routed according to the electrical planning guidelines of the drive The EMC recommendations are obeyed 4 The drive is installed according to its installation instructions The EMC recommendations are obeyed WARNING A drive of category C4 is no...

Page 197: ... fuses given elsewhere in this chapter The ampere rating is based on tests done according to the appropriate UL standard The cables located within the motor circuit must be rated for at least 75 C in UL compliant installations The input cable must be protected with fuses or circuit breakers These protective devices provide branch circuit protection in accordance with the national regulations Natio...

Page 198: ...sponsibility to provide and continuously ensure a secure connection between the product and Customer network or any other network as the case may be Customer shall establish and maintain any appropriate measures such as but not limited to the installation of firewalls prevention of physical access application of authentication measures encryption of data installation of anti virus programs etc to ...

Page 199: ...Dimension drawings Contents of this chapter This chapter contains dimension drawings of the drive modules The dimensions are in mm and inches 18 Dimension drawings 199 ...

Page 200: ...R10 standard configuration 200 Dimension drawings ...

Page 201: ...R10 with options E208 0H354 H356 H370 0H371 Dimension drawings 201 ...

Page 202: ...R10 with option B051 202 Dimension drawings ...

Page 203: ...R10 with options E208 H356 P906 Dimension drawings 203 ...

Page 204: ...R10 with options E208 0H371 H356 0H354 H370 P906 204 Dimension drawings ...

Page 205: ...R10 with options B051 P906 Dimension drawings 205 ...

Page 206: ... H381 P906 1 Shim plate 3AXD50000546336 for Rittal VX25 enclosure There are 8 shim plates attached to the drive module If the drive module is installed into a Rittal TS8 enclosure remove the shim plates 1 206 Dimension drawings ...

Page 207: ...R10 Cabling panels H381 installed into a Rittal VX25 enclosure 3AXD50000439317 Dimension drawings 207 ...

Page 208: ...R11 standard configuration 208 Dimension drawings ...

Page 209: ...R11 with options E208 0H371 H356 0H354 H370 Dimension drawings 209 ...

Page 210: ...R11 with option B051 210 Dimension drawings ...

Page 211: ...R11 with options E208 H356 P906 Dimension drawings 211 ...

Page 212: ...R11 with options E208 0H371 H356 0H354 H370 P906 212 Dimension drawings ...

Page 213: ...R11 with options B051 P906 Dimension drawings 213 ...

Page 214: ... H381 P906 1 Shim plate 3AXD50000546336 for Rittal VX25 enclosure There are 8 shim plates attached to the drive module If the drive module is installed into a Rittal TS8 enclosure remove the shim plates 1 214 Dimension drawings ...

Page 215: ...R11 Cabling panels H381 installed into a Rittal VX25 enclosure 3AXD50000438938 Dimension drawings 215 ...

Page 216: ...B051 This drawing shows the dimensions of the hole in the air baffle around the drive module with option B051 The drawing also shows the correct vertical location area of the air baffle as measured from the top grill 15 0 6 216 Dimension drawings ...

Page 217: ...00 mm wide enclosure installation Note These air baffles are not ABB parts 3AXD50000437368 Material of the air baffles 0 75 mm polycabonate PC film LEXAN FR60 GE with UL94 V 0 listing UV stability Unmarked bend radii 0 6 mm Dimension drawings 217 ...

Page 218: ... for option H381 in Rittal VX25 400 mm wide enclosure installation Note The bottom plate is not an ABB part 3AXD50000433988 1 2 Insert nut PEM S M8 2 or equivalent 2 pcs 1 Cable entry area 2 218 Dimension drawings ...

Page 219: ...an example circuit diagram for a cabinet installed drive module Example circuit diagram This diagram is an example for the main wiring of a drive cabinet Note that the diagram includes components which are not included in a basic delivery 19 Example circuit diagram 219 ...

Page 220: ... 5 Switch fuse disconnector1 6 Common mode filter3 7 du dt filter or sine filter2 8 Drive module 9 Input and output signals 10 Alarm 11 Supply 12 360 degree grounding recommended 13 Brake resistor2 14 1 Must be acquired by the customer 2 Optional can be installed by the customer 3 Optional can be selected with an option code 220 Example circuit diagram ...

