ABB ACH580-31 Hardware Manual Download

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ABB INDUSTRIAL DRIVES

ACH580-31 drives

Hardware manual

Summary of Contents for ACH580-31

Page 1: ... ABB INDUSTRIAL DRIVES ACH580 31 drives Hardware manual ...

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Page 3: ...580 31 drives Hardware manual Table of contents 1 Safety instructions 4 Mechanical installation 6 Electrical installation IEC 10 Start up 3AXD50000037066 Rev F EN Original instructions EFFECTIVE 2022 10 14 ...

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Page 5: ...nual 25 Contents of this chapter 25 Target audience 25 Purpose of the manual 25 Categorization by frame size and option code 26 Quick installation commissioning and operation flowchart 27 Terms and abbreviations 29 Related documents 3 Operation principle 31 Contents of this chapter 31 Operation principle 32 Active braking function option N8056 32 DC voltage boost function 33 Benefits of the DC vol...

Page 6: ... European Union and United Kingdom 58 North America 58 Other regions 58 Implementing a fast switch over between the power line and generator 58 Selecting the main contactor 59 North America 59 Other regions 59 Examining the compatibility of the motor and drive 59 Protecting the motor insulation and bearings 60 Requirements tables 60 Requirements for ABB motors Pn 100 kW 134 hp 61 Requirements for ...

Page 7: ...ng requirements UL NEC 74 Selecting the control cables 74 Shielding 74 Signals in separate cables 74 Signals that can be run in the same cable 75 Relay cable 75 Control panel to drive cable 75 PC tool cable 75 Routing the cables 75 General guidelines IEC 76 General guidelines North America 77 Continuous motor cable shield conduit or enclosure for equipment on the motor cable 78 Separate control ca...

Page 8: ...des 88 Implementing a motor temperature sensor connection 89 Connecting a motor temperature sensor to the drive through an option module 6 Electrical installation IEC 91 Contents of this chapter 91 Safety 91 Required tools 91 Grounding the motor cable shield at the motor end 92 Measuring the insulation 92 Measuring the insulation resistance of the drive 92 Measuring the insulation resistance of th...

Page 9: ... the installation 120 Grounding system compatibility check 120 Connecting the power cables 120 Connection diagram 121 Connection procedure 128 Connecting the control cables 128 Connection diagram 128 Connection procedure 132 Installing optional modules 133 Reinstalling cover s 134 Connecting a PC 134 Connecting a remote panel or chaining one panel to several drives 8 Control unit 135 Contents of t...

Page 10: ...6 Cleaning the heatsink 156 Fans 157 Replacing the main cooling fan frame R3 158 Replacing the main cooling fan frame R6 159 Replacing the main cooling fan frame R8 160 Replacing the auxiliary cooling fan of frame R3 IP55 UL Type 12 and C135 IP21 UL Type 1 161 Replacing the auxiliary cooling fan frame R6 162 Replacing the second auxiliary cooling fan IP55 UL Type 12 frame R6 163 Replacing the auxi...

Page 11: ... UL 184 Circuit breakers IEC 184 ABB miniature and molded case circuit breakers 185 Circuit breakers UL 188 Dimensions weights and free space requirements 188 Free space requirements 189 Package dimensions and weights 190 Losses cooling data and noise 192 Cooling air flow and heat dissipation for flange mounting option C135 194 Terminal and entry data for the power cables 194 IEC 194 UL 195 Termin...

Page 12: ...isclaimer 13 Dimension drawings 214 R3 IP21 UL Type 1 215 R3 Option B056 IP55 UL Type 12 216 R6 IP21 UL Type 1 217 R6 Option B056 IP55 UL Type 12 218 R8 IP21 UL Type 1 219 R8 Option B056 IP55 UL Type 12 14 The Safe torque off function 221 Contents of this chapter 221 Description 222 Compliance with the European Machinery Directive and the UK Supply of Machinery Safety Regulations 223 Wiring 223 Co...

Page 13: ...fault brake system components 244 Selecting a custom brake resistor 245 Selecting and routing the brake resistor cables 245 Minimizing electromagnetic interference 245 Maximum cable length 246 Placing the brake resistors 246 Protecting the system against thermal overload 246 Protecting the system in fault situations 247 Protecting the resistor cable against short circuits 247 Mechanical installati...

