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ABB ACS580-07-0495A-4, Hardware Manual

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ABB ACS580-07-0495A-4 Hardware Manual Download Page 9

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Table of contents

1. Safety instructions

Contents of this chapter   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Use of warnings   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
General safety in installation, start-up and maintenance   . . . . . . . . . . . . . . . . . . . . . . . . 14
Electrical safety in installation, start-up and maintenance   . . . . . . . . . . . . . . . . . . . . . . . 16

Precautions before electrical work  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Additional instructions and notes  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Additional instructions for permanent magnet motor drives   . . . . . . . . . . . . . . . . . . . . . . 19

Safety in installation, start-up and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

2. Introduction to the manual

Contents of this chapter   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Target audience   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Contents of the manual  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Related manuals  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Categorization by frame size and option code   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Quick installation, start-up and operating flowchart   . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Terms and abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

3. Operation principle and hardware description

Contents of this chapter   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Product overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Single-line circuit diagram of the drive  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
General information on the cabinet layout  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Cabinet layout – bottom entry and exit of cables  . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Overview of power and control connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Door switches and lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Main switch-disconnector Q1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Control panel   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Control by PC tools   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Common mode filter  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Descriptions of cabinet options  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Degree of protection  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Definitions   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
IP42 and UL Type 1 Filtered (standard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
IP54 and UL Type 12 (B055)   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Empty cubicles (oC196 to +C201)  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
du/dt filter (E205)  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Cabinet heater with external supply (G300)   . . . . . . . . . . . . . . . . . . . . . . . . . 33
UK gland/conduit plate (H358) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Additional terminal block X504 (L504)  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Type designation label   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Type designation key   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Summary of Contents for ACS580-07-0495A-4

Page 1: ...ABB general purpose drives Hardware manual ACS580 07 drives 250 to 500 kW ...

Page 2: ...r ACS580 07 drives user s manual 3AXD50000032016 CPTC 02 ATEX certified thermistor protection module Ex II 2 GD L537 Q971 user s manual 3AXD50000030058 FCAN 01 CANopen adapter module user s manual 3AFE68615500 FCNA 01 ControlNet adapter module user s manual 3AUA0000141650 FDNA 01 DeviceNet adapter module user s manual 3AFE68573360 FECA 01 EtherCAT adapter module user s manual 3AFE68573360 FENA 01 ...

Page 3: ...re manual ACS580 07 drives 3AXD50000032622 Rev A EN EFFECTIVE 2016 03 16 2016 ABB Oy All Rights Reserved 1 Safety instructions 4 Mechanical installation Table of contents 6 Electrical installation 9 Start up ...

Page 4: ......

Page 5: ...rature supervision of the cabinet is connected between DI6 and 24V aux voltage supply If DI6 is to be used for another purpose see section Changing internal overtemperature supervision from DI6 to another digital input on page 2 This notice concerns ACS580 07 hardware manual 3AXD50000032622 English Rev A Code 3AXD50000131464 Rev A Valid from 2 6 2017 until the release of revision B of the manual C...

Page 6: ...the firmware manual WARNING Always connect the internal overtemperature supervision of the drive cabinet to a free digital input or CMOD 01 multifunction extension module if disconnected from digital input DI6 Activate the change Disconnection of overtemperature supervision leads to overtemperature and can damage the drive PNP configuration for digital inputs DIGITAL IN CHANGED Note By default dig...

Page 7: ... to be changed see section Changing internal overtemperature supervision from DI6 to another digital input on page 2 Internal 24 V power supply External 24 V power supply 10 24V 11 DGND 12 DCOM 13 DI1 14 DI2 15 DI3 16 DI4 17 DI5 18 DI6 NPN connection sink NPN connection sink 10 24V 11 DGND 12 DCOM 13 DI1 14 DI2 15 DI3 16 DI4 17 DI5 18 DI6 0 V DC 24 V DC X504 10 X504 18 X504 10 X504 18 ...

Page 8: ...4 Update notice ...

Page 9: ... 22 Terms and abbreviations 23 3 Operation principle and hardware description Contents of this chapter 25 Product overview 25 Single line circuit diagram of the drive 26 General information on the cabinet layout 26 Cabinet layout bottom entry and exit of cables 27 Overview of power and control connections 29 Door switches and lights 31 Main switch disconnector Q1 31 Control panel 32 Control by PC ...

Page 10: ...9 Selecting the main contactor 49 Protecting the motor insulation and bearings 50 Examining the compatibility of the motor and drive 50 Requirements table 51 Additional requirements for ABB motors of types other than M2_ M3_ M4_ HX_ and AM_ 52 Additional requirements for ABB high output and IP23 motors 52 Additional requirements for non ABB high output and IP23 motors 52 Additional data for calcul...

Page 11: ...otor power supply from direct on line to drive 63 Protecting the contacts of relay outputs 63 Connecting a motor temperature sensor to the drive I O 64 6 Electrical installation Contents of this chapter 65 Warnings 65 Checking the insulation of the assembly 65 Drive 65 Input cable 65 Motor and motor cable 66 Attaching the device stickers on the cabinet door 66 Connecting the power cables 67 Connec...

Page 12: ... up procedure 91 Checks Settings with no voltage connected 91 Powering up the drive 91 Start up with the First start assistant on an assistant panel 92 Setting up the drive parameters and performing the first start 92 On load checks 92 10 Fault tracing Contents of this chapter 97 Warning and fault messages 97 11 Maintenance Contents of this chapter 99 Maintenance intervals 99 Descriptions of symbo...

Page 13: ... the power cables 121 IEC 121 Terminal data for the control cables 124 Electrical power network specification 125 Motor connection data 125 Control unit connection data 125 Efficiency 125 Protection classes 125 Ambient conditions 126 Auxiliary circuit power consumption 127 Materials 127 CE marking 128 Compliance with the European Low Voltage Directive 128 Compliance with the European EMC Directive...

Page 14: ...ety instructions 149 Hardware description 149 Product overview 149 Layout 150 Mechanical installation 150 Necessary tools and instructions 150 Unpacking and checking the delivery 150 Installing the module 150 Electrical installation 151 Warnings 151 Necessary tools and instructions 151 Terminal designations 151 General cabling instructions 151 Wiring 151 Start up 152 Setting the parameters 152 Dia...

Page 15: ... installation 163 Necessary tools and instructions 163 Unpacking and checking the delivery 163 Installing the module 163 Electrical installation 164 Warnings 164 Necessary tools and instructions 164 Terminal designations 164 General cabling instructions 164 Wiring 164 Start up 165 Setting the parameters 165 Diagnostics 166 Faults and warning messages 166 LEDs 166 Technical data 166 CPTC 02 ATEX ce...

Page 16: ...12 ...

Page 17: ...s which can cause injury or death or damage to the equipment They also tell you how to prevent the danger The manual uses these warning symbols Electricity warning tells about hazards from electricity which can cause injury or death or damage to the equipment General warning tells about conditions other than those caused by electricity which can cause injury or death or damage to the equipment Ele...