Page 221: ...ctors of the drive output stage thus preventing the drive from generating the torque required to rotate the motor If the motor is running when Safe torque off is activated it coasts to a stop The Safe torque off function has a redundant architecture that is both channels must be used in the safety function implementation The safety data given in this manual is calculated for redundant use and does...

Page 222: ...ms for the process in dustry sector IEC 61511 1 2017 Adjustable speed electrical power drive systems Part 5 2 Safety requirements Functional IEC 61800 5 2 2016 EN 61800 5 2 2007 Safety of machinery Functional safety of safety related control systems EN IEC 62061 2021 Safety of machinery Safety related parts of control systems Part 1 General principles for design EN ISO 13849 1 2015 Safety of machi...

Page 223: ...0 04 drive internal power supply OUT1 24 V DC SGND STO UDC UDC K 2 1 3 4 OUT2 24 V DC IN1 IN2 34 35 36 37 38 Drive 1 Control unit 2 Control logic 3 To motor 4 Activation switch K Single ACS580 04 drive external power supply OUT1 24 V DC SGND STO UDC UDC 2 1 3 4 OUT2 24 V DC IN1 IN2 34 35 36 37 38 24 V DC K The Safe torque off function 223 ...

Page 224: ...y 24 14 23 13 Y1 A2 Y2 A1 31 32 OUT GND OUT1 34 OUT2 35 SGND 36 IN1 37 IN2 38 STO 1 K 2 Drive 1 Safety PLC 2 Safety relay K Single ACS580 04 drive external power supply 24 14 23 13 Y1 A2 Y2 A1 31 32 OUT GND K 2 24 V DC 1 OUT1 34 OUT2 35 SGND 36 IN1 37 IN2 38 STO Drive 1 Safety PLC 2 Safety relay K 224 The Safe torque off function ...

Page 225: ...r supply 34 35 36 37 38 OUT1 OUT2 SGND IN1 IN2 34 35 36 37 38 OUT1 OUT2 SGND IN1 IN2 STO K 24 V DC 24 V DC 2 1 STO 2 1 34 35 36 37 38 OUT1 OUT2 SGND IN1 IN2 STO 2 1 Drive 1 Control unit 2 Activation switch K The Safe torque off function 225 ...

Page 226: ...4 35 36 37 38 OUT1 OUT2 SGND IN1 IN2 STO 2 1 24 V DC Drive 1 Control unit 2 Activation switch K Activation switch In the wiring diagrams the activation switch has the designation K This represents a component such as a manually operated switch an emergency stop push button switch or the contacts of a safety relay or safety PLC 226 The Safe torque off function ...

Page 227: ...ween external power supply and first control unit Note A short circuit in the wiring between the switch and an STO terminal causes a dangerous fault Therefore it is recommended to use a safety relay including wiring diagnostics or a wiring method shield grounding channel separation which reduces or eliminates the risk caused by the short circuit Note The voltage at the STO input terminals of the d...

Page 228: ... 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 removal of one or both STO signals and will not start until both STO signals are restored and all faults reset Note The loss of only one STO signal always generates a fault as it is interpreted as a malfun...

Page 229: ... new validation tests performed due to changes or maintenance shall be logged into the logbook Validation test procedure After wiring the Safe torque off function validate its operation as follows Note If a CPTC 02 or an FSPS 21 module is installed refer to its documentation Action WARNING Obey the safety instructions If you ignore them injury or death or damage to the equip ment can occur Make su...

Page 230: ... channel of the STO circuit If the motor was running it should coast to a stop The drive generates an FA81 fault indication see the firmware manual Give a start command to verify that the STO function blocks the drive s operation The motor should not start Close the STO circuit Reset any active faults Restart the drive and check that the motor runs normally Open the 2nd input channel of the STO ci...

Page 231: ...tive when the power is restored it is possible that the drive starts without a fresh start command Take this into account in the risk assessment of the system This is also valid when the drive is only powered by a CMOD xx multifunction extension module WARNING Permanent magnet or synchronous reluctance SynRM motors only In case of a multiple IGBT power semiconductor failure the drive can produce a...

Page 232: ...potential hazards The assembler of the machine must inform the final user about the residual risks 232 The Safe torque off function ...

