ABB ACS580-07 Hardware Manual Download Page 1

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ABB GENERAL PURPOSE DRIVES

ACS580-07

Hardware manual

Summary of Contents for ACS580-07

Page 1: ... ABB GENERAL PURPOSE DRIVES ACS580 07 Hardware manual ...

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Page 3: ...re manual Table of contents 1 Safety instructions 4 Mechanical installation 5 Guidelines for planning the electrical installation 9 Start up 2019 ABB Oy All Rights Reserved 3AXD50000045815 Rev D EN EFFECTIVE 2019 07 03 ...

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Page 5: ... frame size and option code 28 Quick installation start up and operating flowchart 29 Terms and abbreviations 3 Operation principle and hardware description 31 Contents of this chapter 31 Product overview 32 Single line circuit diagram of the drive 33 General information on the cabinet layout 33 Cabinet layout R6 and R7 bottom entry and exit of cables 34 Cabinet layout R8 and R9 bottom entry and e...

Page 6: ...ernative 2 Using the holes inside the cabinet 60 Miscellaneous 60 Cable duct in the floor below the cabinet 60 Arc welding 5 Guidelines for planning the electrical installation 63 Contents of this chapter 63 Limitation of liability 63 Selecting the supply disconnecting device 63 Selecting the main contactor 64 Examining the compatibility of the motor and drive 64 Protecting the motor insulation an...

Page 7: ...ility 78 Implementing the emergency stop function 78 Implementing the Safe Torque Off function 78 Implementing the Power loss ride through function 79 Using power factor compensation capacitors with the drive 79 Implementing a safety switch between the drive and the motor 79 Using a contactor between the drive and the motor 80 Implementing a bypass connection 80 Implementing the ATEX certified Saf...

Page 8: ...C frames R6 to R9 100 Connection procedure IEC frames R10 and R11 104 Connecting the control cables 104 Overview of control cable connection procedure 105 Grounding the outer shields of the control cables at the cabinet entry 107 Routing the control cables inside the cabinet 108 Connecting external wiring to the control unit or optional I O terminal block 109 Connecting the emergency stop push but...

Page 9: ...enance intervals after start up 136 Cleaning the interior of the cabinet 137 Cleaning the air inlet door meshes IP42 UL Type 1 Filtered 137 Replacing the air filters IP54 UL Type 12 137 Inlet door filters IP54 UL Type 12 138 Outlet roof filters IP54 UL Type 12 138 Heatsink 139 Fans 139 Replacing the door fan frames R6 to R9 140 Replacing the cabinet fan frames R6 to R9 141 Replacing the door fan f...

Page 10: ...n installation ramp 180 Typical power cable sizes 181 Losses cooling data and noise 182 Terminal and entry data for the power cables 182 IEC Standard configuration 182 IEC With option E205 182 US Standard configuration 183 US With option E205 184 Connection drawings 210 Terminal and connection data for auxiliary control circuits 211 Electrical power network specification 211 Motor connection data ...

Page 11: ...8 Frames R10 and R11 B055 IP54 UL Type 12 239 Frames R10 and R11 F289 240 Frames R10 and R11 H351 H353 241 Frames R10 and R11 B054 IP42 UL type 1 H351 H353 242 Frames R10 and R11 B055 IP54 UL type 12 H351 H353 14 The Safe torque off function 243 Contents of this chapter 243 Description 244 Compliance with the European Machinery Directive 245 Wiring 245 Connection principle 245 Connection with inte...

Page 12: ...echnical data 264 Dimension drawing 266 CHDI 01 115 230 V digital input extension module 266 Hardware description 266 Product overview 266 Layout 266 Mechanical installation 266 Necessary tools and instructions 266 Unpacking and checking the delivery 267 Installing the module 267 Electrical installation 267 Necessary tools and instructions 267 Terminal designations 268 General cabling instructions...

Page 13: ...dware description 280 Product overview 281 Layout 281 Mechanical installation 281 Necessary tools and instructions 281 Unpacking and checking the delivery 282 Installing the module 282 Electrical installation 282 Necessary tools and instructions 282 Terminal designations 282 General cabling instructions 283 Wiring 284 Start up 284 Setting the parameters 284 Diagnostics 284 Faults and warning messa...

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Page 15: ...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 16: ...at nothing presses against the roof side or back plates or door Do not store anything on the roof while the drive is in operation Frames R10 and R11 Do not use the module installation ramp with plinth heights which exceeds the maximum allowed height See the technical data Frames R10 and R11 Secure the module extraction installation ramp carefully Frames R10 and R11 To prevent the drive module from...

Page 17: ...onductive debris inside the drive may cause damage or malfunction Make sure that there is sufficient cooling See the technical data Keep the cabinet doors closed when the drive is powered With the doors open a risk of a potentially fatal electric shock arc flash or high energy arc blast exists If you cannot avoid working on a powered drive obey the local laws and regulations on live working includ...

Page 18: ...o often can damage the charging circuit of the DC capacitors Validate any safety circuits for example Safe torque off or emergency stop in start up See separate instructions for the safety circuits Beware of hot air exiting from the air outlets Do not cover the air inlet or outlet when the drive is running Note If you select an external source for the start command and it is on the drive will star...

Page 19: ...h the I O terminals of the drive Give a stop command to the drive before you reset a fault If you have an external source for the start command and the start is on the drive will start immediately after the fault reset unless you configure the drive for pulse start See the firmware manual Before you activate automatic fault reset functions of the drive control program make sure that no dangerous s...

Page 20: ...ll other possible disconnecting devices that isolate the drive from dangerous voltage sources If you have a permanent magnet motor connected to the drive disconnect the motor from the drive with a safety switch or by other means Disconnect any dangerous external voltages from the control circuits After you disconnect power from the drive always wait 5 minutes to let the intermediate circuit capaci...

Page 21: ...Measuring points of frames R6 to R9 are shown below PE L1 L2 L3 Safety instructions 21 ...

Page 22: ...e equipment can occur If you are not a qualified electrician do not do installation or maintenance work Make sure that the electrical power network motor generator and environmental conditions agree with the drive data Do not do insulation or voltage withstand tests on the drive ABB recommends not to secure the cabinet by arc welding If you have to obey the welding instructions in the drive manual...

Page 23: ...them injury or death or equipment malfunction can occur and electromagnetic interference can increase If you are not a qualified electrician do not do grounding work Always ground the drive the motor and adjoining equipment This is necessary for the personnel safety Proper grounding also reduces electromagnetic emission and interference Make sure that the conductivity of the protective earth PE co...

Page 24: ...conductor current equipment See standard IEC EN 61800 5 1 4 3 5 5 2 and the electrical planning instructions of the drive 24 Safety instructions ...

Page 25: ...ugh any mechanical connection like felt nip rope etc Do the steps in section Electrical safety precautions page 20 Measure that the installation is de energized Use a multimeter with an impedance greater than 1 Mohm Make sure that the voltage between the drive output terminals T1 U T2 V T3 W and the grounding PE busbar is close to 0 V Make sure that the voltage between the drive input power termin...

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Page 27: ... know the fundamentals of electricity wiring electrical components and electrical schematic symbols The manual is written for readers worldwide Both SI and imperial units are shown Related manuals Code Name Drive hardware manuals and guides Multilingual code 3AXD50000037978 Drive converter inverter safety instructions 3AXD50000045815 ACS580 07 drives 75 to 500 kW hardware manual 3AXD50000210268 Co...

Page 28: ...tructions technical data and dimension drawings which concern only certain frame sizes are marked with the symbol of the frame size for example R7 The frame size is marked on the type designation label see Type designation label page 47 The instructions technical data and dimension drawings which concern only certain optional selections are marked with option codes such as L504 The options include...

Page 29: ...ension CMOD 01 Multifunction extension module external 24 V AC DC and isolated PTC interface CMOD 02 Multifunction extension module external 24 V and ATEX certified PTC interface CPTC 02 Electromagnetic compatibility EMC BACnet IP adapter module FBIP 21 Optional CANopen adapter module FCAN Optional ControlNet adapter module FCNA 01 DDCS communication module with two pairs of 10 Mbit s DDCS channel...

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Page 31: ...hapter 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 3 Operation principle and hardware description 31 ...

Page 32: ... circuit breaker option F289 Line contactor option F250 Q2 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 T21 Auxiliary voltage supply fuses F21 Auxiliary circuit protection switch F22 Drive module T1 Common mode filter option E208 for frames R6 to R10 Standard for frame R11 R11 du dt filter option E2...

Page 33: ...n B054 IP21 UL Type 1 Cabinet layout R6 and R7 bottom entry and exit of cables The cabinet layout of frame R7 with dut dt filter option E205 is shown below Degree of protection IP42 option B054 Frame R6 looks similar Operation principle and hardware description 33 ...

Page 34: ...g switch 2 Power cable connection terminals of the drive module behind the shroud 15 Main switch handle 3 Drive module 16 Gratings for cooling air in 4 Additional I O terminal block option L504 17 Gratings for cooling air out 5 Drive control unit 18 Mounting plate see section Mounting plate R6 to R9 page 36 6 Common mode filter option E208 19 Lifting lugs 7 du dt filter option E205 20 Cabinet door...