Page 18: ...of gravity Wear protective gloves and long sleeves Some parts have sharp edges Handle the drive module carefully Use safety shoes with a metal toe cap to avoid foot injury Lift the module with a lifting device only Use the designated lifting points Make sure that the module does not topple over when you move it on the floor Extend the support legs by pressing each leg a little down 1 2 and turning...

Page 19: ... or malfunction Vacuum clean the area below the drive before the start up to prevent the drive cooling fan from drawing the dust inside the drive Make sure that there is sufficient cooling See section Examining the installation site on page 39 Before you connect voltage to the drive make sure that the cabinet doors are closed Keep the doors closed during the operation Before you adjust the drive o...

Page 20: ...le voltage sources Open the main switch disconnector Q1 of the drive Open the disconnector of the supply transformer as the main switch disconnector Q1 of the drive does not remove the voltage from the input busbars of the drive Make sure that reconnection is not possible Lock the disconnectors to open position and attach a warning notice to them Disconnect any external power sources from the cont...

Page 21: ...t a dangerous voltage when the input power is on regardless of whether the motor is running or not External wiring can supply dangerous voltages to the terminals of relay outputs XRO1 XRO2 and XRO3 The Safe torque off function does not remove the voltage from the main and auxiliary circuits The function is not effective against deliberate sabotage or misuse WARNING Use a grounding wrist band when ...

Page 22: ...of the grounding conductors is sufficient See section Selecting the power cables on page 53 Obey the local regulations Connect the power cable shields to protective earth PE of the drive to make sure of personnel safety Make a 360 grounding of the power and control cable shields at the cable entries to suppress electromagnetic disturbances In a multiple drive installation connect each drive separa...

Page 23: ...If you cannot disconnect the motor make sure that the motor cannot rotate during work Make sure that no other system like hydraulic crawling drives can rotate the motor directly or through any mechanical connection like felt nip rope etc Measure that the installation is de energized Use a multimeter with an impedance of at least 1 Mohm Make sure that the voltage between the drive output terminals ...

Page 24: ...20 Safety instructions ...

Page 25: ...hematic symbols The manual is written for readers worldwide Both SI and imperial units are shown Contents of the manual This manual contains the instructions and information for the basic drive configuration The chapters of the manual are briefly described below Safety instructions gives safety instructions for the installation start up operation and maintenance of the drive Introduction to the ma...

Page 26: ...on modules their installation start up diagnostics and technical data Related manuals See List of related manuals on the inside of the front cover Categorization by frame size and option code Some instructions technical data and dimension drawings which concern only certain frame sizes are marked with the symbol of the frame size R10 or R11 The frame size is marked on the type designation label se...

Page 27: ... up Start up page 91 Operate the drive start stop speed control etc Start up page 91 and firmware manual Term Abbreviation Explanation EMC Electromagnetic compatibility FCAN 01 Optional FCAN 01 CANopen adapter module FCNA 01 Optional ControlNet adapter module FDCO 01 Optional DDCS communication module with two pairs of 10 Mbit s DDCS channels FDNA 01 Optional DeviceNet adapter module FECA 01 Optio...

Page 28: ...ldbus adapter module CHDI 01 Optional 115 230 V digital input extension module CMOD 01 Optional multifunction extension module external 24 V AC DC and digital I O extension CMOD 02 Optional multifunction extension module external 24 V AC DC and isolated PTC interface CPTC 02 Optional ATEX certified thermistor protection module R10 R11 Frame size designation of the drive STO Safe torque off Term Ab...

Page 29: ...rdware description Contents of this chapter This chapter briefly describes the operation principle and construction of the drive Product overview The ACS580 07 is an air cooled cabinet installed drive for controlling asynchronous AC induction motors and permanent magnet motors ...

Page 30: ...witch disconnector Q2 Optional line contactor F250 T21 Auxiliary voltage transformer supplying 24 V and 230 115 V control voltage for eg cabinet fan s control devices and I O extension adapter module T1 Drive module with common mode filter R12 Optional du dt filter E205 Q1 Q2 L1 L2 L3 M 3 T21 T1 IP42 IP54 UL Type 1 Filtered UL Type 12 ...

Page 31: ...hown below See also the next page A Main breaker and power cabling cubicle B Drive module cubicle 1 Drive control panel See the next page 2 Operating switch 3 Main switch handle 4 Buffering module 5 Swing out frame 6 Mounting plate with connection terminals for cabinet heater option G300 7 Cabinet fan 2 3 1 B A 4 5 6 7 ...

Page 32: ...an transformer with option B055 8 Drive module 2 AC fuses 9 Control unit see page 79 3 Main switch disconnector 10 Optional terminal block for control unit connections X504 option L504 4 Input and motor cable connection terminals 11 Auxiliary voltage transformer T21 5 PE terminal 12 Cabinet heater 6 Connection terminals for options F250 and Q951 See page 30 7 Power and control cable lead throughs ...

Page 33: ... Option slot 3 for optional embedded fieldbus adapter modules 4 Panel port 5 I O terminal blocks See section Layout on page 80 and section Default I O connection diagram on page 81 6 Control panel see page 32 7 Connection terminals for options see page 30 8 Additional terminal block X504 for control cable connections to the control unit option L504 see page 34 9 du dt option E205 see page 33 L1 L2...

Page 34: ...epends on the options selected X969 2 4 1 3 X951 8 8 7 7 6 6 5 5 4 4 3 3 2 2 1 1 X250 4 4 3 3 2 2 1 1 PE1 PE1 X250 X969 X951 X506 X965 Terminals for X250 Auxiliary contacts of optional line contactor F250 X506 Not in use X951 Push buttons for emergency stop option Q951 X957 Not in use X965 Not in use X969 External STO customer connection for safety option Q951 X957 ...

Page 35: ...DY Ready pilot light option G327 2 RUN Run pilot light option G328 3 FAULT Fault pilot light option G329 4 MAIN CONT Operating switch with option F250 5 EMERGENCY STOP RESET Emergency stop reset push button with option Q951 6 EMERGENCY STOP Emergency stop push button with option Q951 The layout depends on the options selected 1 2 3 4 5 6 OFF ON 0 Opens the main contactor Q2 and disables starting o...

Page 36: ...al 3AUA0000085685 English Control by PC tools There is a USB connector on the front of the panel that can be used to connect a PC to the drive When a PC is connected to the control panel the control panel keypad is disabled Common mode filter The drive is equipped with a common mode filter as standard The filter contains ferrite rings mounted around the drive AC busbars The filter protects the mot...

Page 37: ...ft hand side of the converter cubicle 400 mm wide with option C199 600 mm wide with option C200 and 800 mm wide with option C201 du dt filter option E205 The du dt filter protects the motor insulating system by reducing the voltage rise speed at the motor terminals The filter also protects the motor bearings by reducing the bearing currents More information on when the option is required See secti...