Page 233: ...grity requirement for the safety function is SIL 2 HFT 1 or PL d cat 3 the proof test for the function must be performed at least every 12 months The STO function of the drive does not contain any electromechanical components In addition to proof testing it is a good practice to check the operation of the function when other maintenance procedures are carried out on the machinery Include the Safe ...

Page 234: ...ion function is performed and the drive trips on an FA81 or FA82 fault An attempt to use the STO in a non redundant manner for example activating only one channel will trigger the same reaction See the firmware manual of the drive control program for the indications generated by the drive and for details on directing fault and warning indications to an output on the control unit for external diagn...

Page 235: ...ety data The safety data for the Safe torque off function is given below Note The safety data is calculated for redundant use and applies only if both STO channels are used The Safe torque off function 235 ...

Page 236: ...t SFF DC MTTF D a PFD avg T 1 10 a PFD avg T 1 5 a PFD avg T 1 2 a PFH T 1 20 a 1 h PL SC SIL Frame size 6 44E 09 7 52E 07 6 44E 11 20 80 1 3 99 55 90 15080 1 83E 04 9 14E 05 3 66E 05 4 18E 09 e 3 3 R10 R11 3AXD10001613536 A 236 The Safe torque off function ...

Page 237: ...uent behavior in the fault condition and which is achieved by the structural arrangement of the parts fault detection and or by their reliability The categories are B 1 2 3 and 4 EN ISO 13849 1 Cat Common cause failure EN ISO 13849 1 CCF Diagnostic coverage EN ISO 13849 1 DC Hardware fault tolerance IEC 61508 HFT Mean time to dangerous failure Total number of life units Number of dangerous undetec...

Page 238: ...y EN ISO 13849 valid IEC 61508 6 T1 See also section Maintenance Mission time the period of time covering the intended use of the safety function device After the mission time elapses the safety device must be replaced Note that any TM values given cannot be regarded as a guarantee or warranty EN ISO 13849 1 TM Dangerous failure rate per hour of the diagnostics function of STO IEC 61508 6 λDiag_d ...

Page 239: ...ents of EU Machinery Directive 2006 42 EC when the listed safety function is used for safety component functionality Adjustable speed electrical power drive systems Part 5 2 Safety requirements Functional Safety of machinery Functional safety of safety related control systems Safety of machinery Safety related parts of control systems Part 1 General requirements Safety of machinery Safety related ...

Page 240: ...ve systems Part 5 2 Safety requirements Functional Safety of machinery Functional safety of safety related control systems declare under our sole responsibility that the following product ACS580 04 Safe Torque Off Safe stop 1 SS1 t with FSPS 21 PROFIsafe module Q986 Functional safety of electrical electronic programmable electronic safety related systems Adjustable speed electrical power drive sys...

Page 241: ... as add on kits The brake chopper handles the energy generated by a decelerating motor The extra energy increases the DC link voltage The chopper connects the brake resistor to the intermediate DC circuit whenever the voltage in the circuit exceeds the limit defined by the control program Energy consumption by the resistor losses lowers the voltage until the resistor can be disconnected Planning t...

Page 242: ...diated emissions inductive load and voltage peaks over the IGBT semiconductors of the brake chopper Note ABB has not verified that the EMC requirements are fulfilled with custom brake resistors and cabling The customer must consider the EMC compliance of the complete installation Protecting the resistor cable against short circuits The input fuses of the drive will also protect the resistor cable ...

Page 243: ... according to the instructions and the internal brake chopper is in use The drive will disable power flow through the input bridge if the chopper remains conductive in a fault situation but the charging resistor may fail Note If an external brake chopper outside the drive module is used ABB always requires a main contactor Selecting the default brake system components 1 Calculate the maximum power...

Page 244: ...ller than Rmin This will cause overcurrent that will damage the brake chopper and the drive 2 make sure that the resistance of the custom resistor does not restrict the braking capability needed ie where Maximum power generated by the motor during braking Pmax Drive intermediate DC circuit voltage UDC 1 35 1 2 415 V DC when supply voltage is 380 415 V AC 1 35 1 2 500 V DC when supply voltage is 44...

Page 245: ...r circuit page 102 Connection diagram See section Power cable connection diagram page 105 Connection procedure Connect the resistor cables to the R and R terminals in the same way as the other power cables If a shielded three conductor cable is used cut the third conductor and ground the twisted shield of the cable protective earth conductor of the resistor assembly at both ends Wire the thermal s...