Page 35: ...ls of the drive module behind the shroud 15 Main switch handle 3 Drive module 16 Gratings for cooling air in 4 Additional I O terminal block option L504 17 Gratings for cooling air out 5 Drive control unit 18 Mounting plate see section Mounting plate R6 to R9 page 36 6 Common mode filter option E208 19 Lifting lugs 7 du dt filter option E205 20 Cabinet door fan 8 Motor cable connection terminals 2...

Page 36: ...t breaker option F289 X289 Switch disconnector and miniature circuit breaker for cabinet heater option G300 Q95 F95 Connection terminals for cabinet heater option G300 X300 Auxiliary transformer fuses F21 Connection of external emergency stop button options Q951 and Q963 X951 Auxiliary transformer s secondary side miniature circuit breaker F22 Connection of external Safe torque off but ton X969 24...

Page 37: ...of molded case circuit breaker op tion F289 X289 Push buttons for emergency stop option Q951 or Q963 See section Connecting the emergency stop push buttons options Q951 and Q963 page 109 X951 External STO customer connection for safety option Q951 or Q963 See section Connecting the Safe torque off circuit page 109 X969 Operation principle and hardware description 37 ...

Page 38: ...tings for cooling air out 1 Lifting lugs 10 Operating switch 2 Drive control unit 11 Drive control panel 3 Mounting plate see section Mounting plate page 39 12 Main switch handle 4 Behind the shroud Additional I O terminal block option L504 13 Gratings for cooling air in 5 Additional fan in IP54 cabinets option B055 14 Door fan at the back of the mounting plate 6 38 Operation principle and hardwar...

Page 39: ...net shrouds removed C Drive module 18 Power and control cable entries 15 Auxiliary voltage transformer T21 19 Motor cable connection terminals 16 Mounting plate The components and terminals on the mounting plate of frames R10 and R11 are shown below Operation principle and hardware description 39 ...

Page 40: ...ff but ton X969 Cabinet fan control relay K26 Additional I O terminal block option L504 X504 Auxiliary transformer s secondary side miniature circuit breaker F22 Ready pilot light control relay option G327 K41 1 24VDC power supply and buffer with emer gency stop options Q951 and Q963 also with line contactor option F250 T22 C22 Run pilot light control relay option G328 K41 2 External main contacto...

Page 41: ... Cooling air flow The figure below shows cooling air flow in frames R6 to R9 side view and in frames R10 and R11 front view R6 R9 R10 R11 Operation principle and hardware description 41 ...

Page 42: ...slot 2 for optional I O extension modules 2 Embedded fieldbus connector 3 Panel port 4 I O terminal blocks See section Layout page 115 and section Default I O connection diagram page 117 5 Control panel page 43 6 Connection terminals for options see sections Mounting plate R6 to R9 page 36 and Mounting plate page 39 7 Additional terminal block X504 option L504 page 46 8 du dt filter option E205 pa...

Page 43: ... STOP 6 Main switch disconnector Q1 The switch disconnector handle switches the main voltage to the drive on and off Control panel The control panel is the user interface of the drive It provides the essential controls such as Start Stop Direction Reset Reference and the parameter settings for the control program One control panel can be used to control several drives through a panel link The cont...

Page 44: ...criptions of cabinet options Note All options are not available for all drive types or do not coexist with certain other options Check actual availability with ABB Degree of protection Definitions According to IEC EN 60529 the degree of protection is indicated by an IP code where the first numeral means protection against ingress of solid foreign objects and the second numeral protection against i...

Page 45: ...y made holes all components UL Listed Recognized maximum supply voltage 480 V Related options H351 top entry of cables H353 top exit of cables and H358 cable conduit entry Plinth height options C164 and C179 The standard height of the cabinet plinth is 50 mm These options specify a plinth height of 100 mm C164 or 200 mm C179 Empty cubicles options C196 to C201 Note This option is available for US ...

Page 46: ... actual wiring Top cable entry exit options H351 and H353 The default input and output cabling direction is through the bottom of the cabinet The top entry H351 and top exit H353 options provide power and control cable entries at the roof of the cabinet The entries are equipped with grommets and 360 grounding hardware The options add an additional 125 mm 4 92 in wide cable channel to the cabinet w...

Page 47: ...ignation contains information on the specifications and configuration of the drive The first digits from left express the basic configuration eg ACS580 07 0640A 4 The optional selections are given thereafter separated by plus signs eg B055 The main selections are described below Not all selections are available for all types or with all options For more information refer to ACX580 07 Ordering Info...

Page 48: ...mm on the left hand side For US market only Not available with C164 and C179 Not available with C164 and C179 C200 Empty cabinet 800 mm on the left hand side For US market only Not available with C164 and C179 Not available with C164 and C179 C201 Filters du dt filter option E205 page 45 E205 Common mode filter page 44 E208 Line options Line contactor F250 Molded case circuit breaker MCCB for US m...

Page 49: ...02 external 24 V and isolated PTC interface L523 CPTC 02 ATEX certified thermistor protection module L537 Specialties Extended warranty for 36 month from delivery P931 Extended warranty for 60 month from delivery P932 Seaworthy packing P912 Container packing P929 Safety functions Emergency stop of Category 0 with opening the main contactor or breaker Q951 Emergency Stop Category 0 without opening ...

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Page 51: ...ations See the technical data There is enough free space above the drive to enable cooling maintenance and operation of the pressure relief if present The floor that the drive cabinet 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...

Page 52: ...ie the standard plinth height of the drive 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 slate spud bar jack and rollers Pozidriv and Torx screwdrivers torque wrench set of wrenches or sockets 52 Mechanical installation ...

Page 53: ...horizontal position preferably in the original package to installation site as shown below to avoid damaging the cabinet surfaces and door devices When you use a pallet truck check its load capacity before you move the drive Horizontal package Mechanical installation 53 10 ...

Page 54: ...Vertical package 1088 2321 A B 1 Lifting the transport package with slings A Lifting points 1 Lifting the transport package with forklift B 54 Mechanical installation ...

Page 55: ...let 4 Remove the plastic wrapping 5 After checking the delivery see section Checking the delivery page 55 lift the drive cabinet to its installation place see section Lifting the cabinet page 56 Unpack the vertical transport package as follows 1 Undo the screws that hold the wooden elements of the transport crate together 2 Remove the elements 3 Remove the clamps with which the drive cabinet is mo...

Page 56: ...s delivery documents Check that there are no signs of damage Before attempting installation and operation check the information on the type designation labels of the drive to verify that the delivery is of the correct type Lifting the cabinet Lift the drive cabinet up using its lifting lugs 56 Mechanical installation ...

Page 57: ... cabinet after unpacking Move drive cabinet carefully in the upright position Avoid tilting The center of gravity of the cabinet is high Moving on rollers Lay the cabinet on the rollers and move it carefully until close to its final location Remove the rollers by lifting the unit with a crane forklift pallet truck or jack Mechanical installation 57 10 ...

Page 58: ...in an upright vertical position with its back against a wall a or back to back with another cabinet b Leave 400 mm 15 75 in free space above the basic roof level of the cabinet for cooling 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 all...

Page 59: ...e or bolt the cabinet to the floor through the holes inside if they are accessible Alternative 1 Clamping 1 Insert the clamps into the twin slots along the front and rear edges of the cabinet frame body and at tach them to the floor with a bolt The recommen ded maximum distance between the clamps in the front edge is 800mm 31 5 2 If floor mounting from back is not possible attach the cabinet at th...

Page 60: ...he cooling air flow from the cable duct to the cabinet by bottom plates To ensure the degree of protection for the cabinet use the original bottom plates delivered with the unit With user defined cable entries take care of the degree of protection fire protection and EMC compliance 500 19 68 50 1 97 500 19 68 50 1 97 Arc welding ABB does not recommend attaching the cabinet by arc welding However i...

Page 61: ...connected improperly the welding circuit can damage electronic circuits in the cabinet WARNING Do not inhale the welding fumes Mechanical installation 61 10 ...

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Page 63: ...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 main switch disconnector as standard The disconnector can be...

Page 64: ... current See the appropriate parameters in the firmware manual Protecting the motor insulation and bearings The drive employs modern IGBT inverter technology Regardless of frequency the drive output comprises pulses of approximately the drive DC bus voltage with a very short rise time The pulse voltage can almost double at the motor terminals depending on the attenuation and reflection properties ...

Page 65: ...dard 500 V UN 600 V or N CMF N Reinforced N du dt CMF N du dt 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 n a 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 manu facturer 380 V UN 690 V Old1 form wound HX_ and modular N CMF Enamelled wire...

Page 66: ... UN 600 V or N CMF N or CMF Reinforced ÛLL 1800 V N du dt CMF du dt N du dt Reinforced ÛLL 1800 V 600 V UN 690 V N CMF N CMF Reinforced ÛLL 2000 V 0 3 micro second 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 in the applied drive...

Page 67: ...l requirements for the regenerative and low harmonics drives It is possible to increase the intermediate circuit DC voltage from the nominal standard level with a parameter in the control program If you choose to do this select the motor insulation system which withstands the increased DC voltage level Additional requirements for ABB high output and IP23 motors The rated output power of high outpu...

Page 68: ...N or CMF Reinforced ÛLL 1800 V N du dt CMF N du dt Reinforced ÛLL 1800 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 in the applied drive operation range Additiona...