Page 38: ...m2 24 to 14 AWG stranded wire without ferrule 0 08 to 2 5 mm2 28 to 14 AWG Stripping length 10 mm 0 5 in Note The option modules inserted in the slots of the control unit are not wired to the additional terminal block The customer must connect the option module control wires directly to the modules Type designation label The type designation label includes an IEC rating appropriate markings a type...

Page 39: ...es 07 When no options are selected cabinet installed drive IP42 UL Type 1 main switch disconnector AC fuses ACS AP S assistant control panel EMC filtering for second environment TN and IT grounded and ungrounded systems category C3 input AC choke common mode filter coated boards ACS580 control program RS 485 Modbus RTU adapter module CEIA 01 Safe torque off function bottom entry and exit of cables...

Page 40: ... TCP and PROFINET IO protocols K475 FENA 21 Ethernet adapter module for EtherNet IP Modbus TCP and PROFINET IO protocols 2 port I O extensions and feedback interfaces L501 CMOD 01 external 24 V DC AC and digital I O extension module two relay outputs and one digital output L504 Additional I O terminal block L512 CHDI 01 115 230 V digital input extension module six digital inputs and two relay outp...

Page 41: ...Operation principle and hardware description 37 R703 Dutch R704 Danish R705 Swedish R706 Finnish R707 French R708 Spanish R709 Portuguese R711 Russian Code Description ...

Page 42: ...38 Operation principle and hardware description ...

Page 43: ...d the unit is of non flammable material There is enough free space above the drive to enable cooling air flow service and maintenance The floor that the unit is installed on is of non flammable material as smooth as possible and strong enough to support the weight of the unit Check the floor flatness with a spirit level The maximum allowed deviation from the surface level is 5 mm 0 2 in in every 3...

Page 44: ...be used when replacing the drive modules that run on wheels Necessary tools The tools required for moving the unit to its final position fastening it to the floor and wall and tightening the connections are listed below crane fork lift or pallet truck check load capacity iron bar jack and rollers Pozidriv and Torx 2 5 6 mm screwdrivers torque wrench set of wrenches or sockets ...

Page 45: ...avoid damaging the cabinet surfaces and door devices When you use a pallet truck check its load capacity before you move the drive Note Transportation of the cabinet on its back is only allowed if it is packed for such transportation at the factory A Lifting the transport package with slings 1 Lifting points B Lifting the transport package with forklift 1088 2321 A B 1 ...

Page 46: ...ection Checking the delivery on page 42 lift the drive cabinet to its installation place see section Lifting the cabinet on page 43 Checking the delivery The drive delivery contains drive cabinet line up option modules if ordered installed onto the control unit at the factory appropriate drive and option module manuals delivery documents Check that there are no signs of damage Before attempting in...

Page 47: ... of IP54 UL Type 12 cabinets is 2 meters 6 5 ft Moving the cabinet after unpacking Move drive cabinet carefully in the upright position Avoid tilting The center of gravity of the cabinet is high Laying the cabinet on its back If the cabinet needs to be laid on its back support it from below beside the cubicle seams 1 cabinet back panel 2 support IP54 IP42 Max 20 UL Type 1 Filtered UL Type 12 1 2 2...

Page 48: ... it carefully until close to its final location Remove the rollers by lifting the unit with a crane fork lift pallet truck or jack Move the cabinet into its final position with an iron bar Place a wooden piece at the bottom edge of the cabinet in order not to damage the cabinet frame with the iron bar ...

Page 49: ...oof as follows 1 Undo the mounting screws of the front top profile of the cabinet and remove it Undo the back mounting screws of the roof from the cabinet top 2 Connect the power supply wires to the fan 3 Install the front top profile of the cabinet in reverse order to step 1 4 Attach the back mounting screws of the roof 2 3 1 4 1 ...

Page 50: ...IP54 UL Type 12 fan replacement requires 320 mm 12 6 in free space above Leave some space at the side where the cabinet outmost hinges are to allow the doors to open sufficiently w The doors must open 120 to allow the drive module replacement Note 1 Make height adjustments before attaching the cabinet with metal shims between the cabinet bottom and the floor Note 2 If you remove the lifting eyes a...

Page 51: ... The recommended maximum distance between the clamps in the front edge is 800 mm 31 5 2 If floor mounting from back is not possible attach the cabinet at the top to wall with L brackets not included in the delivery using the lifting lug attaching holes 1 Attach the cabinet to the floor through the bottom attaching holes with M10 to M12 3 8 to 1 2 bolts The recommended maximum distance between the ...

Page 52: ...rotection and EMC compliance Arc welding ABB does not recommend attaching of the cabinet by arc welding However if arc welding is the only mounting option proceed as follows Connect the return conductor of the welding equipment to the cabinet frame at the bottom within 0 5 meters 1 5 ft of the welding point Note The thickness of the zinc coating of the cabinet frame is 100 to 200 micrometers WARNI...

Page 53: ...s be designed and made according to applicable local laws and regulations ABB does not assume any liability whatsoever 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 supply disconnecting device The drive is equipped with a ma...

Page 54: ...end non drive end bearings protect the motor bearings Examining the compatibility of the motor and drive Use an asynchronous AC induction motor permanent magnet synchronous motor AC induction servomotor or ABB synchronous reluctance motor SynRM motor with the drive Several induction motors can be connected to the drive at a time Select the motor size and drive type from to the rating tables in cha...

Page 55: ...3_and M4_ UN 500 V Standard N N CMF Form wound HX_and AM_ 380 V UN 690 V Standard N CMF PN 500 kW N CMF PN 500 kW N du dt CMF Old form wound HX_and modular 380 V UN 690 V Check with the motor manufacturer N du dt with voltages over 500 V CMF Random wound HX_and AM_ 0 V UN 500 V Enamelled wire with fiber glass taping N CMF HDP Consult the motor manufacturer manufactured before 1 1 1998 For motors m...

Page 56: ...or the particular frame size in EN 50347 2001 The table below shows the requirements for random wound and form wound non ABB motors with nominal power smaller than 350 kW For bigger motors consult the motor manufacturer CMF Common mode filter option E208 N N end bearing insulated motor non drive end bearing Nominal AC supply voltage Requirement for Motor insulation system ABB du dt and common mode...

Page 57: ...t the input power and motor cables according to local regulations Select a cable capable of carrying the drive nominal current See section Ratings page 117 for the rated currents Select a cable rated for at least 70 C maximum permissible temperature of conductor in continuous use Make sure that the inductance and impedance of the PE conductor cable grounding wire is rated according to permissible ...

Page 58: ... The table below gives copper and aluminum cable types with concentric copper shield for the drives with nominal current For the cable sizes accepted by the drive cabinet lead throughs and connection terminals see page 121 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 t...