Page 14: ...57 Wiring 258 Start up 258 Setting the parameters 259 Diagnostics 259 LEDs 259 Technical data 260 Isolation areas 261 Dimension drawings 18 CHDI 01 115 230 V digital input extension module 263 Contents of this chapter 263 Product overview 264 Layout and connection examples 265 Mechanical installation 265 Necessary tools 265 Unpacking and examining the delivery 265 Installing the module 265 Electri...

Page 15: ...lts and warning messages 273 LEDs 273 Technical data 274 Dimension drawing 20 CMOD 02 multifunction extension module external 24 V AC DC and isolated PTC interface 277 Contents of this chapter 277 Product overview 278 Layout and example connections 279 Mechanical installation 279 Necessary tools 279 Unpacking and examining the delivery 279 Installing the module 279 Electrical installation 279 Nece...

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Page 17: ...you how to prevent the danger Notes draw attention to a particular condition or fact or give information on a subject The manual uses these warning symbols WARNING Electricity warning tells about hazards from electricity which can cause injury or death or damage to the equipment WARNING General warning tells about conditions other than those caused by electricity which can cause injury or death or...

Page 18: ... because it is heavy and has a high center of gravity Whenever possible secure the module with chains Do not leave an unsupported module unattended especially on a sloping floor Beware of hot surfaces Some parts such as heatsinks of power semiconductors and brake resistors remain hot for a while after disconnection of the electrical supply Vacuum clean the area around the drive before the start up...

Page 19: ...r of drive power ups is five in ten minutes Too frequent power ups can damage the charging circuit of the DC capacitors If you have connected safety circuits to the drive for example Safe torque off or emergency stop validate them at 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 runni...

Page 20: ...tors discharge before you continue 3 Protect any other energized parts in the work location against contact 4 Take special precautions when close to bare conductors 5 Measure that the installation is de energized Use a quality voltage tester Before and after measuring the installation verify the operation of the voltage tester on a known voltage source Make sure that the voltage between the drive ...

Page 21: ...ields present which can interfere with the function of such devices This can cause a health hazard Note When the drive is connected to the input power the motor cable terminals and the DC bus are at a dangerous voltage The brake circuit including the brake chopper and brake resistor if installed are also at a dangerous voltage After disconnecting the drive from the input power these remain at a da...

Page 22: ...djoining equipment This is necessary for the personnel safety Make sure that the conductivity of the protective earth PE conductors is sufficient and that other requirements are met See the electrical planning instructions of the drive Obey the applicable national and local regulations When using shielded cables make a 360 grounding of the cable shields at the cable entries to reduce electromagnet...

Page 23: ...s can occur These functions reset the drive automatically and continue operation after a fault or supply break If these functions are activated the installation must be clearly marked as defined in IEC EN UL 61800 5 1 subclause 6 5 3 for example THIS MACHINE STARTS AUTOMATICALLY Note The maximum number of drive power ups is five in ten minutes Too frequent power ups can damage the charging circuit...

Page 24: ...ly or through any mechanical connection like belt nip rope etc Do the steps in section Electrical safety precautions page 20 Install temporary grounding to the drive output terminals T1 U T2 V T3 W Connect the output terminals together as well as to the PE During the start up Make sure that the motor cannot run overspeed for example driven by the load Motor overspeed causes overvoltage that can da...

Page 25: ...ns for the end user of the drive concerning the installation and maintenance of the drive Read the manual before you work on the drive You are expected to know the fundamentals of electricity wiring electrical components and electrical schematic symbols Purpose of the manual This manual provides information needed for planning the installation installing and servicing the drive Categorization by f...

Page 26: ...nnection andothertechnical data Technical data page 169 Unpacking and examining delivery page 47 Unpack and check the drive Grounding system compatibility check page 93 If the drive will be connected to an IT un grounded system or corner grounded delta system check that the integrated EMC filter and round to phase varistor are disconnec ted Mechanical installation page 43 Install the drive on a wa...

Page 27: ...pper Dissipates the drive surplus braking energy conducted by the brake chopper to heat Brake resistor The capacitors connected to the DC link Capacitor bank Configuration adapter CCA 01 Type of control unit CCU Communication adapter module CDPI 01 115 230 V digital input extension module CHDI 01 Multifunction extension module external 24 V AC DC and digital I O extension CMOD 01 Multifunction ext...