Page 69: ...ing the power cables General guidelines Select the input power and motor cables according to local regulations Current Select a cable capable of carrying the drive or motor nominal current Temperature For an IEC installation select a cable rated for at least 70 C 90 C for IP55 UL Type 12 maximum permissible temperature of conductor in continuous use For North America select a cable rated for at le...

Page 70: ...e phase conductor and the protective conductor are made of the same metal If this is not so the cross sectional area of the protective earthing conductor shall be determined in a manner which produces a conductance equivalent to that which results from the application of this table Minimum cross sectional area of the corresponding protective conductor Sp mm2 Cross sectional area of the phase condu...

Page 71: ...ctor 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 Use as input power cabling Cable type Yes with phase conductor smaller than 10 mm2 8 AWG or motors up to 30 kW 40 hp Yes with phase conductor smaller than 10 mm2 8 AWG PVC Note Shielded or armored cable or cabling in metal co...

Page 72: ...methods for wiring the drive in the intended application See NEC 70 along with state and local codes for the appropriate materials for your application In all applications ABB prefers the use of symmetrical shielded VFD cable between drive and motor s Notes Wiring method Conduit Metallic1 2 Use separate conduit run for each motor Do not run power feed wiring and motor wiring in the same conduit El...

Page 73: ...otor frame Use separate conduits for input power motor brake resistor and control wiring Note Do not run motor wiring from more than one drive in the same conduit Power cable shield If the cable shield is used as the sole protective earth PE conductor make sure that its conductivity agrees with the PE conductor requirements To effectively suppress radiated and conducted radio frequency emissions t...

Page 74: ... separate shielded cables Do not mix 24 V DC and 115 230 V AC signals in the same cable Signals that can be run in the same cable If their voltage does not exceed 48 V relay controlled signals can be run in the same cables as digital input 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...

Page 75: ...ssible Do not run extra cables through the drive Make sure that the cable trays have good electrical bonding to each other and to the grounding electrodes Aluminum tray systems can be used to improve local equalizing of potential This figure illustrates the cable routing guidelines with an example drive Note When motor cable is symmetrical and shielded and it has short parallel runs with other cab...

Page 76: ... conduits for the input power motor brake resistor optional and control cabling Use separate conduit for each motor cabling The drawing below illustrates general guidelines for routing input power and motor cabling in conduits 1 1 1 1 1 2 2 2 2 2 3 3 3 3 Input power cabling 1 Motor cabling 2 Conduit 3 76 Guidelines for planning the electrical installation ...

Page 77: ...24 V DC Implementing thermal overload and short circuit protection Protecting the input cabling and the drive upon a short circuit To protect the input cabling in short circuit situations install fuses or a suitable circuit breaker at the supply side of the cabling The drive is equipped with internal AC fuses as standard In case of a short circuit inside the drive the AC fuses protect the drive re...

Page 78: ...firmware manual for more information on the motor thermal protection function Protecting the drive against ground faults The drive is equipped with an internal ground fault protective function to protect the unit 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 devic...

Page 79: ...er line while the drive is connected The connection will cause voltage transients that may trip or even damage the drive 2 If capacitor load is increased decreased step by step when the AC drive is connected to the power line make sure that the connection steps are low enough not to cause voltage transients that would trip the drive 3 Check that the power factor compensation unit is suitable for u...

Page 80: ...or disconnection function option Q971 With option Q971 the drive provides ATEX certified safe motor disconnection without contactor using the drive Safe torque off function For more information see ATEX certified Safe disconnection function Ex II 2 GD for ACS880 drives Q971 Application guide 3AUA0000132231 English FPTC 02 ATEX certified thermistor protection module Ex II 2 GD option L537 Q971 for ...

Page 81: ...uirement Temperature sensor type Option module Pt100 Pt1000 KTY PTC Insulation Isolation Type Reinforced insulation x x Galvanic isolation between sensor connector and other connectors in cluding drive control unit connector FIO 11 Reinforced insulation x x Galvanic isolation between sensor connector and other connectors in cluding drive control unit connector FEN xx Basic insulation Connectors of...

Page 82: ...f the drive from position 1 to 0 does not generate an emergency stop of the motor or separate the drive from dangerous potential See the user s manual for the wiring start up and operation instructions Manual code English User s manual Option code 3AXD50000171828 Emergency stop stop category 0 option Q951 for ACS580 07 ACH580 07 and ACQ580 07 drives user s manual Q951 3AXD50000171835 Emergency Sto...

Page 83: ...power returns the contactor closes However if the power loss situation lasts so long that 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 ...

Page 84: ... will damage or even burn the contactor completely Implementing a bypass connection If bypassing is required employ mechanically or electrically interlocked contactors between the motor and the drive and between the motor and the power line Make sure with interlocking that the contactors cannot be closed simultaneously The installation must be clearly marked as defined in IEC EN 61800 5 1 subclaus...

Page 85: ...ly extra low voltage circuits are protected against contact and insulated with basic insulation from other low voltage circuits The insulation must be rated for the same voltage level as the drive main circuit Note that extra low voltage circuits such as 24 V DC typically do not meet these requirements 3 You can connect the sensor to an extension module with reinforced insulation eg CMOD 02 betwee...

Page 86: ...00 KTY PTC Insulation Type X Reinforced insulation between the sensor connector and the other connectors of the module including drive control unit connect or No special requirements for the thermistor insulation level CMOD 02 X CPTC 02 The drive control unit is PELV compatible also when the module and a thermistor protection circuit are installed 86 Guidelines for planning the electrical installa...

Page 87: ...ibed in this chapter Obey the instructions in chapter Safety instructions If you ignore them injury or death or damage to the equipment can occur Attaching the device stickers on the cabinet door A multilingual device label sticker is delivered with the drive Attach the stickers in the local language on the English texts see section Door switches and lights page 43 6 Electrical installation 87 11 ...

Page 88: ...s in front of the terminals are removed The layout is similar for the other frame sizes L1 L2 L3 1 1 U2 V2 W2 1 1 2 3 4 5 Input power cable terminals L1 L2 L3 Motor cable terminals U2 V2 W2 Strain relief 1 PE ground terminal 2 Emi conductive cushion for grounding of the outer shields of the control cables 3 Power cable entry 4 Control cable entry 5 88 Electrical installation ...

Page 89: ...minals are removed The layout is similar for frame R11 U2 V2 W2 5 4 L1 L2 L3 1 3 6 2 Input power cable terminals L1 L2 L3 Motor cable terminals U2 V2 W2 Strain relief 1 Input power cable entry 2 PE ground terminal 3 Emi conductive cushion for grounding of the outer shields of the control cables 4 Motor cable entry 5 Control cable entry 6 Electrical installation 89 11 ...

Page 90: ...in frames R10 and R11 5 du dt filter option E205 6 Use a separate grounding cable if the shield does not meet the requirements of IEC 61439 1 and there is no symmetrically constructed grounding conductor in the cable 7 Drive module 8 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 ground...

Page 91: ...stor connected can be installed to a symmetrically grounded TN S system If you install the drive to another system you may need to disconnect the varistor WARNING Do not install the drive with the ground to phase varistor connected to a system that the varistor is not suitable for If you do the varistor circuit can be damaged When to disconnect the ground to phase varistor TN S IT corner grounded ...

Page 92: ...es Ground to phase varistor screws EMC filter E200 screws Frame size VAR Two EMC screws R6 R9 Guidelines for installing the drive to a TT system The drive can be connected to a TT system under these conditions 1 Residual current device has been installed in the supply system 2 This wire has been disconnected Otherwise EMC filter and ground to phase varistor capacitor leakage current will cause the...

Page 93: ... transformer connection If that is not possible measure these voltages at the distribution board before you connect power to the drive 1 input voltage line to line UL L 2 input voltage line 1 to ground UL1 G 3 input voltage line 2 to ground UL2 G 4 input voltage line 3 to ground UL3 G The line to ground voltages in relation to the line to line voltage of the electrical power system types are shown...

Page 94: ...d to phase varistor R6 to R9 To disconnect the internal EMC filter or ground to phase varistor do as follows 1 Switch off the power from the drive 2 Open the cover if not already opened 3 To disconnect the internal EMC filter remove the two EMC screws 4 To disconnect the ground to phase varistor remove the varistor screw EMC DC A EMC AC B VAR C Disconnecting the ground to phase varistor R10 and R1...

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Page 96: ...onductors and then 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 exceed 100 Mohm reference value at 25 C 77 F For the insulation resistance of other motors consult the manufacturer s instructions Note Moisture inside the motor casing reduces the insulation resistance If moisture is suspected dry t...

Page 97: ...r cable terminals release the clips with a screwdriver and pull the shroud out 4d For drives with option E205 Remove the shrouds 4a 4b 3 4a 4b 4c 4d 5 For drives without option E205 Knock out holes in the shroud for the motor cable conductors 6 Peel off 3 to 5 cm of the outer insulation of the cables above the cable entries with the conductive sleeves for the 360 high frequency grounding 5 7 Prepa...

Page 98: ...be connected Cut adequate holes into the rubber grommets Slide the grommets onto the cables Slide the cables through the bottom plate with the conductive sleeves and attach the grommets to the holes 11 Attach the conductive sleeves to the cable shields with cable ties Tie up the unused conductive sleeves with cable ties 12 Seal the slot between the cable and mineral wool sheet if used with sealing...