Page 59: ...trical shielded cable with three phase conductors and a concentric PE conductor as shield The shield must meet the requirements of IEC 61439 1 see section Motor cable shield on page 53 Check with local state country electrical codes for allowance Symmetrical shielded cable with three phase conductors and a concentric PE conductor as shield A separate PE conductor is required if the shield does not...

Page 60: ...signals The relay controlled signals should be run as twisted pairs Relay cable type The cable type with braided metallic screen for example ÖLFLEX by LAPPKABEL Germany has been tested and approved by ABB Control panel cable length and type In remote use the cable that connects the control panel to the drive must not be longer than three meters 10 ft Cable type shielded CAT 5e or better Ethernet p...

Page 61: ...nsulation sleeving for 230 V 120 V Continuous motor cable shield or enclosure for equipment on the motor cable To minimize the emission level when safety switches contactors connection boxes or similar equipment are installed on the motor cable between the drive and the motor European Union Install the equipment in a metal enclosure with 360 degree grounding for the shields of both the incoming an...

Page 62: ...e sized according to the nominal current of the drive No additional thermal protection devices are needed WARNING If the drive is connected to multiple motors use a separate circuit breaker or fuses for protecting each motor cable and motor against overload The drive overload protection is tuned for the total motor load It may not trip due to an overload in one motor circuit only Protecting the mo...

Page 63: ...on Implementing the emergency stop function The drive can be equipped with emergency stop function of stop category 0 For safety reasons install the emergency stop devices at each operator control station and at other operating stations where emergency stop can be needed Note Pressing the stop key on the control panel of the drive or turning the operating switch of the drive from position 1 to 0 d...

Page 64: ... the drive trips on undervoltage it must be reset and started again to continue operation If the power loss situation lasts so long that the buffering module C22 empties the main contactor remains open and the drive operates only after reset and a new start Supplying power for the auxiliary circuits The drive is equipped with an auxiliary control voltage transformer which supplies control voltage ...

Page 65: ...tactor WARNING When the vector control mode is in use never open the output contactor while the drive controls the motor The vector control operates extremely fast much faster than it takes for the contactor to open its contacts When the contactor starts opening while the drive controls the motor the vector control will try to maintain the load current by immediately increasing the drive output vo...

Page 66: ... mode 2 Open the main contactor of the drive with S11 3 Switch the motor power supply from the drive to direct on line with S40 4 Wait for 10 seconds to allow the motor magnetization to die away 5 Start the motor with S41 Q1 Drive main switch S11 Drive main contactor on off control Q4 Bypass circuit breaker S40 Motor power supply selection drive or direct on line K1 Drive main contactor S41 Start ...

Page 67: ...e Protecting the contacts of relay outputs Inductive loads relays contactors motors cause voltage transients when switched off ABB highly recommends to equip inductive loads with noise attenuating circuits varistors RC filters AC or diodes DC in order to minimize the EMC emission at switch off If not suppressed the disturbances can connect capacitively or inductively to other conductors in the con...

Page 68: ... inputs of the drive are protected against contact and insulated with basic insulation the same voltage level as the drive main circuit from other low voltage circuits Another way is to use an optional thermistor protection module or an external thermistor relay The insulation of the relay must be rated for the same voltage level as the main circuit of the drive For connection to the relay see the...

Page 69: ...eath or damage to the equipment can occur Checking the insulation of the assembly Drive Do not make any voltage tolerance or insulation resistance tests on any part of the drive as testing can damage the drive Every drive has been tested for insulation between the main circuit and the chassis at the factory Also there are voltage limiting circuits inside the drive which cut down the testing voltag...

Page 70: ...f an ABB motor must exceed 100 Mohm reference value at 25 C or 77 F For the insulation resistance of other motors consult the manufacturer s instructions Note Moisture inside the motor casing will reduce the insulation resistance If moisture is suspected dry the motor and repeat the measurement Attaching the device stickers on the cabinet door A multilingual device label sticker is delivered with ...

Page 71: ...ter option E205 7 Use a separate grounding cable if the shield does not meet the requirements of IEC 61439 1 see page 53 and there is no symmetrically constructed grounding conductor in the cable see page 54 8 Drive module Note If there is a symmetrically constructed grounding conductor on the motor cable in addition to the conductive shield connect the grounding conductor to the grounding termina...

Page 72: ...ft the plate up Unplug the fan supply cables 6 Remove the shrouds on the power cable terminals 7 Peel off 3 to 5 cm of the outer insulation of the cables above the lead through plate for the 360 high frequency grounding 8 Prepare the ends of the cables WARNING Apply grease to stripped aluminum conductors before attaching them to non coated aluminum cable lugs Obey the grease manufacturer s instruc...

Page 73: ...able ties 13 Seal the slot between the cable and mineral wool sheet if used with sealing compound eg CSD F ABB brand name DXXT 11 code 35080082 14 Tie up the unused conductive sleeves with cable ties 15 Connect the twisted shields of the motor cables to the ground bar and the phase conductors to the U2 V2 and W2 terminals 16 Connect the twisted shields of the input cables and separate ground cable...

Page 74: ...70 Electrical installation PE PE 8 PE 13 11 7 8 12 13 ...

Page 75: ... cables as described under Control cable connection procedure on page 71 Control cable connection procedure WARNING Obey the instructions in chapter Safety instructions If you ignore them injury or death or damage to the equipment can occur 1 Stop the drive and do the steps in section Precautions before electrical work on page 16 before you start the work 2 Run the control cables to the inside of ...

Page 76: ...ugh plate just enough to ensure proper connection of the bare shield and the EMI conductive cushions 4 Tighten the two tightening screws so that the EMI conductive cushions press tightly round the bare shield Note 1 Keep the shields continuous as close to the connection terminals as possible Secure the cables mechanically at the lead through strain relief Note 2 If the outer surface of the shield ...

Page 77: ...n each group according to size 4 Group the cables for each grommet as follows ensuring that each cable has a proper contact to the cushions on both sides 5 Divide the bunches so that cables will be arranged according to size from thickest to the thinnest between the EMI conductive cushions 6 If more than one cable go through a grommet seal the grommet by applying Loctite 5221 catalogue number 2555...

Page 78: ...ssible Twisting the wire with its return wire reduces disturbances caused by inductive coupling Note Leave slack to the control wires to make it possible to lift the control unit mounting plate a little when the drive module is replaced Drives without additional I O terminal block option L504 Ground the pair cable shields and all grounding wires to the clamp next to the control unit as shown below...

Page 79: ...p between the end points Connect the conductors to the appropriate terminals see page 81 of the control unit or optional terminal block X504 Connecting the emergency stop push buttons options Q951 Connect the emergency stop push buttons to terminals according to the circuit diagrams delivered with the drive Connecting the external power supply cables for the cabinet heater and lighting and motor h...