Page 28: ...rnating current and voltage Inverter Rectifies three phase AC current to direct current for the intermediate DC link of the drive Line side converter A networking platform LonWorks Converts intermediate DC link current to AC current for the motor Motor side converter Remote monitoring tool NETA 21 With fieldbus protocols based on the Common Industrial Protocol CIPTM such as DeviceNet and Ethernet ...

Page 29: ...anuals and other product documents in PDF format on the Internet at www abb com drives documents The code and link below open an online listing of the manuals applicable to this product ACH580 31 manuals Introduction to the manual 29 ...

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Page 31: ...he ACH580 31 is a ultra low harmonic drive for controlling asynchronous AC induction motors permanent magnet motors in open loop control and synchronous reluctance motors The drive includes a line side converter and a motor side converter The parameters and signals for both converters are combined into one primary user program 3 Operation principle 31 ...

Page 32: ...urrent harmonics is low The LCL filter suppresses the harmonics further The line side and motor side converters have their own control programs The parameters of both programs can be viewed and changed using a control panel Active braking function option N8056 The line side converter with active braking function can transfer regenerated energy up to 50 of the rated power back to the electrical pow...

Page 33: ...ly 460 V to a 460 V motor Impact of DC voltage boost on input current When the DC voltage is boosted the drive can be drawing more input current than what is rated in the type designation label Derating is needed when the motor is running at the field weakening area or close to it and the drive is running at nominal load or close to it when the situation lasts long when the boost is more than 10 T...

Page 34: ...5 1 IP20 UL Open Type option P940 R3 UL Type 12 R6 7 Front cover 5 Lifting eyes 2 pcs in frame R3 6 pcs in frames R6 and R8 1 Control panel behind the control panel cover 6 Control panel 2 Hood in frames R6 and R8 7 Heatsink 3 Mounting points 4 pcs 4 34 Operation principle ...

Page 35: ...ives Another auxiliary cooling fan at right hand side of the control panel is included in IP55 UL Type 12 frames R8 and frame R6 types 062A 4 and 052A 4 and bigger 8 Input power cable entry behind the 360 degree grounding clamps 15 Clamps for securing the FSO wiring mechanically 9 Control cable entry 4 pcs 16 Power cable connection terminals be hind the shroud 10 Operation principle 35 ...

Page 36: ...ew of power and control connections The logical diagram below shows the power connections and control interfaces of the drive Slot 2 L1 L2 L3 PE T1 U T2 V T3 W M 3 L1 L2 L3 PE UDC UDC Slot 1 1 2 Panel port 3 4 Option slot 1 for optional fieldbus adapter modules 1 Option slot 2 for optional I O extension modules 2 Panel port 3 Common mode filter additional du dt or sine filter Refer to Common mode ...

Page 37: ...stall the control panel put the bottom of the container in position 2a press the retaining clip at the top 2b and push the control panel in at the top edge 2c 2b 2c 2a For the use of the control panel see the firmware manual and ACS AP I S W and ACH AP H W Assistant control panels user s manual 3AUA0000085685 English Operation principle 37 ...

Page 38: ... platform for control panels installation guide Control panel mounting platform cover option J424 CDOM 01 control panel mounting platform cover can be used to cover the control panel mounting platform when no control panel is on it Power and fault indication LEDs are visible on the cover Remote control panel panel bus CDPI 01 communication adapter module can be used to connect the drive control pa...

Page 39: ...Operation principle 39 ...

Page 40: ...on 4 Degree of protection 5 Nominal ratings in the supply voltage range see the technical data 6 Rated conditional short circuit current see the technical data 7 Valid markings 8 9 Serial number of format MYYWWXXXX where S N Manufacturer M 16 17 18 for 2016 2017 2018 YY 01 02 03 for week 1 week 2 week 3 WW Integer starting every week from 0001 XXXXX Link to product information 10 40 Operation prin...

Page 41: ...ilter C2 in all frames internal common mode filter to be installed by the customer for frame R8 Safe torque off function coated boards cable entry from bottom multilingual quick installation and start up guide EN DE ES FR IT TR 31 Refer to Option codes page 41 for options Size See the technical data xxxx Voltage range 380 480 V 4 Option codes Description Code IP55 UL Type 12 B056 Flange mounting C...