Page 99: ...lds of the input cables and separate ground cable if present to the PE terminal of the cabinet and the phase conductors to the L1 L2 and L3 terminals 13 14 14 13 15 Tighten the power cable screws to the torque given in Terminal and entry data for the power cables page 182 16 Reinstall the shrouds and mounting plate Electrical installation 99 11 ...

Page 100: ...ecautions page 20 before you start the work 2 Open the cabinet door 3 Remove the shrouding With bottom entry and bottom exit Undo the mounting screws and pull the shroud out With top entry option H351 and bottom exit Undo the mounting screws and pull the shroud out 100 Electrical installation ...

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Page 102: ...ge 141 Undo the mounting screws and pull the shrouds out 4 Remove the door fan mounting plate See section Replacing the door fan frames R10 and R11 page 141 5 Peel off 3 to 5 cm of the outer insulation of the cables above the cable entries with the conductive sleeves for the 360 high frequency grounding 102 Electrical installation ...

Page 103: ...cables through the bottom plate 9 Remove rubber grommets from the bottom plate for the cables to be connected Cut adequate holes into the rubber grommets Slide the grommets onto the cables Slide the cables through the bottom plate with the conductive sleeves and attach the grommets to the holes 10 Attach the conductive sleeves to the cable shields with cable ties Tie up the unused conductive sleev...

Page 104: ...iring Connect the cables as described under Overview of control cable connection procedure page 104 Overview of 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 Electrical safety precautions page 20 before you start the work 2 Run the c...

Page 105: ...stic sheath above the entry 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 3 2 4 1 2 4 1 4 1 3 Note 1 Keep the shields continuous as close to the connection terminals as possible Secure the cables mechanically at the entry strain relief Note ...

Page 106: ...r contact to the cushions on both sides Max number of cables per grommet Cable diameter in mm 4 13 3 17 2 25 1 25 5 Arrange the bunches according to size from thickest to the thinnest between the EMI conductive cushions Electrical installation 99 5 Arrange the bunches according to size from thickest to the thinnest between the EMI conductive cushions 6 If more than one cable go through a grommet s...

Page 107: ...inside the cabinet The route of the control cables is shown below in frame R9 The route is similar frames R6 R7 and R8 X504 L504 The route of the control cables for frames R10 and R11 is shown below Electrical installation 107 11 ...

Page 108: ...nals as possible 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 Ground the pair cable shields and all grounding wires to the grounding clamp 108 Electrical installation ...

Page 109: ...nuals of the options Internal connections 1 2 3 4 5 6 7 8 9 10 X951 6 1 2 1 3 2 3 4 5 7 Emergency stop push button on the cabinet door 1 Emergency stop push button on the cabinet door 2 Emergency stop circuit 3 Emergency stop reset button on the cabinet door 4 Emergency stop indication on the cabinet door 5 Customer connections Customer external emergency stop button 6 Customer external emergency ...

Page 110: ...rnal power supply wires for the cabinet heater option G300 Connect the external power supply wires for the cabinet heater to terminal block X300 at the back of the mounting plate 1 Internal wiring of the cabinet heater heater off fault contact open Frames R6 R9 1 2 PE 4 5 N L X300 PE 1 1 Internal wiring of the cabinet heater heater off fault contact open Frames R10 R11 1 3 XPE95 1 L N Q95 PE X300 ...

Page 111: ...ng the control panel into the panel holder or platform if present or by using an Ethernet eg Cat 5e networking cable 2 Remove the USB connector cover on the front of the control panel 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 will display an indication whenever the connection is active Start Stop Loc ...

Page 112: ...ion Electrical safety precautions page 20 before you start the work 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 The screw grounds the module It is necessary for fulfilling the EMC requirements and for correct operation of the module 1 2 3 112 Electrical installatio...

Page 113: ...screw tightens the connections and grounds the module It is necessary for fulfilling the EMC requirements and for correct operation of the module 1 2 Wiring the optional modules See the appropriate optional module manual or for I O options chapter Optional I O extension modules for specific installation and wiring instructions Electrical installation 113 11 ...

Page 114: ...114 ...

Page 115: ...ntains the default I O connection diagram descriptions of the terminals and technical data for the drive control unit CCU 24 Layout The layout of the external control connection terminals on the drive module control unit is shown below 7 Control unit 115 ...

Page 116: ...erature 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 S101 End termination switch TERM S100 Connection terminals 29 31 SLOT 2 Option slot 2 I O extension modules 24 V AC DC exter...

Page 117: ... RO1C Ready run 250 V AC 30 V DC 2 A 20 RO1A 21 RO1B 22 RO2C Running 250 V AC 30 V DC 2 A 23 RO2A 24 RO2B 25 RO3C Fault 1 250 V AC 30 V DC 2 A 26 RO3A 27 RO3B X5 EIA 485 Modbus RTU 29 B Embedded Modbus RTU EIA 485 30 A 31 DGND S4 TERM Serial data link termination switch S5 BIAS Serial data link bias resistors switch X4 Safe torque off 34 OUT1 Safe torque off Factory connection Both circuits must b...

Page 118: ... shield of the cable 360 degrees under the grounding clamp on the grounding shelf for the control cables 7 With option E202 in frames R10 and R11 digital input DI6 is reserved for internal overtemperature supervison of the cabinet See section Option E205 in frames R10 and R11 DI6 internal overtemperature supervision page 118 Option E205 in frames R10 and R11 DI6 internal overtemperature supervisio...

Page 119: ...3 16 DI4 17 DI5 18 DI6 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 18 X503 1 X504 18 Power supply connections for PNP without option L504 Internal and external 24 V power supply connections without option L504 for PNP configuration are shown below PNP connection source X4 24 V DC 0 V DC PNP connection source 10 24V 11 DGND 12 DCOM 13 DI1...

Page 120: ...ter 31 01 External event 1 source 2 Check that parameter 31 02 External event 1 type is set to Fault 0 For more information see the firmware manual WARNING Always connect the internal overtemperature supervision of the drive cabinet to a free digital input or to CMOD 01 multifunction extension module if disconnected from digital input DI6 Activate the change Disconnection of overtemperature superv...

Page 121: ...figuration are shown in the figure below External 24 V power supply Internal 24 V power supply NPN connection sink NPN connection sink X2 X3 10 24V 11 DGND 12 DCOM 13 DI1 14 DI2 15 DI3 16 DI4 17 DI5 18 DI6 0 V DC 24 V DC X2 X3 10 24V 11 DGND 12 DCOM 13 DI1 14 DI2 15 DI3 16 DI4 17 DI5 18 DI6 WARNING Do not connect the 24 V AC cable to the control unit ground when the control unit is powered from an...

Page 122: ...ement 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 DGND 4 20 mA P I An example of a three wire sensor transmitter supplied by the drive auxiliary voltage output is shown below The sensor is supplied through its current output and the drive feeds the supply voltage 24 V DC Thus the output signal must be 4 20 mA not 0 20 mA X1 5 AI2 Pro...

Page 123: ...g input AI1or with S2 for analog input AI2 Set the appropriate analog input unit to V volt in parameter group 12 Standard AI 2 Select the excitation mode in parameter group 13 Standard AO WARNING As the inputs pictured above are not insulated according to IEC 60664 the connection of the motor temperature sensor requires double or reinforced insulation between motor live parts and the sensor If the...

Page 124: ...Note Only 24 V DC can be used for STO Only PNP input configuration can be used 124 Control unit ...

Page 125: ...en DI6 and 24VDC 1 5 kohm 1 low temperature 4 kohm 0 high temperature open circuit 0 high temperature DI6 is not a reinforced double insulated input Connecting the motor PTC sensor to this input requires usage of a reinforced double insulated PTC sensor inside the motor 250 V AC 30 V DC 2 A Terminal size 0 14 2 5 mm2 Relay outputs RO1 RO3 Term 19 27 See section Isolation areas page 126 Current vol...

Page 126: ... 7 ft Control panel PC connection 19 21 RO1 22 24 RO2 25 27 RO3 EFB EIA R5 485 connection 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 Fieldbus module SLOT 2 I O extension module Panel port Isolation areas Reinforced insulation IEC EN 61800 5 1 2007 Functional insulation IEC EN 61800 5 1 2007 The terminals on the control board fulfil...

Page 127: ...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 Ground Slot 1 Slot 2 Jumper installed at factory Control unit 127 ...

Page 128: ...128 ...

Page 129: ...p the drive and do the steps in section Electrical safety precautions page 20 before you start the work Make sure that The ambient operating conditions meet the drive ambient conditions specification and enclosure rating IP code or UL enclosure type The supply voltage matches the nominal input voltage of the drive See the type designation label The drive cabinet has been attached to floor and if n...

Page 130: ...ed to the proper torque The motor cable has been routed away from other cables No power factor compensation capacitors have been connected to the motor cable The control cables have been connected to the appropriate terminals and the terminals have been tightened to the proper torque The voltage setting of the auxiliary voltage transformers if any is correct See the electrical installation instruc...

Page 131: ...ure See chapter Safety instruc tions page 15 Checks Settings with no voltage connected Check the mechanical and electrical installation of the drive See Installation checklist of the drive page 129 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 or circuits that have been wired from outsi...

Page 132: ...ks 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 when controlled with the control panel Check that the motor starts stops and follows the speed refe...