Page 80: ...ing the panel into the panel holder WARNING Do not connect the PC directly to the control panel connector of the control unit as this can cause damage 2 Lift the USB connector cover on the control panel from bottom upwards 3 Connect an USB cable Type A to Type Mini B between the USB connector on the control panel 3a and a free USB port on the PC 3b 4 The panel displays an indication whenever the c...

Page 81: ...outward and put the other module carefully into its position Option slot 2 I O extension modules 1 Put the module carefully into its position on the control unit 2 Tighten the mounting screw 3 Tighten the grounding screw CHASSIS to 0 8 N m Note The screw grounds the module It is necessary for fulfilling the EMC requirements and for correct operation of the module Option slot 1 fieldbus adapter mod...

Page 82: ...78 Electrical installation ...

Page 83: ...Control unit 79 7 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 12 ...

Page 84: ...Safe torque off connection FAN2 Internal fan 2 connection FAN1 Internal fan 1 connection X12 Panel port control panel connection wired at the factory to the control panel X15 Reserved to internal use SLOT 3 Embedded EIA R5 485 fieldbus module CEIA 01 is installed on SLOT 3 as standard BIAS S101 Bias resistor switch TERM S100 End termination switch 29 31 Connection terminals of the CEIA 01 SLOT 2 O...

Page 85: ...0 mA 4 11 DGND Auxiliary voltage output common 12 DCOM Digital input common for all Programmable digital inputs DI1 DI3 13 DI1 Stop 0 Start 1 14 DI2 Forward 0 Reverse 1 15 DI3 Constant frequency speed selection 6 Programmable digital inputs DI4 DI6 16 DI4 Constant frequency speed selection 6 17 DI5 Ramp set1 0 Ramp set 2 1 7 18 DI6 Not configured Relay outputs 19 RO1C Ready run 250 V AC 30 V DC 2 ...

Page 86: ...group 22 Speed reference selection 7 In scalar control default See Menu Primary settings Ramps or parameter group 28 Frequency reference chain In vector control See Menu Primary settings Ramps or parameter group 23 Speed reference ramp 8 Connected with jumpers at the factory unless with options L537 and Q951 9 Note Use shielded twisted pair cables for digital signals 10 Ground the outer shield of ...

Page 87: ...t Current I default Voltage U TERM Drive to drive link termination Must be set to the terminated ON position when the drive or another device is the first or last unit on the link Bus not terminated default Bus terminated BIAS 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 off default Bias on U I AI1 U I AI1 U I AI2 U...

Page 88: ...ound AGND Examples are shown in the figure below Internal 24 V power supply External 24 V power supply 10 24V 11 DGND 12 DCOM 13 DI1 14 DI2 15 DI3 16 DI4 17 DI5 18 DI6 NPN connection sink NPN connection sink 10 24V 11 DGND 12 DCOM 13 DI1 14 DI2 15 DI3 16 DI4 17 DI5 18 DI6 0 V DC 24 V DC 8 AO2 Analog output 2 Default output 0 20 mA 9 AGND Analog common ground Internally connected to chassis through...

Page 89: ... 4 20 mA not 0 20 mA An example of a three wire sensor transmitter supplied by the drive auxiliary voltage output is shown below DI6 as frequency input If DI6 is used as a frequency input see the firmware manual for how to set parameters accordingly 5 AI2 Process actual value measurement or reference 0 4 20 mA Rin 100 ohm 6 AGND 10 24V Auxiliary voltage output non isolated 24 V DC max 250 mA 11 DG...

Page 90: ...ent the I O board terminals must be protected against contact and must not be connected to other equipment or the temperature sensor must be isolated from the I O terminals Safe torque off STO 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 t...

Page 91: ...l size 0 14 2 5 mm2 Analog inputs AI1 and AI2 Term 2 and 5 Current voltage input mode selected with a dip switch see page 86 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 Inaccuracy typical 1 max 1 5 of full scale Inaccuracy for Pt100 sensors 10 C 50 F Analog outputs AO1 and AO2 Term 7 and 8 Current voltage output mode for AO1 selected with a di...

Page 92: ...higher voltages relay outputs Note There is reinforced insulation also between the individual relay outputs Note There is reinforced insulation on the power unit Symbol Description Reinforced insulation IEC EN 61800 5 1 2007 19 21 RO1 22 24 RO2 25 27 RO3 SLOT 3 Embedded fieldbus module 34 38 STO 40 41 Ext 24 V Power unit connection 10 12 24 V GND 13 15 DI 16 18 DI 1 3 AI1 4 6 AI2 7 8 AO SLOT 1 Fie...

Page 93: ...ctrical work on page 16 before you start the work Go through the checklist together with another person Check that The ambient operating conditions meet the specifications given in chapter Technical data The drive cabinet has been fixed to floor and if necessary due to vibration etc also from top to the wall or roof The cooling air will flow freely in and out of the drive cabinet If the drive has ...

Page 94: ...nd the terminals have been tightened Pull the conductors to check The motor cable has been connected to the appropriate terminals the phase order is right and the terminals have been tightened Pull the conductors to check The motor cable and brake resistor cable if present has been routed away from other cables No power factor compensation capacitors have been connected to the motor cable If a dri...

Page 95: ...y the safety instructions during the start up procedure See chapter Safety instructions on page 13 Checks Settings with no voltage connected Check the mechanical and electrical installation of the drive See Installation checklist on page 89 Powering up the drive Close the cabinet doors Make sure that it is safe to connect voltage Ensure that cabinet doors are closed nobody is working on the drive ...

Page 96: ...drive firmware manual Not all control programs include assistants Check that the communication works between the drive and the PLC On load checks Check that the cooling fans rotate freely in the right direction and the air flows upwards A paper sheet set on the intake door gratings stays The fans run noiselessly Check that the motor starts stops and follows the speed reference in right direction w...

Page 97: ...art assistant guides you through the start up The assistant starts automatically Wait until the control panel enters the view shown on the right Select the language you want to use by highlighting it if not already highlighted and pressing OK Note After you have selected the language it takes a few minutes for the control panel to wake up Select Start set up and press Next Select the localization ...

Page 98: ...n induction asynchronous motor Check that the motor data is correct Values are predefined on the basis of the drive size but you should verify that they correspond to the motor Start with the motor nominal current Motor nominal cos Φ and nominal torque are optional Press Next to continue This step is optional and requires rotating the motor Do not do this if it could cause any risk or if the mecha...

Page 99: ... selected signals is shown on the panel 2 Additional settings in the Primary settings menu Make any additional adjustments for example macro ramps and limits starting from the Main menu press Menu to enter the Main menu Select Primary settings and press Select or We recommend that you make at least these additional settings Choose a macro or set start stop and reference values individually Ramps L...

Page 100: ...l program match each other You can check the current I O use in the I O menu under the Main menu After making the adjustments go back to the Primary settings menu by pressing Back 2 Additional settings Ramps acceleration and deceleration times for the motor Select Ramps and press Select or Adjust the parameters according to your needs Select a parameter and press Edit After making the adjustments ...