Page 246: ...arameter 43 07 Brake chopper run enable to Other bit and select from parameter 10 01 DI status the digital input where the thermal switch of the brake resistor is wired 5 Set the resistance value of the resistor to parameter 43 10 Brake resistance With these parameter settings the drive generates a fault and coasts to a stop on brake resistor overtemperature WARNING If the drive is equipped with a...

Page 247: ...he resistor when placed correctly PRrcont The ratings apply at an ambient temperature of 40 C 104 F SAFUR resistors The degree of protection of SAFUR resistors is IP00 The resistors are not UL listed The thermal time constant of the resistors is 555 seconds Dimensions weights and ordering codes 234 300 1320 Ø 7 345 1270 ABB ordering code Weight Brake resistor type 68759285 25 kg 55 lb SAFUR125F500...

Page 248: ...248 ...

Page 249: ...IO 01 bipolar analog I O module expands the inputs and outputs of the drive control unit It has three bipolar current voltage inputs and two unipolar current voltage outputs The inputs can handle positive and negative signals The way the drive interprets the negative range of the inputs depends on the parameter settings of the drive The voltage current selection of the inputs is done with a parame...

Page 250: ... signal AI3 82 Cable shield connection SHIELD 93 Cable shield connection SHIELD 83 Analog output 4 signal AO4 94 Analog input 4 positive signal AI4 84 Analog ground potential AGND 95 Analog input 4 negative signal AI4 85 Cable shield connection SHIELD 86 Analog input 5 positive signal AI5 87 Analog input 5 negative signal AI5 88 Control unit slot interface 6 Grounding hole 7 Diagnostic LED 8 Mount...

Page 251: ...e If you ignore them injury or death or damage to the equipment can occur Stop the drive and do the steps in section Electrical safety precautions page 21 before you start the work Necessary tools Screwdriver and a set of suitable bits Wiring Connect the external cables to the applicable module terminals Ground the outer shield of the cables to the SHIELD terminal CAIO 01 11 V 22 mA AI 3 AI 4 AI 5...

Page 252: ...on 1 Set limits for the supervision function 32 09 Supervision 1 low and 32 10 Supervision 1 high Select the supervision action 32 06 Supervision 1 action Connect 32 07 Supervision 1 signal to 15 52 AI3 scaled value Diagnostics LEDs The adapter module has one diagnostic LED Description Color The adapter module is powered up Green There is no communication with the drive control unit or the adapter...

Page 253: ...O and AO 20 ohm Output resistance 10 kohm Recommended load 1 Typical 1 5 Max of full scale value Inaccuracy Optional cable shield connections Isolation areas 2 2 2 Plugged to drive control unit SLOT 2 1 Reinforced insulation IEC 61800 5 1 2007 CAIO 01 bipolar analog I O adapter module 253 ...

Page 254: ...Dimension drawings The dimensions are in millimeters 254 CAIO 01 bipolar analog I O adapter module ...

Page 255: ...cal data Product overview The CBAI 01 includes two bipolar analog inputs two unipolar analog outputs and a switch which can be used to select scaling of the analog output level The module converts the bipolar analog inputs 10 10 V to respective unipolar analog inputs 0 10 V which can be connected to the drive control unit It offers no additional inputs 23 CBAI 01 bipolar analog IO adapter module 2...

Page 256: ... 4 negative signal AI4 84 Cable shield connection SCR 91 Cable shield connection SCR 85 Grounding hole 4 Analog output scale switch 2 2 Diagnostic LED 6 Control unit SLOT 2 interface 5 Grounding hole 7 Mechanical installation Necessary tools Screwdriver and a set of suitable bits Unpacking and examining the delivery 1 Open the option package Make sure that the package contains the option module a ...

Page 257: ...3 24 5 6 80 81 82 AI3 SCR AI3 83 84 85 AI4 SCR AI4 86 87 88 AO3 SCR AGND 89 90 91 AO4 SCR AGND AI1 AGND SCR AI2 AGND 0 10 V 0 10 V 10 V 10 V 10 V 10 V Start up Setting the parameters 1 Power up the drive 2 Verify that the diagnostic LED is on Parameter setting example for AI1 This example shows how to set the control unit parameters for a bipolar speed reference ranging from 50 Hz to 50 Hz with de...