Page 133: ...r 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 10 Fault tracing 133 ...

Page 134: ...134 ...

Page 135: ...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 shorter maintenance intervals for certain components Consult your local ABB Service representative for additional ...

Page 136: ... fans frames R10 and R11 Cabinet cooling fans R R Cabinet cooling fan door frames R6 to R9 R R Cabinet cooling fan 50 Hz internal door IP54 frames R10 to R11 R R R Cabinet cooling fan 60 Hz internal IP54 frames R10 to R11 R R Cabinet cooling fan 60 Hz door frames R10 to R11 Aging R R Control panel battery real time clock 4FPS10000309652 Cleaning the interior of the cabinet WARNING Obey the instruc...

Page 137: ...ozzle proceed as follows 1 Stop the drive and do the steps in section Electrical safety precautions page 20 before you start the work 2 Remove the fasteners at the top of the grating 3 Lift the grating and pull it away from the door 4 Vacuum clean the mesh 5 Reinstall the mesh and grating in reverse order Replacing the air filters IP54 UL Type 12 Check the air filters and replace if necessary see ...

Page 138: ...into overtemperature warnings and faults if the heatsink is not clean When necessary clean the heatsink as follows WARNING Obey the instructions in chapter Safety instructions If you ignore them injury or death or damage to the equipment can occur WARNING Use a vacuum cleaner with antistatic hose and nozzle Using a normal vacuum cleaner creates static discharges which can damage circuit boards 1 S...

Page 139: ...nd dust concentration See the firmware manual for the actual signal which indicates the running time of the cooling fan Reset the running time signal after fan replacement Replacement fans are available from ABB Do not use other than ABB specified spare parts Replacing the door fan frames R6 to R9 Applicability For drives with option F250 L537 B055 Q951 Q963 Q971 or G300 WARNING Obey the instructi...

Page 140: ...er 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 Electrical safety precautions page 20 before you start the work 2 Open the cabinet door 3 Unplug the power supply wires 4 Remove the shroud 5 Undo the mounting screws and nuts of the fan 6 Install the new fan in reverse order 140 Maintenance ...

Page 141: ...ety precautions page 20 before you start the work 2 Open the cabinet door 3 Unplug the connector of the fan power supply at the front of the mounting plate 4 Pull the mounting plate outwards somewhat and unplug the connectors at the back of the mounting plate 5 Remove the mounting plate 6 Undo the fan assembly mounting screws 7 Remove the fan and the fan grating from the mounting plate 8 Install t...

Page 142: ...142 Maintenance ...

Page 143: ...ection Electrical safety precautions page 20 before you start the work 2 Open the cabinet door 3 Undo the fastening screws a of the fan mounting plate 4 Pull the mounting plate outwards and unplug the power supply cable b of the fan behind the mounting plate 5 Remove the fan mounting plate 6 Undo the mounting screws and nuts of the fan and take it out of the mounting plate 7 Install the new fan in...

Page 144: ...rt the work 2 Open the cabinet door 3 Remove the drive module from the cabinet as described in section Replacing the drive module frames R6 to R9 page 148 4 Remove the two mounting screws of the fan mounting plate at the bottom of the drive module 5 Unplug the fan power supply wires from the drive 6 Pull the fan mounting plate down from the side edge 7 Unplug the fan power supply wires from the dr...

Page 145: ...ge 20 before you start the work 2 Open the cabinet door 3 Remove the drive module from the cabinet as described in section Replacing the drive module frames R6 to R9 page 148 4 Undo the two mounting screws of the fan mounting plate at the bottom of the drive module 5 Turn the mounting plate downwards 6 Unplug the fan power supply wires from the drive 7 Remove the fan mounting plate 8 Remove the fa...

Page 146: ...e cabinet as described in section Replacing the drive module frames R10 and R11 page 154 4 Open the support legs of the pedestal 5 Undo the two screws that fasten the fan assembly plate 6 Tilt the fan assembly plate down 7 Disconnect the power supply wires of the fans 8 Remove the fan assembly from the drive module 9 Undo the fastening screws of the fan s and remove the fan s from the assembly pla...

Page 147: ... order Note Make sure that the arrow on the fan points up 3 4 Replacing the circuit board compartment cooling fans frames R10 and R11 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 Electrical safety precautions page 20 before you start the work 2 Open the cabinet door ...

Page 148: ... with a metal toe cap to avoid foot injury Lift the drive module only by the lifting lugs 1 Stop the drive and do the steps in section Electrical safety precautions page 20 before you start the work 2 Open the cabinet door 3 To attach the sliding rails 3 a Remove the sliding rails 2 pcs from the left hand side cabinet frame 3 b Undo the four screws from the top horizontal studs 3 c Attach the left...

Page 149: ... 3c 3e Torx M6x16 Torx M6x16 4 Unplug the wires connected to the mounting plate connectors if present 5 Remove the mounting plate four screws 6 Remove the shroud two screws 7 Remove the shroud on the power cable connection terminals Maintenance 149 ...

Page 150: ...les from the control unit 9 For drives with additional I O terminal block option L504 disconnect the upper terminals and remove any fastening Move the wires aside before you lift the module out Note Mark the wires for reconnection 150 Maintenance ...

Page 151: ...wires from the control unit Note Mark the wires for reconnection 11 For drives with line contactor option F250 disconnect the input power cables from the output of the contactor 12 Disconnect the input power cable conductors and motor cable conductors from the drive module terminals Maintenance 151 ...

Page 152: ...ule with chains from the lifting eyes 14 Undo the mounting screws of the flange 15 Slide the drive module forwards along the sliding bars 16 Lift the module out of the cabinet with a lifting device 14 13 15 16 152 Maintenance ...

Page 153: ...17 Remove the flange M6 nut 6 N m M6 10 T30 6 N m Combiscrew M6 25 T25 M6 nut 6 N m 18 Install the new module in reverse order Maintenance 153 ...

Page 154: ...on bar of 500 mm 20 in chains for securing the module during the installation The drawings show frame R10 The details in frame R11 are slightly different 1 Stop the drive and do the steps in section Electrical safety precautions page 20 before you start the work 2 Open the cabinet door 3 Remove the shrouds 4 Unplug the quick connectors at the top and bottom of the control unit mounting plate 5 Dis...

Page 155: ...3 4 5 Maintenance 155 ...

Page 156: ...6 7 Disconnect the drive module input busbars with a torque wrench withn an extension bar of 500 mm 20 in Combi screw M12 70 N m 52 lbf ft 156 Maintenance ...

Page 157: ...8 Disconnect the drive module output busbars M12 70 N m 52 lbf ft 7 8 Maintenance 157 ...

Page 158: ...9 Remove the shroud Undo the screws that attach the drive module to the cabinet at the top and behind the front support legs 158 Maintenance ...

Page 159: ...mp to the cabinet base with two screws 11 Attach the drive module lifting lugs to the cabinet lifting lug with chains 12 Pull the drive module carefully out of the cabinet preferably with help from another person Maintenance 159 ...

Page 160: ...with an extension bar of 500 mm 20 in chains for securing the module during the installation The drawings show frame R10 The details in frame R11 are slightly different 1 Stop the drive and do the steps in section Electrical safety precautions page 20 before you start the work 2 Open the cabinet door 3 Remove the shrouds and the additional IP54 fan 4 Unplug the quick connectors at the top and bott...

Page 161: ...4 5 3 Maintenance 161 ...

Page 162: ...6 7 Disconnect the drive module input busbars with a torque wrench withn an extension bar of 500 mm 20 in Combi screw M12 70 N m 52 lbf ft 162 Maintenance ...

Page 163: ...8 Disconnect the drive module output busbars M12 70 N m 52 lbf ft 7 8 Maintenance 163 ...

Page 164: ...9 Remove the shroud Undo the screws that attach the drive module to the cabinet at the top and behind the front support legs 164 Maintenance ...

Page 165: ...mp to the cabinet base with two screws 11 Attach the drive module lifting lugs to the cabinet lifting lug with chains 12 Pull the drive module carefully out of the cabinet preferably with help from another person Maintenance 165 ...

Page 166: ...r spare parts and repair services Reforming the capacitors The capacitors must be reformed if the drive has not been powered either in storage or unused for a year or more The manufacturing date is on the type designation label For information on reforming the capacitors see Converter module capacitor reforming instructions 3BFE64059629 English in the ABB Library https library abb com en If the dr...

Page 167: ...binet door 3 Remove the shrouding from in front of the fuses 4 Slacken the nuts of the headless screws of the fuses so that you can slide out the fuse blocks Make a note of the order of the washers on the screws 5 Remove the screws nuts and washers from the old fuses and attach them to the new fuses Make sure to keep the washers in the original order 6 Insert the new fuses into their slots in the ...

Page 168: ... ten years Note The battery is NOT required for any control panel 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...

Page 169: ...1 2 3 5a 5b CR2032 Maintenance 169 ...

Page 170: ...170 ...

Page 171: ...Input rating Frame size Drive type ACS580 07 Heavy overload use Light overload use No overload use PHd IHd PLd ILd PN SN I2 Imax I1 kW A kW A kW kVA A A A UN 400 V 55 105 75 138 75 100 145 178 145 R6 0145A 4 75 145 90 161 90 117 169 247 169 R7 0169A 4 90 169 110 196 110 143 206 287 206 R7 0206A 4 110 206 132 234 132 170 246 350 246 R8 0246A 4 132 246 160 278 160 203 293 418 293 R8 0293A 4 160 293 ...