Page 101: ...ntents of this chapter This chapter describes the fault tracing possibilities of the drive Warning and fault messages See the firmware manual for the descriptions causes and remedies of the drive control program warning and fault messages ...

Page 102: ...98 Fault tracing ...

Page 103: ... Service representative www abb com searchchannels The 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 re...

Page 104: ...r IP42 UL Type 1 Filtered drives see section Cleaning the air inlet door meshes IP42 UL Type 1 Filtered below For IP54 UL Type 12 drives see section Replacing the air filters IP54 UL Type 12 Action Description I Visual inspection and maintenance action if needed P Performance of on off site work commissioning tests measurements or other work R Replacement of component Action Target I IP42 air inle...

Page 105: ...arges which can damage circuit boards Check the dustiness of the air inlet meshes If the dust cannot be removed by vacuum cleaning from outside through the grating holes with a small nozzle proceed as follows 1 Remove the fasteners at the top of the grating 2 Lift the grating and pull it away from the door 3 Vacuum clean the mesh 4 Reinstall the mesh and grating in reverse order 1 2 3 4 3 ...

Page 106: ... Lift the grating and pull it away from the door 3 Remove the air filter mat 4 Place the new filter mat in the grating the metal wire side facing the door 5 Reinstall the grating in reverse order Outlet roof filters IP54 UL Type 12 1 Remove the front and back gratings of the fan cubicle by lifting them upwards 2 Remove the air filter mat 3 Place the new filter mat in the grating 4 Reinstall the gr...

Page 107: ...Remove the drive module from the cabinet See section Replacing the drive module on page 108 3 Undo the attaching screws of the handle plate of the drive module 4 Remove the handle plate 5 Vacuum the interior of the heatsink from the opening 6 Blow clean compressed air not humid or oily upwards from the opening and at the same time vacuum from the top of the drive module 7 Reinstall the handle plat...

Page 108: ...tion Precautions before electrical work on page 16 before you start the work 2 Undo the mounting screws of the grille 3 Loosen the four mounting screws of the fan mounting plate 4 Lift the mounting plate off 5 Unplug the power supply quick connector 6 Disconnect the fan capacitor wires 7 Install the new fan in reverse order 2 3 Combi screw M6 16 T25 4 pcs Combi screw M6 16 T25 4 pcs Combi screw M6...

Page 109: ...tart the work 2 Remove the drive module out of the cabinet as described in section Replacing the drive module on page 108 3 Open the support legs of the pedestal 4 Undo the two mounting screws of 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 Undo the mounting screws of the fan s and remove...

Page 110: ...e equipment can occur 1 Stop the drive and do the steps in section Precautions before electrical work on page 16 before you start the work 2 Remove the drive module out of the cabinet as described in section Replacing the drive module on page 108 3 Undo the fastening screw of the fan enclosure 4 Unplug the power supply cable of the fan 5 Install the new fan in reverse order 4 3 ...

Page 111: ...steps in section Precautions before electrical work on page 16 before you start the work 2 Slide the front and back gratings upwards and remove them 3 Remove the mounting screws of the upper cover and lift the cover off 4 Disconnect the fan power supply wires 5 Remove the mounting screws of the fan 6 Remove the mounting screws of the fan cover 7 Lift the fan off 8 Install the new fan in reverse or...

Page 112: ...little down 1 2 and turning it aside Whenever possible secure the module also with chains Do not tilt the drive module A 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 Stop the drive and do the steps in section Precautions before electrical work on page 16 before you start the work 2 Unplu...

Page 113: ...xtraction ramp to the cabinet base with two screws 13 Attach the drive module lifting lugs to the cabinet lifting lug with chains 14 Pull the drive module carefully out of the cabinet preferably with help from another person 15 For frame R11 Remove the clear plastic shroud 16 Remove the air baffle 17 Install the new module in reverse order ...

Page 114: ...110 Maintenance R10 and R11 4 5 2 7 6 3 8 ...

Page 115: ...Maintenance 111 R10 and R11 9 10 ...

Page 116: ...112 Maintenance R10 and R11 11 ...

Page 117: ...Maintenance 113 R10 and R11 12b 12a ...

Page 118: ...114 Maintenance R10 and R11 R10 and R11 17 14 13 R11 15 16 ...

Page 119: ...trip Contact ABB if capacitor failure is suspected Replacements are available from ABB Do not use other than ABB specified spare parts Reforming the capacitors Reform the capacitors if the drive has not been powered for a year or more See page 34 for information on finding out the manufacturing date For information on reforming the capacitors see Converter module capacitor reforming instructions 3...

Page 120: ... or drive functions except the clock 1 To remove the control panel from the drive press the retaining clip at the top and pull it forward from the top edge 2 Disconnect the panel cable 3 To remove the battery use a coin to rotate the battery cover on the back of the control panel 4 Replace the battery with type CR2032 Dispose the old battery according to local disposal rules or applicable laws 5 T...

Page 121: ...ow The symbols are described below the table IEC RATINGS Drive type ACS580 07 Frame size Input rating Output ratings No overload use Light overload use Heavy duty use I1 Imax I2 PN SN ILd PLd IHd PHd A A A kW kVA A kW A kW UN 400 V 0495A 4 R10 495 560 495 250 343 485 250 361 200 0575A 4 R10 575 730 575 315 398 575 315 429 250 0640A 4 R10 640 730 640 355 443 634 355 477 250 0715A 4 R11 715 1020 715...

Page 122: ...ower network specification on page 125 I1 Nominal rms input current I2 Nominal output current available continuously with no over loading S Apparent power no overload PN Typical motor power in no overload use ILd Continuous rms output current allowing 10 overload for 1 minute every 5 minutes PLd Typical motor power in light overload use Imax Maximum output current Available for two seconds at star...

Page 123: ... frequency calculate the derated output current by multiplying the current given in the rating table by the derating factor given in this table Note Changing the value of parameter 97 01 Switching frequency reference does not require derating Derating factor 1 00 Derating factor 0 95 Derating factor 0 9 Derating factor 0 85 Derating factor 0 80 Frame size Derating factor k for the minimum switchin...

Page 124: ...s V Manufacturer Type Type with option F289 Size UN 400 V 0495A 4 495 800 465000 690 Bussmann 170M6412 170M6412 3 0575A 4 575 900 670000 690 Bussmann 170M6413 170M6413 3 0640A 4 640 1000 945000 690 Bussmann 170M6414 170M6414 3 0715A 4 715 1250 1950000 690 Bussmann 170M6416 170M6416 3 0810A 4 810 1250 1950000 690 Bussmann 170M6416 170M6416 3 0870A 4 870 1400 2450000 690 Bussmann 170M6417 170M6417 3...