Page 42: ...et default for SV CZ HU DA NL includes EN DE ES PT FR SV CZ HU DA NL N2901 Asian software language set default for KO TH includes EN DE ES PT FR ZH KO TH N2902 Active braking N8056 Extended warranty 36 months from delivery P931 Extended warranty 60 months from delivery P932 Version for cabinet mounting P940 Drive module without front covers and bottom plate ATEX certified safe disconnection functi...

Page 43: ...s into a user defined cabinet see Drive modules cabinet design and construction instructions 3AUA0000107668 English Flange mounting option C135 See also Code English Manual name 3AXD50000349838 ACS880 11 ACS880 31 ACH580 31 and ACQ580 31 C135 drives with flange mounting kit supplement 3AXD50000181506 ACS880 11 ACS880 31 ACH580 31 and ACQ580 31 C135 frame R3 flange mounting kit quick installation g...

Page 44: ...l data The material behind above and below the drive is non flammable The installation surface is as close to vertical as possible and strong enough to support the drive There is sufficient free space around the drive for cooling maintenance and operation See the free space specifications for the drive Make sure that there are no sources of strong magnetic fields such as high current single core c...

Page 45: ...filled Note IP21 UL Type 1 construction only meets IP20 UL Type Open in horizontal position Free space requirements Free space requirements are shown in the drawings below 200 mm 7 87 in 300 mm 11 81 in 200 mm 7 87 in 30 mm 1 18 in 300 mm 11 81 in 200 mm 7 87 in 30 mm 1 18 in 200 mm 7 87 in 300 mm 11 81 in Mechanical installation 45 ...

Page 46: ... a heavy drive you need crane fork lift or pallet truck check load capacity To lift a heavy drive you need a hoist To install the drive mechanically you need the following tools drill with suitable bits screwdriver set Torx flat and or Phillips as appropriate torque wrench 46 Mechanical installation ...

Page 47: ...s transport package to the installation site Unpacking and examining delivery The figure below shows the drive package with its contents Examine that all items are present and there are no signs of damage Read the data on the type designation label of the drive to make sure that the drive is of the correct type Mechanical installation 47 ...

Page 48: ...rdboard sleeve 10 I O option module 4 Cardboard box which contains control panel box 1 and option boxes 4 and 5 11 Fieldbus option module 5 Drive 12 Printed quick installation and start up guide and manuals multilingual resid ual voltage warning sticker 6 To unpack Cut the straps 3 Remove the tray 9 and sleeve 10 Remove the cover protecting film Lift the drive 48 Mechanical installation ...

Page 49: ...n and stat up guide and manuals multilingual resid ual voltage warning sticker 1 Outer box 7 Accessories 2 Pallet 8 Mounting template 3 VCI bag 9 Package straps 4 Plastic bag 5 To unpack Cut the straps 4 Remove the outer box 7 Open the VCI bag 9 Undo the attaching screws A B Lift the drive Mechanical installation 49 ...

Page 50: ...e and manuals multilingual resid ual voltage warning sticker 1 Outer box 8 Accessories 2 Cardboard insert 9 Bubble wrap 3 Pallet 10 Mounting template 4 VCI bag 11 Package straps 5 UL Type 12 hood 12 Plastic bag 6 To unpack Cut the straps 5 Remove the outer box 8 Open the VCI bag 11 Undo the attaching screws A B Lift the drive 50 Mechanical installation ...

Page 51: ... warning sticker 1 Packing bracket 9 VCI bag 2 Pallet 10 Mounting template 3 Screw 11 Package straps 4 Screw 12 Plastic bag 5 Drive with factory installed options 13 Plywood support 6 Common mode filter option E208 14 Tray 7 To unpack Cut the straps 4 Remove the tray 7 and cardboard sleeve 8 Open the VCI bag 2 Undo the attaching screws a b Lift the drive Mechanical installation 51 ...

Page 52: ...icker 1 Plywood support 10 VCI bag 2 Pallet 11 Bubble wrap 3 UL Type 12 hood 12 Mounting template 4 Drive with factory installed options 13 Package straps 5 Screws 14 Plastic bag 6 Common mode filter option E208 15 Packing bracket 7 Tray 8 To unpack Cut the straps 5 Remove the tray 8 and cardboard sleeve 9 Open the VCI bag 2 Undo the attaching screws a b Lift the drive 52 Mechanical installation ...