Page 258: ... technical data Ambient conditions Cardboard Package Analog inputs 80 82 83 85 1 5 mm2 Maximum wire size 10 V 10 V Input voltage AI and AI 200 kohm Input resistance Optional cable shield connection Analog outputs 86 88 89 91 1 5 mm2 Maximum wire size 0 V 10 V Output voltage AO and AGND 20 ohm Output resistance 10 kohm Recommended load typical 1 max 1 5 of full scale Inaccuracy Optional cable shiel...

Page 259: ...drive control unit SLOT2 1 Switch 2 Reinforced insulation IEC 61800 5 1 2007 Functional insulation IEC 61800 5 1 2007 Dimension drawing The dimensions are in millimeters and inches 1 A B C D E F 2 3 4 5 6 7 8 Original drawing made with 3D CAD Set the correct scale factor when adding dimensions after DWG DXF conversion First angle projection 31 1 20 109 4 28 59 2 31 71 2 79 ABB Oy PROPRIETARY AND S...

Page 260: ...260 ...

Page 261: ... optional CHDI 01 multifunction extension module The chapter also contains diagnostics and technical data Product overview The CHDI 01 115 230 V digital input extension module expands the inputs of the drive control unit It has six high voltage inputs and two relay outputs 24 CHDI 01 115 230 V digital input extension module 261 ...

Page 262: ...Normally open NO RO4A 52 Neutral point NEUTRAL 1 72 Common C RO5C 53 115 230 V input 3 HDI9 73 Normally closed NC RO5B 54 115 230 V input 4 HDI10 74 Normally open NO RO5A 55 Neutral point NEUTRAL 1 75 Grounding screw 1 115 230 V input 5 HDI11 76 Hole for mounting screw 2 115 230 V input 5 HDI12 77 DiagnosticLED Green Theextensionmodule is powered up 5 Neutral point NEUTRAL 1 78 1 Neutral points 72...

Page 263: ...ables to the applicable module terminals Ground the outer shield of the control cables at the cabinet entry Start up Setting the parameters 1 Power up the drive 2 If no warning is shown make sure that the value of both parameters 15 01 Extension module type and 15 02 Detected extension module is CHDI 01 If warning the A7AB Extension I O configuration failure is shown make sure that the value of pa...

Page 264: ...ts 50 52 53 55 1 5 mm2 Maximum wire size 12 V 10 mA Minimum contact rating 250 V AC 30 V DC 2 A Maximum contact rating 1500 VA Maximum breaking capa city 115 230 V inputs 70 78 1 5 mm2 Maximum wire size 115 to 230 V AC 10 Input voltage 2 mA Maximum current leak age in digital off state Isolation areas HDI CHDI 01 RO5 RO4 HDI HDI 1 Plugged to drive SLOT2 1 Reinforced insulation IEC 61800 5 1 2007 F...

Page 265: ...CHDI 01 115 230 V digital input extension module 265 ...

Page 266: ...266 ...

Page 267: ...sistor output which can operate 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 unit in case the drive power supply is not on If you do not need the backup power supply you do not have to connect it because the module is powered from the drive control unit by default With CCU 24 control unit a ...

Page 268: ...pen NO RO4B 52 3 pin terminal block for for transistor output 4 24 V DC 42 43 44 DO1 SRC DO1 OUT DO1 SGND 1 42 43 44 DO1 SRC DO1 OUT DO1 SGND 2 Common C RO5C 53 Source input DO1 SRC 42 Normally closed NC RO5A 54 Digital or frequency output DO1 OUT 43 Normally open NO RO5B 55 Ground earth potential DO1 SGND 44 1 Digital output connection example 2 An externally supplied frequency indicator which pr...

Page 269: ...ternal control cables to the applicable module terminals Ground the outer shield of the control cables at the cabinet entry WARNING Do not connect the 24 V AC cable to the control unit ground when the control unit is powered using an external 24 V AC supply Start up Setting the parameters 1 Power up the drive 2 If no warning is shown make sure that the value of both parameters 15 01 Extension modu...