Page 125: ... 4 R10 2950 1837 8622 72 ACS580 07 0715A 4 R11 2950 1837 9264 72 ACS580 07 0810A 4 R11 2950 1837 10362 72 ACS580 07 0870A 4 R11 3170 1978 11078 71 Frame size Number of holes in the lead through plate for the power cables Hole diameter 60 mm Terminals L1 L2 L3 U2 V2 W2 Grounding terminals Max phase conductor size Bolt size Tightening torque Bolt size Tightening torque mm2 N m R10 12 3 240 or 4 185 ...

Page 126: ...122 Technical data Input and motor cable terminal dimensions of frame R10 Bottom entry and exit ...

Page 127: ...Technical data 123 Input and motor cable terminal dimensions of frame R11 Bottom entry and exit ...

Page 128: ...124 Technical data Terminal data for the control cables See chapter Control unit on page 79 Input and motor cable terminal dimensions of frames R10 and R11 Top entry and exit option H351 H353 ...

Page 129: ...l power factor cos phi1 0 98 at nominal load Motor connection data Motor types Asynchronous AC induction motors permanent magnet synchronous motors Voltage U2 0 to U1 3 phase symmetrical This is indicated in the type designation label as typical output voltage level 3 0 U1 Umax at the field weakening point Frequency f2 0 500 Hz For drives with du dt filter 200 Hz Current See section Ratings Switch...

Page 130: ...entalconditions Part 3 3 Classification of groups of environmental parameters and their severities Stationary use of weather protected locations IEC 60721 3 1 1997 IEC 60721 3 2 1997 Chemical gases Class 3C2 Class 1C2 Class 2C2 Solid particles Class 3S2 No conductive dust allowed Class 1S3 packing must support this otherwise 1S2 Class 2S2 Atmospheric pressure 70 to 106 kPa 0 7 to 1 05 atmospheres ...

Page 131: ...and and air transport when storage time prior to installation exceeds 6 months or storage is arranged in partially weather protected conditions Seaworthy package timber plywood VCI sheet film PE thickness 0 15 mm VCI stretch film PE thickness 0 04 mm VCI emitter bags PP tape PET strap sheet metal steel for sea transport with or without containerization for long storage periods in environments wher...

Page 132: ...These functions of the drive comply with European harmonized standards such as EN 61800 5 2 The declaration of conformity is shown below Applicable standards The drive complies with the standards below The compliance with the European Low Voltage Directive is verified according to standard EN 61800 5 1 European electrical safety requirements product standards EN 61800 5 1 2007 Adjustable speed ele...

Page 133: ...Technical data 129 Declaration of Conformity Safe torque off See also chapter Safe torque off function on page 137 and section Implementing the emergency stop function on page 59 ...

Page 134: ...130 Technical data ...

Page 135: ...category C4 drive of rated voltage equal to or above 1000 V or rated current equal to or above 400 A or intended for use in complex systems in the second environment Category C3 The drive complies with the standard with the following provisions 6 The motor and control cables are selected as specified in the hardware manual 7 The drive is installed according to the instructions given in the hardwar...

Page 136: ... 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 application of authentication measures encryption of data installation of anti virus programs etc to protect the product the network its system and the interface against any kind of security breaches unauthorized access interference intrusion lea...

Page 137: ...Dimension drawings 133 13 Dimension drawings Example dimension drawings are shown below ...

Page 138: ...134 Dimension drawings Frames R10 and R11 IP42 ...

Page 139: ...Dimension drawings 135 Frames R10 and R11 IP54 option B055 ...

Page 140: ...136 Dimension drawings ...

Page 141: ...stage A see diagram below 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 not a...

Page 142: ...ed out to the open position The contacts of the switch or relay must open close within 200 ms of each other An CPTC 02 option module can be used For more information see section CPTC 02 ATEX certified thermistor protection module external 24 V AC DC and isolated PTC interface on page 168 Cable types and lengths We recommend double shielded twisted pair cable IEC 61508 1 2010 Functional safety of e...

Page 143: ...terminals of each drive must be at least 13 V DC to be interpreted as 1 Grounding of protective shields Ground the shield in the cabling between the activation switch and the control unit at the control unit Ground the shield in the cabling between two control units at one control unit only Single drive internal power supply OUT2 OUT1 24 V DC IN1 IN2 T1 U T2 V T3 W Control unit SGND 24 V DC STO UD...

Page 144: ...140 Safe torque off function Single drive external 24 V DC power supply OUT2 OUT1 IN1 IN2 T1 U T2 V T3 W Control unit SGND 24 V DC STO UDC UDC A Drive 34 35 36 37 38 Control logic 24 V DC 24 V DC K ...

Page 145: ...ower supply ACS580 07 ACS580 07 ACS580 07 STO Control unit Control unit Control unit K STO OUT2 OUT1 24 V DC IN1 IN2 SGND 24 V DC 34 35 36 37 38 STO OUT2 OUT1 24 V DC IN1 IN2 SGND 24 V DC 34 35 36 37 38 OUT2 OUT1 24 V DC IN1 IN2 SGND 24 V DC 34 35 36 37 38 ...

Page 146: ... supply ACS580 07 ACS580 07 ACS580 07 STO Control unit Control unit Control unit STO OUT2 OUT1 24 V DC IN1 IN2 SGND 24 V DC 34 35 36 37 38 STO OUT2 OUT1 24 V DC IN1 IN2 SGND 24 V DC 34 35 36 37 38 24 V DC K OUT2 OUT1 24 V DC IN1 IN2 SGND 24 V DC 34 35 36 37 38 ...

Page 147: ...arried out by a competent person with adequate expertise and knowledge of the safety function as well as functional safety as required by IEC 61508 1 clause 6 The test procedures and report must be documented and signed by this person Acceptance test reports Signed acceptance test reports must be stored in the logbook of the machine The report shall include documentation of start up activities and...

Page 148: ...ith synchronous reluctance SynRM motors degrees regardless of the activation of the Safe torque off function p denotes the Close the disconnector and switch the power on Test the operation of the STO function when the motor is stopped Give a stop command for the drive if running and wait until the motor shaft is at a standstill Make sure that the drive operates as follows Open the STO circuit The ...

Page 149: ...ty requirement for the safety function is SIL 3 or PL e cat 3 or 4 the proof test for the function must be performed at least every month When the safety integrity 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 p...

Page 150: ...ime 85 C board temperature at 2 3 of time The safety data is calculated for redundant use and does not apply if both channels are not used The STO is a type A safety component as defined in IEC 61508 2 Relevant failure modes The STO trips spuriously safe failure The STO does not activate when requested A fault exclusion on the failure mode short circuit on printed circuit board has been made EN 13...

Page 151: ...ditions PFD IEC 61508 Probability of failure on demand PFH IEC 61508 Probability of dangerous failures per hour PL EN ISO 13849 1 Performance level Levels a e correspond to SIL SC IEC 61508 Systematic capability SFF IEC 61508 Safe failure fraction SIL IEC 61508 Safety integrity level 1 3 SILCL IEC EN 62061 Maximum SIL level 1 3 that can be claimed for a safety function or subsystem SS1 IEC EN 6180...