Page 172: ...45A 4 100 124 125 156 171 247 156 R7 0169A 4 125 156 150 180 199 287 180 R7 0206A 4 150 180 200 240 242 350 240 R8 0246A 4 150 240 200 260 290 418 260 R8 0293A 4 250 302 300 361 345 498 361 R9 0363A 4 300 361 350 414 376 542 414 R9 0430A 4 300 361 400 483 388 560 483 R10 0505A 4 350 414 450 573 506 730 573 R10 0585A 4 400 477 500 623 506 730 623 R10 0650A 4 450 566 600 705 589 850 705 R11 0725A 4 ...

Page 173: ...t start then as long as allowed by drive temperature Imax Continuous rms output current allowing 50 overload for 1 minute every 10 minutes IHd Continuous rms output current allowing 30 overload for 1 minute every 10 minutes Continuous rms output current allowing 25 overload for 1 minute every 10 minutes Typical motor power in heavy duty use PHd Note 1 The ratings apply at an ambient temperature of...

Page 174: ...plying the current given in the rating table by the derating factor k T 1 00 0 90 40 C 104 F 50 C 122 F k 0 80 35 C 95 F 0 85 0 95 Altitude derating At altitudes from 1000 to 2000 m 3300 to 6561 ft above sea level the derating is 1 for every 100 m 328 ft Multiply the output current given in Ratings page 171 by the coefficient value given in this table Coeffficient Frame 4000 m 13123 ft 3000 m 9842...

Page 175: ...0 C 77 F 86 F 40 C 104 F 35 C 95 F 20 C 68 F 3300 ft 4921 ft 2000 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 Ambient temperature Deratings for special settings in the drive control program If you change the minimum switching frequency with parameter 97 02 Minimum switching frequency multiply the output current given in Ratings page 171 by the c...

Page 176: ...46930K 170M5410 690 155000 500 293 0293A 4 3 X300078C 170M6410 690 210000 630 363 0363A 4 3 Y300079C 170M6411 690 300000 700 430 0430A 4 3 W1046956F 170M6412 690 465000 800 505 0505A 4 3 X1046957F 170M6413 690 670000 900 585 0585A 4 3 Y1046958F 170M6414 690 945000 1000 650 0650A 4 3 A1046960F 170M6416 690 1950000 1250 725 0725A 4 3 A1046960F 170M6416 690 1950000 1250 820 0820A 4 3 B1046961F 170M64...

Page 177: ...00 DFJ 300 600 300 180 0206A 4 2 170M5408 2 H300065A 170M5408 690 400 240 0246A 4 2 170M5410 2 S1046930K 170M5410 690 500 260 0293A 4 3 170M6410 3 X300078C 170M6410 690 630 361 0363A 4 3 170M6411 3 Y300079C 170M6411 690 700 414 0430A 4 3 170M6412 3 W1046956F 170M6412 690 800 483 0505A 4 3 170M6413 3 X1046957F 170M6413 690 900 573 0585A 4 3 170M6414 3 Y1046958F 170M6414 690 1000 623 0650A 4 3 170M6...

Page 178: ... be used Note 3 Fuses from other manufacturers can be used if they meet the ratings and the melting curve of the fuse does not exceed the melting curve of the fuse mentioned in the table Note 4 Circuit breakers must not be used without fuses Fuses for branch circuit protection The drive is suitable for use on a circuit capable of delivering not more than 100 000 rms symmetrical amperes at 480 V ma...

Page 179: ...e ratings and the melting curve of the fuse does not exceed the melting curve of the fuse mentioned in the table Dimensions and weights Weight Depth Width Height Drive type ACS580 07 lb kg in mm in mm in mm 463 210 26 50 673 16 93 430 84 43 2145 R6 485 220 26 50 673 16 93 430 84 43 2145 R7 562 255 26 50 673 20 87 530 84 43 2145 R8 606 275 26 50 673 20 87 530 84 43 2145 R9 904 410 27 48 698 32 68 8...

Page 180: ...entry data for the power cables page 182 US 2 IEC 1 Frame size Drive type ACS580 07 Cu cable type Al cable type Cu cable type AWG kcmil per phase mm2 mm2 UN 400 V 3 0 3 120 3 95 R6 0145A 4 250 MCM 3 150 3 120 R7 0169A 4 300 MCM 3 240 3 150 R7 0206A 4 2 2 0 2 3 95 2 3 70 R8 0246A 4 2 3 0 2 3 120 2 3 95 R8 0293A 4 2 250 MCM 2 3 185 2 3 120 R9 0363A 4 2 300 MCM 2 3 240 2 3 150 R9 0430A 4 2 500 MCM or...

Page 181: ... in raceway or cable or earth directly buried For other conditions size the cables according to local safety regulations appropriate input voltage and the load current of the drive Losses cooling data and noise Noise Heat dissipa tion Air flow Drive type ACS580 07 IP54 UL Type 12 IP21 IP42 UL Type 1 dB A W ft3 min m3 h ft3 min m3 h UN 480 V 67 2487 344 585 403 685 0145A 4 67 2497 353 600 412 700 0...

Page 182: ...40 R7 30 44 M10 40 2 3 150 2 3 50 20 40 M10 2 3 150 R8 30 44 M10 70 2 3 240 2 3 95 50 75 M12 2 3 240 R9 30 44 M10 50 75 4 3 150 50 75 M12 4 3 150 R10 30 44 M10 50 75 4 3 240 50 75 M12 4 3 240 R11 1 Note Minimum wire size does not necessarily have enough current capability for full load Make sure the installation complies with local laws and regulations IEC With option E205 Input and motor cable te...

Page 183: ... 51 6 M12 7 16 4 3 500 MCM R11 1 Note Minimum wire size does not necessarily have enough current capability for full load Make sure the installation complies with local laws and regulations 2 01 246A 4 2 1 0 01 293A 4 2 3 0 US With option E205 Input and motor cable terminal bolt sizes maximum accepted wire sizes per three phases and tightening torques are given below PE grounding L1 L2 L3 U2 V2 W2...

Page 184: ...Connection drawings Frame R6 Input and motor cable terminal dimensions bottom entry and exit switch fuse OS250 DET A 184 Technical data ...

Page 185: ...Frame R6 Input and motor cable terminal dimensions bottom entry and exit switch fuse OS400 DET A Technical data 185 ...

Page 186: ...Frame R6 Input and motor cable terminal dimensions option F289 DET A 186 Technical data ...

Page 187: ...Frames R6 and R7 Input and motor cable terminal dimensions bottom entry and exit switch fuse OS250 du dt filter option E205 Technical data 187 ...

Page 188: ...Frames R6 and R7 Input and motor cable terminal dimensions bottom entry and exit switch fuse OS400 du dt filter option E205 188 Technical data ...

Page 189: ...Frames R6 and R7 Input and motor cable terminal dimensions bottom entry and exit options F289 and E205 Technical data 189 ...

Page 190: ...Frame R7 Input and motor cable terminal dimensions bottom entry and exit switch fuse OS250 DET A 190 Technical data ...

Page 191: ...Frame R7 Input and motor cable terminal dimensions bottom entry and exit switch fuse OS400 DET A Technical data 191 ...

Page 192: ...Frame R7 Input and motor cable terminal dimensions bottom entry and exit option F289 192 Technical data ...

Page 193: ...Frames R6 and R7 Input and motor cable terminal dimensions top entry and exit options H351 and H353 Technical data 193 ...

Page 194: ...Frame R8 Input and motor cable terminal dimensions bottom entry and exit switch disconnector OT400 DET A 194 Technical data ...

Page 195: ...Frame R8 Input and motor cable terminal dimensions bottom entry and exit switch disconnector OT400 du dt filter option E205 Technical data 195 ...

Page 196: ...Frame R8 Input and motor cable terminal dimensions bottom entry and exit option F289 196 Technical data ...

Page 197: ...Frame R9 Input and motor cable terminal dimensions bottom entry and exit switch disconnector OT630 DET A Technical data 197 ...

Page 198: ...Frame R9 Input and motor cable terminal dimensions bottom entry and exit switch disconnector OT630 du dt filter option E205 198 Technical data ...

Page 199: ...Frames R8 and R9 Input and motor cable terminal dimensions top entry and exit options H351 and H353 Technical data 199 ...

Page 200: ...Frames R8 and R9 Input and motor cable terminal dimensions bottom entry and exit options F289 and E205 200 Technical data ...

Page 201: ...Frame R9 Input and motor cable terminal dimensions option F289 Technical data 201 ...

Page 202: ...Frame R10 Input and motor cable terminal dimensions bottom entry and exit 202 Technical data ...

Page 203: ...Frame R10 Input and motor cable terminal dimensions bottom entry and exit option E205 Technical data 203 ...

Page 204: ...Frame R10 Input and motor cable terminal dimensions top entry and exit 204 Technical data ...

Page 205: ...Frame R10 Input and motor cable terminal dimensions top entry and exit option F289 Technical data 205 ...

Page 206: ...Frame R11 Input and motor cable terminal dimensions bottom entry and exit 206 Technical data ...

Page 207: ...Frame R11 Input and motor cable terminal dimensions bottom entry and exit option E205 Technical data 207 ...