Page 53: ...gs 1 2 Drill the mounting holes 3 Insert anchors or plugs into the holes and start the screws or bolts into the anchors or plugs Drive the screws or bolts long enough into the wall to make them carry the weight of the drive 4 Put the drive onto the bolts on the wall 5 For R6 and R8 with option B056 UL Type 12 Install the hood on top of the drive before you tighten the upper attaching bolts Put the...

Page 54: ... 4 2 a b R8 R6 R3 in mm in mm in mm 37 20 945 29 64 753 18 66 474 a 10 33 262 5 8 37 212 5 6 30 160 b R8 R6 R3 lb kg lb kg lb kg 260 118 135 61 0 47 21 3 IP21 UL Type 1 273 124 139 63 52 23 3 IP55 UL Type 12 54 Mechanical installation ...

Page 55: ...on Installing the drive vertically page 53 Installing the drive horizontally The drive can be installed with either the left or right side up Follow the steps in section Installing the drive vertically page 53 For free space requirements see section Free space requirements page 45 Mechanical installation 55 ...

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Page 57: ...ever for any installation which breaches the local laws and or other regulations Furthermore if the recommendations given by ABB are not followed the drive may experience problems that the warranty does not cover Selecting the main supply disconnecting device You must equip the drive with a main supply disconnecting device which meets the local safety regulations You must be able to lock the disco...

Page 58: ...a fast switch over between the power line and generator You can do a fast switch over between the power line and generator without stopping the drive Starting and stopping the drive takes more time than the fast switch over WARNING The drive requires at least a 50 ms fast switch over time and the same phase order in the switching A shorter switch over time or a different phase order can cause a dr...

Page 59: ...he motor manufacturer before using a motor with nominal voltage that differs from the AC line voltage connected to the drive input The voltage peaks at the motor terminals are relative to the supply voltage of the drive not to the drive output voltage Protecting the motor insulation and bearings The drive employs modern IGBT inverter technology Regardless of frequency the drive output comprises pu...

Page 60: ...and frame size IEC 315 Pn 134 hp and frame size NEMA 500 Standard Un 500 V Random wound M2_ M3_ and M4_ du dt Standard 500 V Un 600 V Reinforced du dt Reinforced 600 V Un 690 V cable length 150 m Reinforced 600 V Un 690 V cable length 150 m N A Standard 380 V Un 690 V Form woundHX_ and AM_ N du dt with voltages over 500 V CMF Check with the motor manufac turer 380 V Un 690 V Old1 form wound HX_ an...

Page 61: ... CMF N Reinforced N du dt CMF N du dt Reinforced 600 V Un 690 V cable length 150 m N CMF N Reinforced 600 V Un 690 V cable length 150 m Pn 500 kW N CMF N CMF Standard 380 V Un 690 V Form woundHX_ and AM_ Pn 500 kW N du dt CMF N du dt with voltages over 500 V CMF Check with the motor manufac turer 380 V Un 690 V Old1 form wound HX_ and modular N CMF Enamelled wire with fiber glass taping 0 V Un 500...

Page 62: ... V Random wound and form wound du dt Standard ÛLL 1300 V 420 V Un 500 V Reinforced ÛLL 1600 V 0 2 µs rise time du dt Reinforced ÛLL 1600 V 500 V Un 600 V Reinforced ÛLL 1800 V du dt Reinforced ÛLL 1800 V 600 V Un 690 V Reinforced ÛLL 2000 V 0 3 µs rise time1 1 If the intermediate DC circuit voltage of the drive is increased from the nominal level due to long term resistor braking cycles check with...

Page 63: ...n 420 V Random wound and form wound N du dt CMF du dt N or CMF Standard ÛLL 1300 V 420 V Un 500 V N CMF N or CMF Reinforced ÛLL 1600 V 0 2 µs rise time N du dt CMF du dt N or CMF Reinforced ÛLL 1600 V 500 V Un 600 V N CMF N or CMF Reinforced ÛLL 1800 V N du dt CMF du dt N Reinforced ÛLL 1800 V 600 V Un 690 V N CMF N CMF Reinforced ÛLL 2000 V 0 3 µs rise time1 1 If the intermediate DC circuit volta...