Page 152: ...148 Safe torque off function ...

Page 153: ...lso contains their diagnostics and technical data CHDI 01 115 230 V digital input extension module Safety instructions WARNING Obey the safety instructions for the drive If you ignore the safety instructions injury or death can occur Hardware description 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...

Page 154: ...ackage contains CHDI 01 high voltage digital extension module mounting screw 3 Make sure that there are no signs of damage Installing the module See chapter Installing option modules on page 77 Item Description Additional information 1 Grounding screw 2 Hole for mounting screw 3 3 pin terminal blocks for relay outputs Page 151 4 3 pin terminal block for 115 230 V inputs Page 151 6 Diagnostic LED P...

Page 155: ...on the connectors see section Technical data on page 160 Relay outputs 115 230 V inputs General cabling instructions Obey the instructions given in chapter Guidelines for planning the electrical installation on page 49 Wiring Connect the external control cables to the applicable module terminals Ground the outer shield of the cables 360 degrees under a grounding clamp next to the control unit Mark...

Page 156: ...5 01 Extension module type to CHDI 01 You can now see the parameters of the extension module in parameter group 15 I O extension module 3 Set the parameters of the extension module to applicable values Parameter setting example for relay output This example shows how make relay output RO4 of the extension module indicate the reverse direction of rotation of the motor with a one second delay Diagno...

Page 157: ...echnical data Dimension drawing The dimensions are in millimeters and inches Installation Into an option slot on the drive control unit Degree of protection IP20 Ambient conditions See the drive technical data Package Cardboard Color Description Green The extension module is powered up ...

Page 158: ...tact rating 250 V AC 30 V DC 2 A Maximum breaking capacity 1500 VA 115 230 V inputs 70 78 Wire size max 1 5 mm2 Input voltage 115 to 230 V AC 10 Maximum current leakage in digital off state 2 mA Symbol Description Reinforced insulation IEC 61800 5 1 2007 Functional insulation IEC 61800 5 1 2007 CHDI 01 RO5 RO4 Plugged to drive SLOT2 HDI HDI HDI ...

Page 159: ...outputs of the drive control unit It has two relay outputs and one transistor output which can function as a digital or frequency output In addition the extension module has an external power supply interface which can be used to power up the drive control unit in case the drive power supply fails If you do not need the back up power supply you do not have to connect it because the module is power...

Page 160: ...ultifunction extension module mounting screw 3 Make sure that there are no signs of damage Installing the module See chapter Installing option modules on page 77 Item Description Additional information 1 Grounding screw 2 Hole for mounting screw 3 3 pin terminal blocks for relay outputs Page 157 4 3 pin terminal block for transistor output Page 157 5 2 pin terminal block for external power supply ...

Page 161: ...supply The external power supply is needed only if you want to connect an external back up power supply for the drive control unit The control unit has corresponding terminals 40 and 41 for external power supply connection General cabling instructions Obey the instructions given in chapter Guidelines for planning the electrical installation on page 49 Wiring Connect the external control cables to ...

Page 162: ... control unit is powered using an external 24 V AC supply 24 V DC 50 51 52 CMOD 01 RO4C RO4A RO4B 24 V DC 42 43 44 CMOD 01 DO1 SRC DO1 OUT DO1 SGND 42 43 44 1 1 An externally supplied frequency indicator which provides for example a 40 mA 12 V DC power supply for the sensor circuit CMOD frequency output suitable voltage pulse input 10 Hz 16 kHz CMOD 01 DO1 SRC DO1 OUT DO1 SGND 40 41 1 1 External p...

Page 163: ...f rotation of the motor with a one second delay Parameter setting example for digital output This example shows how to make digital output DO1 of the extension module indicate the reverse direction of rotation of the motor with a one second 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 ...

Page 164: ...echnical data Dimension drawing The dimensions are in millimeters and inches Installation Into an option slot on the drive control unit Degree of protection IP20 Ambient conditions See the drive technical data Package Cardboard Color Description Green The extension module is powered up ...

Page 165: ... Transistor output PNP Maximum switching voltage 30 V DC Maximum switching current 100 mA 30 V DC short circuit protected Frequency 10 Hz 16 kHz Resolution 1 Hz Inaccuracy 0 2 External power supply 40 41 Wire size max 1 5 mm2 24 V AC V DC 10 GND user potential Maximum current consumption 25 W 1 04 A at 24 V DC Symbol Description Reinforced insulation IEC 61800 5 1 2007 Functional insulation IEC 61...

Page 166: ...t connect this overtemperature indication back to the drive for example to its Safe torque off input 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 fails 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 de...

Page 167: ...ifunction extension module mounting screw 3 Make sure that there are no signs of damage Installing the module See chapter Installing option modules on page 77 Item Description Additional information 1 Grounding screw 2 Hole for mounting screw 3 2 pin terminal block for motor thermistor connection Page 164 4 2 pin terminal block for relay output Page 164 5 2 pin terminal block for external power su...

Page 168: ... on page 166 Motor thermistor connection Relay output External power supply The external power supply is needed only if you want to connect an external back up power supply for the drive control unit The control unit has corresponding terminals 40 and 41 for external power supply connection General cabling instructions Obey the instructions given in chapter Guidelines for planning the electrical i...

Page 169: ...ng between the motor PTC and CMOD 02 PTC terminal Relay output connection example Power supply connection example 1 External power supply 24 V AC DC 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 parame...

Page 170: ...ee the parameters of the extension module in parameter group 15 I O extension module Diagnostics Faults and warning messages Warning A7AB Extension I O configuration failure LEDs The extension module has one diagnostic LED Technical data Dimension drawing The dimensions are in millimeters and inches Installation Into an option slot on the drive control unit Degree of protection IP20 Color Descript...

Page 171: ...d 3 6 kohm Recovery threshold 1 6 kohm PTC terminal voltage 5 0 V PTC terminal current 1 mA Short circuit detection 50 ohm Relay output 62 63 Wire size max 1 5 mm2 Maximum contact rating 250 V AC 30 V DC 5 A Maximum breaking capacity 1000 VA External power supply 40 41 Wire size max 1 5 mm2 24 V AC V DC 10 GND user potential Maximum current consumption 25 W 1 04 A at 24 V DC Symbol Description Rei...

Page 172: ...ion modules CPTC 02 ATEX certified thermistor protection module external 24 V AC DC and isolated PTC interface See CPTC 02 ATEX certified thermistor protection module Ex II 2 GD L537 Q971 user s manual 3AXD50000030058 English ...

Page 173: ...ntacts can be found 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 Drives 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 ...

Page 174: ...Contact us www abb com drives www abb com drivespartners 3AXD50000032622 Rev A EN 2016 03 16 ...

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