Page 270: ...FF delay Parameter setting example for frequency output This example shows how to make digital output DO1 of the extension module indicate the motor speed 0 1500 rpm with a frequency range of 0 10000 Hz Setting Parameter Frequency output 15 22 DO1 configuration 01 01 Motor speed used 15 33 Freq out 1 source 0 15 34 Freq out 1 src min 1500 00 15 35 Freq out 1 src max 1000 Hz 15 36 Freq out 1 at src...

Page 271: ...00 mA 30 V DC short circuit protected Maximum switching cur rent 10 Hz 16 kHz Frequency 1 Hz Resolution 0 2 Inaccuracy External power supply 40 41 1 5 mm2 Maximum wire size 24 V AC V DC 10 GND user potential Input voltage 25 W 1 04 A at 24 V DC Maximum power con sumption Isolation areas DO1 CMOD 01 RO5 RO4 24 Vin 1 Plugged to drive SLOT2 1 Reinforced insulation IEC 61800 5 1 2007 Functional insula...

Page 272: ...272 CMOD 01 multifunction extension module external 24 V AC DC and digital I O ...

Page 273: ...indication relay to the certified Safe torque off input of the drive In addition the extension module has an external power supply interface which can be used to power up the drive control unit in case the drive power supply is not on If you do not need the back up power supply you do not have to connect it because the module is powered from the drive control unit by default There is reinforced in...

Page 274: ...V AC DC input 24 V AC DC in 40 Normally open NO RO PTC B 63 External 24 V AC DC input 24 V AC DC in 41 Grounding screw 1 Motor thermistor connection 5 60 61 PTC IN PTC IN One to six PTC thermistors connected in series Hole for mounting screw 2 PTC connection PTC IN 60 Diagnostic LED 6 Ground earth potential PTC IN 61 Mechanical installation Necessary tools Screwdriver and a set of suitable bits 27...

Page 275: ...Ground the outer shield of the control cables at the cabinet entry WARNING Do not connect the 24 V AC cable to the control unit ground when the control unit is powered using an external 24 V AC supply Start up Setting the parameters 1 Power up the drive 2 If no warning is shown make sure that the values of both parameters 15 01 Extension module type and 15 02 Detected extension module are CMOD 02 ...

Page 276: ...tion The PTC input is reinforced double insulated If the motor part of the PTC sensor and wiring are rein forced double insulated voltages on the PTC wiring are within SELV limits If the motor PTC circuit is not reinforced double insulated ie it is basic insulated it is mandatory to use reinforced double insulated wiring between the motor PTC and CMOD 02 PTC terminal Relay output 62 63 1 5 mm2 Max...

Page 277: ...d to drive SLOT2 1 Reinforced insulation IEC 61800 5 1 2007 Functional insulation IEC 61800 5 1 2007 Dimension drawing The dimensions are in millimeters and inches CMOD 02 multifunction extension module external 24 V AC DC and isolated PTC interface 277 ...

Page 278: ...278 ...

Page 279: ...d drive page 74 Selection table The du dt filter types for the drive module types are given below du dt filter type Frame FOCH0610 70 R10 FOCH0875 70 R11 Ordering codes ABB ordering code Filter type 68550505 FOCH 0610 70 3AUA0000129544 FOCH 0875 70 Description installation and technical data of the FOCH filters See FOCH du dt filters hardware manual 3AFE68577519 English 27 Filters 279 ...

Page 280: ...280 ...

Page 281: ...zed as live working Continue only if you are an electrical professional certified for the work Obey the local regulations If you ignore them injury or death can occur To identify the grounding system examine the supply transformer connection See the applicable electrical diagrams of the building If that is not possible measure these voltages at the distribution board and use the table to define th...

Page 282: ... level versus time Varying level versus time X TT system the protective earth connection for the consumer is provided by a local earth electrode and there is another independently installed at the generator Varying level versus time Varying level versus time Varying level versus time X When to disconnect ground to phase varistor TN S IT corner grounded delta and mid point grounded delta systems Sy...

Page 283: ...stem under these conditions 1 There is a residual current device in the supply system 2 The ground to phase varistor is disconnected If the varistor is not disconnected its leakage current will cause the residual current device to trip Note ABB does not guarantee the functioning of the ground leakage detector built inside the drive In large systems the residual current device can trip without a re...

Page 284: ...t the varistor VAR grounding wire The varistor grounding wire is adjacent to the control circuit compartment Refer to the image that follows 2 Insulate the end of the varistor grounding wire Attach the wire to the module frame with a cable tie 284 Ground to phase varistor disconnecting instructions IEC not North America ...