Page 64: ... motors Additional requirements for braking applications When the motor brakes the machinery the intermediate circuit DC voltage of the drive increases the effect being similar to the motor supply voltage increasing by up to 20 percent Consider this voltage increase when specifying the motor insulation requirements if the motor will be braking a large part of its operation time Example Motor insul...

Page 65: ...N Reinforced du dt N CMF du dt N du dt Reinforced 600 V Un 690 V Additional requirements for non ABB high output and IP23 motors The rated output power of high output motors is higher than what is stated for the particular frame size in EN 50347 2001 If you plan to use a non ABB high output motor or an IP23 motor consider these additional requirements for protecting the motor insulation and bearin...

Page 66: ...e intermediate DC circuit voltage of the drive is increased from the nominal level due to long term resistor braking cycles check with the motor manufacturer if additional output filters are needed Additional data for calculating the rise time and the peak line to line voltage The diagrams below show the relative peak line to line voltage and rate of change of voltage as a function of the motor ca...

Page 67: ...le length I Nominal AC line voltage Un Relative peak line to line voltage ÛLL Un Relative du dt value du dt Un Note ÛLL and du dt values are approximately 20 higher during the resistor braking Additional note for sine filters A sine filter also protects the motor insulation system The peak phase to phase voltage with a sine filter is approximately 1 5 Un Guidelines for planning the electrical inst...

Page 68: ...d for up to 500 V AC 750 V AC cable is accepted for up to 600 V AC 1000 V AC cable is accepted for up to 690 V AC To comply with the EMC requirements of the CE mark use one of the preferred cable types See Preferred power cable types page 68 Symmetrical shielded cable reduces electromagnetic emission of the whole drive system as well as the stress on motor insulation bearing currents and wear Meta...

Page 69: ...e types Use as motor cabling and as brake resistor cabling Use as input power cabling Cable type Yes with phase conductor smaller than 10 mm2 8 AWG Cu or motors up to 30 kW 40 hp Yes with phase conductor smaller than 10 mm2 8 AWG Cu PVC Four conductor cabling in PVC conduit or jacket three phase conductors and PE Note Shielded or armored cable or cabling in metal conduit is always recommen ded to ...

Page 70: ...ed on the shield inductance which must be low and only slightly dependent on frequency The requirements are easily met with a copper or aluminum shield armor The cross section of a steel shield must be ample and the shield helix must have a low gradient A galvanized steel shield has a better high frequency conductivity than a non galvanized steel shield Not allowed power cable types Use as motor c...

Page 71: ...al ground path provided this path is a solid path capable of handling ground currents 2 See NFPA NFPA 70 NEC UL and local codes for your application 3 Non metallic conduit use underground is allowed however these installations inherently have an increased chance for nuisance problems due to the potential for water moisture in the conduit Water moisture in the conduit increases the likelihood of VF...

Page 72: ...ring regulations state otherwise the cross sectional area of the protective earth conductor must agree with the conditions that require automatic disconnection of the supply required in 411 3 2 of IEC 60364 4 41 2005 and be capable of withstanding the prospective fault current during the disconnection time of the protective device The cross sectional area of the protective earth conductor must be ...

Page 73: ... grounding requirements IEC ThissectiongivesgroundingrequirementsaccordingtostandardIEC EN61800 5 1 Because the normal touch current of the drive is more than 3 5 mA AC or 10 mA DC the minimum size of the protective earth conductor must comply with the local safety regulations for high protective earth conductor current equipment and you must use one of these connection methods 1 a fixed connectio...

Page 74: ...ecting the control cables Shielding Only use shielded control cables Use a double shielded twisted pair cable for analog signals ABB recommends this type of cable also for the pulse encoder signals Use one individually shielded pair for each signal Do not use common return for different analog signals A double shielded cable a is the best alternative for low voltage digital signals but single shie...

Page 75: ...next to each other Install the motor cable input power cable and control cables on separate trays Avoid long parallel runs of motor cables with other cables Where control cables must cross power cables make sure that they are arranged at an angle as near to 90 degrees as possible Do not run extra cables through the drive Make sure that the cable trays have good electrical bonding to each other and...