Page 208: ...Frame R11 Input and motor cable terminal dimensions top entry and exit 208 Technical data ...

Page 209: ...Frame R11 Input and motor cable terminal dimensions top entry and exit option F289 Technical data 209 ...

Page 210: ...8 12 AWG Stranded wire 0 08 2 5 mm2 28 14 AWG 230V AC 4A X300 Solid wire 0 14 4 mm2 28 12 AWG Stranded wire 0 08 2 5 mm2 28 14 AWG 24V DC X951 Solid wire 0 14 4 mm2 28 12 AWG Stranded wire 0 08 2 5 mm2 28 14 AWG 24V DC X969 Solid wire 0 14 4 mm2 28 12 AWG Stranded wire 0 08 2 5 mm2 28 14 AWG 24V DC X3 Solid wire 0 14 4 mm2 28 12 AWG Stranded wire 0 08 2 5 mm2 28 14 AWG 230V AC 24V DC 2A X504 Solid...

Page 211: ...rt circuit current protection UL 508C 50 60 Hz Variation 5 of nominal frequency Frequency f1 Max 3 of nominal phase to phase input voltage Imbalance 0 98 at nominal load Fundamental power factor cos phi1 Motor connection data Asynchronous AC induction motors permanent magnet synchronous motors Motor types 0 to U1 3 phase symmetrical This is indicated in the type designation label as typical output...

Page 212: ...0529 UL Type 1 standard UL Type 1 option B054 UL Type 12 option B055 For indoor use only Enclosure types UL50 III except for auxiliary power connections fan control heating lighting cooling unit pump etc which are category II Overvoltage category IEC EN 60664 1 I Protective class IEC EN 61800 5 1 212 Technical data ...

Page 213: ...7 IEC EN 60721 3 3 2002 Contamination IEC 60721 3 x Class 2C2 Class 1C2 Class 3C2 Chemical gases Class 2S2 Class 1S3 packing must support this otherwise 1S2 Class 3S2 No conductive dust allowed Solid particles 60 to 106 kPa 0 6 to 1 05 atmospheres 70 to 106 kPa 0 7 to 1 05 atmospheres 70 to 106 kPa 0 7 to 1 05 atmospheres Atmospheric pressure IEC EN 60721 3 2 1997 IEC EN 60721 3 1 1997 IEC EN 6072...

Page 214: ...0 R11 cabinets are transported vertically For drives with empty cabinet options C196 to C201 Standard package timber polyethylene sheet thickness 0 15 mm stretch film thickness 0 023 mm PP tape PET strap sheet metal steel for land and air transport when planned storage time is less than 2 months or when storage can be arranged in clean and dry conditions less than 6 months can be used when product...

Page 215: ... for compliance The final assembler of the machine is responsible for installing emergency stop device Degrees of protection provided by enclosures IP code IEC 60529 1989 EN 60529 1991 Insulation coordination for equipment within low voltage systems Part 1 Principles requirements and tests IEC EN 60664 1 2007 Low voltage switchgear and control gear assemblies Part 1 General rules IEC EN 61439 1 20...

Page 216: ...ch can be recycled CE marking A CE mark is attached to the drive to verify that the drive complies with the provisions of the European Low Voltage and EMC Directives The CE marking also verifies that the drive in regard to its safety functions such as Safe torque off conforms with the Machinery Directive as a safety component Compliance with the European Low Voltage Directive The compliance with t...

Page 217: ...Declaration of Conformity Technical data 217 ...

Page 218: ...218 Technical data ...

Page 219: ...ven in the hardware manual 3 Maximum motor cable length is 150 meters WARNING The drive may cause radio interference if used in a residential or domestic environment The user is required to take measures to prevent interference in addition to the requirements for CE compliance listed above if necessary Note Do not install a drive equipped with EMC filter on IT ungrounded systems The supply network...

Page 220: ...ed to be used on a low voltage public network which supplies domestic premises Radio frequency interference is expected if the drive is used on such a network UL marking The drive is cULus listed with option C129 The approval is valid with rated voltages up to 480 V UL checklist WARNING Operation of this drive requires detailed installation and operation instructions provided in the hardware and s...

Page 221: ...nce with the national regulations National Electrical Code NEC or Canadian Electrical Code Obey also any other applicable local or provincial codes Note Circuit breakers must not be used without fuses in the USA For suitable circuit breakers contact your local ABB representative WARNING The opening of the branch circuit protective device may be an indication that a fault current has been interrupt...

Page 222: ...usly 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 application of authentication measures encryption of data installation of anti virus programs etc to protect the product the network its system and the interface again...

Page 223: ...Dimension drawings Example dimension drawings are shown below 13 Dimension drawings 223 ...

Page 224: ...Frames R6 and R7 IP21 UL Type 1 224 Dimension drawings ...

Page 225: ...Frames R6 and R7 B054 IP42 UL Type 1 Dimension drawings 225 ...

Page 226: ...Frames R6 and R7 B055 IP54 UL Type 12 226 Dimension drawings ...

Page 227: ...Frames R6 and R7 H351 and H353 top entry and exit Dimension drawings 227 ...

Page 228: ...Frames R6 and R7 F289 228 Dimension drawings ...

Page 229: ...Frames R6 and R7 F289 H351 H353 Dimension drawings 229 ...

Page 230: ...Frames R8 and R9 IP21 230 Dimension drawings ...

Page 231: ...Frames R8 and R9 B054 IP42 UL Type 1 Dimension drawings 231 ...

Page 232: ...Frames R8 and R9 B055 IP54 UL Type 12 232 Dimension drawings ...

Page 233: ...Frames R8 and R9 H351 and H353 top entry and exit Dimension drawings 233 ...

Page 234: ...Frames R8 and R9 F289 234 Dimension drawings ...

Page 235: ...Frames R8 and R9 F289 H351 H353 Dimension drawings 235 ...

Page 236: ...Frames R10 and R11 IP21 236 Dimension drawings ...

Page 237: ...Frames R10 and R11 B054 IP42 UL Type 1 Dimension drawings 237 ...

Page 238: ...Frames R10 and R11 B055 IP54 UL Type 12 238 Dimension drawings ...

Page 239: ...Frames R10 and R11 F289 T Dimension drawings 239 ...

Page 240: ...Frames R10 and R11 H351 H353 240 Dimension drawings ...

Page 241: ...Frames R10 and R11 B054 IP42 UL type 1 H351 H353 T Dimension drawings 241 ...

Page 242: ...Frames R10 and R11 B055 IP54 UL type 12 H351 H353 T 242 Dimension drawings ...

Page 243: ...utput stage A see the diagrams 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...

Page 244: ...C 61511 1 2016 Adjustable speed electrical power drive systems Part 5 2 Safety require ments Functional IEC 61800 5 2 2016 EN 61800 5 2 2007 Safety of machinery Functional safety of safety related electrical elec tronic and programmable electronic control systems IEC 62061 2005 A1 2012 A2 2015 EN 62061 2005 AC 2010 A1 2013 A2 2015 Safety of machinery Safety related parts of control systems Part 1 ...

Page 245: ...echnical data of the control unit Connection principle Connection with internal power supply OUT1 24 V DC SGND STO UDC UDC A 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 The Safe torque off function 245 ...

Page 246: ... 34 35 36 37 38 24 V DC K Drive 1 Control unit 2 Control logic 3 To motor 4 Activation switch K Wiring examples Wiring with internal power supply 24 14 23 13 Y1 A2 Y2 A1 31 32 OUT GND K 1 2 OUT1 34 OUT2 35 SGND 36 IN1 37 IN2 38 STO Drive 1 Safety PLC 2 Safety relay K 246 The Safe torque off function ...

Page 247: ...odule can also be used For more information see the module documentation Cable types and lengths Double shielded twisted pair cable is recommended Maximum cable lengths 300 m 1000 ft between activation switch K and drive control unit 60 m 200 ft between multiple drives or inverter units 60 m 200 ft between external power supply and first control unit Note A short circuit in the wiring between the ...

Page 248: ...elds Ground the shield in the cabling between the activation switch and the control unit at the control unit only Ground the shield in the cabling between two control units at one control unit only 248 The Safe torque off function ...

Page 249: ... 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 250: ...stored in the logbook of the machine The report shall include documentation of start up activities and test results references to failure reports and resolution of failures Any new acceptance tests performed due to changes or maintenance shall be logged into the logbook Acceptance test procedure After wiring the Safe torque off function validate its operation as follows Note If the drive is equipp...

Page 251: ...he operation when the motor is stopped Close the STO circuit Reset any active faults Restart the drive and check that the motor runs normally Test the operation of the failure detection of the drive The motor can be stopped or running Open the 1st channel of the STO circuit wire coming to IN1 If the motor was running it should coast to a stop The drive generates a FA81 Safe Torque Off 1 loss fault...

Page 252: ...e IGBT power semiconductor failure the drive can produce an alignment torque which maximally rotates the motor shaft by 180 p degrees with permanent magnet motors or 180 2p degrees with synchronous reluctance SynRM motors regardless of the activation of the Safe torque off function p denotes the number of pole pairs Notes If a running drive is stopped by using the Safe torque off function the driv...

Page 253: ...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 254: ...function is performed and the drive trips on an STO hardware failure 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 d...