Page 285: ...tegorized as live working Continue only if you are an electrical professional certified for the work Obey the local regulations If you ignore them injury or death can occur To identify the grounding system examine the supply transformer connection See the applicable electrical diagrams of the building If that is not possible measure these voltages at the distribution board and use the table to def...

Page 286: ...el versus time Varying level versus time X TT system the protective earth connection for the consumer is provided by a local earth electrode and there is another independently installed at the generator Varying level versus time Varying level versus time Varying level versus time X When you can connect the EMC filter and ground to phase varistor TN S IT corner grounded delta and mid point grounded...

Page 287: ... to a symmetrically grounded TN S system corner grounded delta or mid point grounded delta system you can connect the internal EMC filter Contact ABB for the connection instructions Connecting ground to phase varistor North America This section is valid the UL NEC drive types The internal ground to phase varistor of the drive is disconnected as default If you install the drive to TN S system corne...

Page 288: ...288 Step by step drawings for an installation example of a drive module with the B051 option in a Rittal VX25 600 mm wide enclosure ...

Page 289: ...0 lbf in Combi screw M8 30 Hex 20 N m 14 75 lbf ft Combi screw M4 8 Torx T20 2 N m 18 lbf in Combi screw M4 8 Torx T20 2 N m 18 lbf in M6x20 Torx T25 8 N m 71 lbf in Combi screw M8 30 Hex 20 N m 14 75 lbf ft Tapping screw M6 12 Torx T30 Hex 9 N m 80 lbf in M8 Kalei nut or similar 2 pcs Step by step drawings for an installation example of a drive module with the B051 option in a Rittal VX25 600 mm ...

Page 290: ...x T25 8 N m 71 lbf in Combi screw M12 25 Hex 70 N m 52 lbf ft Hex screw M12 35 full thread 70 N m 52 lbf ft Washer M12 or equal Hex nut M12 70 N m 52 lbf ft Washer M12 or equal 290 Step by step drawings for an installation example of a drive module with the B051 option in a Rittal VX25 600 mm wide enclosure ...

Page 291: ... 70 N m 52 lbf ft Washer M12 or equal Combi screw M6 20 Torx T25 2 N m 18 lbf in Combi screw M4 8 Torx T20 2 N m 18 lbf in Combi screw M6 20 Torx T25 2 N m 18 lbf in Combi screw M4 10 Torx T20 2 N m 18 lbf in B051 B051 B051 B051 B051 Step by step drawings for an installation example of a drive module with the B051 option in a Rittal VX25 600 mm wide enclosure 291 ...

Page 292: ...1 These air baffles are compatible with option B051 only 1 292 Step by step drawings for an installation example of a drive module with the B051 option in a Rittal VX25 600 mm wide enclosure ...

Page 293: ...arts not ABB or Rittal product Air baffles 5 Installation procedure 1 Install three Rittal support rails 4396 500 on the bottom of the enclosure 2 Install the pedestal guide onto the support rails 3 Install the Rittal punched sections 8617 030 5 pcs 4 Install the Rittal punched sections 8617 010 3 pcs Step by step drawings for installing full cabling panels option H381 in a Rittal VX25 400 mm wide...

Page 294: ...e guides to the output cabling panel 2 screws for each side guide 9 Attach the grounding busbar to the input cabling panel Back view is shown above 10 Attach the input cabling panel to the punched section 11 Install the telescopic extraction and insertion ramp 294 Step by step drawings for installing full cabling panels option H381 in a Rittal VX25 400 mm wide enclosure ...

Page 295: ...3AXD50000439317 Step by step drawings for installing full cabling panels option H381 in a Rittal VX25 400 mm wide enclosure 295 ...

Page 296: ...3AXD50000439317 296 Step by step drawings for installing full cabling panels option H381 in a Rittal VX25 400 mm wide enclosure ...

Page 297: ... by navigating to www abb com searchchannels Product training For information on ABB product training navigate to new abb com service training Providing feedback on ABB manuals Your comments on our manuals are welcome Navigate to new abb com drives manuals feedback form Document library on the Internet You can find manuals and other product documents in PDF format on the Internet at www abb com dr...

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