Page 255: ... 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 13849 2 table D 5 The analysis is based on an assumption that one failure occurs at one time No accumulated failures have been analyzed STO response times STO reaction time shortest detectable break 1 ms STO response time 2 ms typical 5 ms maximum Fau...

Page 256: ...rrespond to SIL EN ISO 13849 1 PL Systematic capability IEC 61508 SC Safe failure fraction IEC 61508 SFF Safety integrity level 1 3 IEC 61508 SIL Maximum SIL level 1 3 that can be claimed for a safety function or subsystem IEC EN 62061 SILCL Safe torque off IEC EN 61800 5 2 STO Proof test interval T1 is a parameter used to define the probabilistic failure rate PFH or PFD for the safety function or...

Page 257: ... Declaration of conformity The Safe torque off function 257 ...

Page 258: ... TÜV certificate The TÜV certificate is available on the Internet at www abb com drives documents 258 The Safe torque off function ...

Page 259: ...CMOD 02 multifunction extension module CPTC 02 ATEX certified thermistor protection module This chapter also contains diagnostics and technical data of these modules CBAI 01 bipolar analog IO extension module Hardware description Product overview The CBAI 01 bipolar analog IO extension module includes two bipolar analog inputs two unipolar analog outputs and a switch which can be used to select sc...

Page 260: ...age 263 Diagnostic LED 6 Terminal designations page 261 Analog output 4 7 Terminal designations page 261 Analog input 4 8 Mechanical installation Necessary tools and instructions Screwdriver and a set of suitable bits Unpacking and checking the delivery 1 Open the option package Make sure that the package contains CBAI 01 bipolar analog IO extension module a mounting screw 2 Make sure that there a...

Page 261: ...1 Cable shield connection routed directly to output SCR SCR 82 Analog input positive signal AI4 83 Analog input negative signal AI4 84 Cable shield connection routed directly to output SCR SCR 85 Analog outputs Description Marking Analog output signal AO3 86 Analog ground potential AGND 87 Cable shield connection routed directly to output SCR SCR 88 Analog output signal AO3 89 Analog ground potent...

Page 262: ...o make the connection is to connect the cable shield to the SCR terminal of the control board Analog input connection example 2 82 81 80 SCR CBAI 01 AI3 AI3 V GND V Analog output connection example 2 88 86 87 1 SCR AO3 AGND CBAI 01 0 10 V Cable shield connected to control board SCR terminal 1 262 Optional I O extension modules ...

Page 263: ...0 Hz with detection of a wire break between the extension module and the control board of the drive Default Setting Parameter 4 000 mA or 0 000 V 0 5 V 12 17 AI1 min 20 000 mA or 10 000 V 9 5 V 12 18 AI1 max 0 000 50 12 19 AI1 scaled at AI1 min 50 50 12 20 AI1 scaled at AI1 max Disabled Low 32 05 Supervision 1 function No action Fault 32 06 Supervision 1 action Frequency AI1 32 07 Supervision 1 si...

Page 264: ...ed A Piirainen 04 Oct 17 Title DIMENSION DRAWING Doc des Scale Form Check P Viitala 04 Oct 17 CBAI 01 DIMENSION DRAWING DIMENSION DRAWING 1 1 A4 Appr J Viman 04 Oct 17 Resp dept Rev ind 2 DR Project name Doc No 3AXD50000182008 Weight kg 0 11 Installation Into an option slot on the drive control board Degree of protection IP20 Ambient conditions See the drive technical data Package Cardboard 264 Op...

Page 265: ...drive SLOT2 2 SWITCH Reinforced insulation IEC 61800 5 1 2007 Functional insulation IEC 61800 5 1 2007 CBAI 01 1 AO3 AO4 AI4 AI4 2 Description Symbol Plugged to drive SLOT2 1 SWITCH 2 Reinforced insulation IEC 61800 5 1 2007 Functional insulation IEC 61800 5 1 2007 Analog inputs 80 82 83 85 Wire size max 1 5 mm2 Input voltage AI and AI 10 V 10 V Input resistance 200 kohm Optional cable shield conn...

Page 266: ...ng screw 2 Terminal designations page 267 3 pin terminal blocks for relay outputs 3 Terminal designations page 267 3 pin terminal block for 115 230 V inputs 4 LEDs page 270 Diagnostic LED 5 Mechanical installation Necessary tools and instructions Screwdriver and a set of suitable bits Unpacking and checking the delivery 1 Open the option package 2 Make sure that the package contains CHDI 01 high v...

Page 267: ...If the drive is already connected to the input power wait for 5 minutes after disconnecting the input power Necessary tools and instructions Screwdriver and a set of suitable bits Cabling tools Terminal designations For more detailed information on the connectors see section Technical data page 270 Relay outputs Description Marking Common C RO4C 50 Normally closed NC RO4A 51 Normally open NO RO4B ...

Page 268: ...ce 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 02 and 15 01 is CHDI 01 If warning A7AB Extension I O configuration failure is shown make sure that the value of parameter 15 02 is CHDI 01 set parameter 15 01 value to CHDI 01 You can now see the parameters of the extension module in parameter group 15 I O extension modu...

Page 269: ...Setting Parameter 1 s 15 09 RO4 OFF delay Optional I O extension modules 269 ...

Page 270: ...ne diagnostic LED Description Color The extension module is powered up Green 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 Ambient conditions See the drive technical data 270 Optional I O extension modules ...

Page 271: ...ation IEC 61800 5 1 2007 Relay outputs 50 52 53 55 Wire size max 1 5 mm2 Minimum contact rating 12 V 10 mA Maximum contact 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 Optional I O extension modules 271 ...

Page 272: ...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 Note In frames R6 R9 you do not need a CMOD 01 module to use external 24 V AC DC supply The external supply is connected directly to terminals 40 and 41 on the control unit WARNING Do not connect the 24 V AC cable to the control unit ground when t...

Page 273: ... section Installing optional modules in chapter Electrical installation Electrical installation WARNING Obey the instructions in chapter Safety instructions If you ignore them injury or death or damage to the equipment can occur If you are not a qualified electrician do not do electrical work Make sure that the drive is disconnected from the input power during installation If the drive is already ...

Page 274: ...terminals 40 and 41 on the control unit Description Marking External 24 V AC DC input 24 V AC DC in 40 External 24 V AC DC input 24 V AC DC in 41 General cabling instructions Obey the instructions given in chapter Guidelines for planning the electrical installation Wiring Connect the external control cables to the applicable module terminals Ground the outer shield of the cables 360 degrees under ...

Page 275: ...re that the value of both parameters 15 02 and 15 01 is CMOD 01 If warning A7AB Extension I O configuration failure is shown make sure that the value of parameter 15 02 is CMOD 01 set the parameter 15 01 value to CMOD 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 Examples are gi...

Page 276: ...xtension module indicate the reverse direction of rotation of the motor with a one second delay Setting Parameter Digital output 15 22 DO1 configuration Reverse 15 23 DO1 source 1 s 15 24 DO1 ON delay 1 s 15 25 DO1 OFF delay 276 Optional I O extension modules ...

Page 277: ... 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 min 10000 Hz 15 37 Freq out 1 at src max Diagnostics Faults and warning messages Warning A7AB Extension I O configuration failure LEDs The extension module has one diagnostic LED Description Color The extension module is powered up Green O...

Page 278: ...ng 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 278 Optional I O extension modules ...

Page 279: ... A Maximum breaking capacity 1500 VA Transistor output 42 44 Wire size max 1 5 mm2 Type Transistor output PNP Maximum load 4 kohm Maximum switching voltage 30 V DC Maximum switching current 100 mA 30 V DC short circuit protected 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 power consumption 25 W 1...

Page 280: ...rnal 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 insulation between the motor thermistor connection the relay output and the drive control unit interface Thus you c...

Page 281: ...terminal block for external power supply 5 LEDs page 284 Diagnostic LED 6 Mechanical installation Necessary tools and instructions Screwdriver and a set of suitable bits Unpacking and checking the delivery 1 Open the option package 2 Make sure that the package contains CMOD 02 multifunction extension module a mounting screw support part Note The support part is needed for the following frame R1 dr...

Page 282: ... information on the connectors see section Technical data page 284 Motor thermistor connection Description Marking PTC connection PTC IN 60 Ground earth potential PTC IN 61 Relay output Description Marking Common C RO PTC C 62 Normally open NO RO PTC B 63 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 uni...

Page 283: ...lated 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 connection example 62 63 CMOD 02 CCU 34 35 X4 36 37 38 OUT1 OUT2 SGND IN1 IN2 RO PTC C RO PTC B Power supply connection example 40 41 1 24V A...

Page 284: ...is CMOD 02 set the parameter 15 01 value to CMOD 02 You can now see 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 Description Color The extension module is powered up Green Technical data Dimension drawing The dimensions are i...

Page 285: ...Installation Into an option slot on the drive control unit Degree of protection IP20 Ambient conditions See the drive technical data Package Cardboard Optional I O extension modules 285 ...

Page 286: ...nal voltage 5 0 V PTC terminal current 1 mA Short circuit detection 50 ohm 10 Relay output 62 63 Wire size max 1 5 mm2 Maximum contact 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 power consumption 25 W 1 04 A at 24 V DC CPTC 02 ATEX certified thermistor protection module external 24 V AC ...

Page 287: ... 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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