Page 76: ...guidelines North America Make sure that the installation is in accordance with national and local codes Obey these general guidelines Use separate conduits for the input power motor brake resistor optional and control cabling Use separate conduit for each motor cabling The following figure illustrates the cable routing guidelines with an example drive 76 Guidelines for planning the electrical inst...

Page 77: ...quipment are installed on the motor cable between the drive and the motor Install the equipment in a metal enclosure Use either a symmetrical shielded cable or install the cabling in a metal conduit Make sure that there is a good and continuous galvanic connection in the shield conduit between drive and motor Connect the shield conduit to the protective ground terminal of the drive and the motor G...

Page 78: ...on Select the fuses or circuit breakers for the drive according to the instructions given in the technical data The fuses or circuit breakers for the drive protection will restrict drive damage and prevent damage to adjoining equipment in case of a short circuit inside the drive Note If the fuses or circuit breakers for the drive protection are placed at the distribution board and the input cable ...

Page 79: ... Motor nominal power in the drive is equal with the value given on the motor rating plate The electronic power output short circuit protection circuitry meets the requirements of IEC 60364 4 41 2005 AMD1 Protecting the motor cables against thermal overload The drive protects the motor cables against thermal overload when the cables are sized according to the nominal output current of the drive No ...

Page 80: ...e motor against overload without using motor thermal model or temperature sensors Motor overload protection is required and specified by multiple standards including the US National Electric Code NEC and the common UL IEC 61800 5 1 standard in conjunction with UL IEC 60947 4 1 The standards allow for motor overload protection without external temperature sensors The protection feature of the drive...

Page 81: ...on type is not known You can connect a sensor to a digital input of the drive via an external relay The sensor and the relay must form a double or reinforced insulation between the motor s live parts and the digital input of the drive Make sure that the voltage does not exceed the maximum allowed voltage over the sensor See sections AI1 and AI2 as Pt100 Pt1000 Ni1000 KTY83 and KTY84 sensor inputs ...

Page 82: ...s of Type B Note As standard the drive contains capacitors connected between the main circuit and the frame These capacitors and long motor cables increase the ground leakage current and may cause nuisance faults in residual current devices Implementing the emergency stop function For safety reasons install the emergency stop devices at each operator control station and at other operating stations...

Page 83: ...ode being used Define the automatic restart time parameter 21 18 WARNING Make sure that a flying restart of the motor will not cause any danger If you are in doubt do not implement the power loss ride through function Using power factor compensation capacitors with the drive Power factor compensation is not needed with AC drives However if a drive is to be connected in a system with compensation c...

Page 84: ...ified Ex motor order an ATEX certified thermistor protection module for the drive option L537 or acquire and install an ATEX compliant protection relay do the necessary connections For more information see Manual code English User s manual 3AXD50000030058 CPTC 02 ATEX certified thermistor protection module Ex II 2 GD option L537 Q971 user s manual Controlling a contactor between drive and motor Th...

Page 85: ...s 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 UL 61800 5 1 subc...

Page 86: ...tor power supply selection drive or direct on line S40 Start when motor is connected direct on line S41 Stop when motor is connected direct on line S42 Switching the motor power supply from drive to direct on line 1 Stop the drive and the motor with the drive control panel stop key drive in the local control mode or the external stop signal drive in the remote control mode 86 Guidelines for planni...

Page 87: ...itch S11 turn to position ST for two seconds and leave to position 1 4 Start the drive and the motor with the drive control panel start key drive in the local control mode or the external start signal drive in the remote control mode Protecting the contacts of relay outputs Inductive loads relays contactors motors cause voltage transients when switched off Install the protective component as close...

Page 88: ...rts of the motor or if the insulation type is not known you can connect the sensor to the drive via an option module The sensor and the module must form a double or reinforced insulation between the motor live parts and the drive control unit See Connecting a motor temperature sensor to the drive through an option module page 81 Make sure that the voltage does not exceed the maximum allowed voltag...

Page 89: ...r to form together with the insulation of the option module a reinforced insulation between the motor live parts and the drive control unit Temperature sensor insulation require ment Temperature sensor type Option module Pt100 Pt1000 KTY PTC Insulation Isolation Type No special require ment x Reinforced insulation between the sensor connector and other connectors including drive control unit conne...

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Page 91: ...ions of the drive If you ignore them injury or death or damage to the equipment can occur Required tools To do the electrical installation you need these tools wire stripper screwdriver set Torx flat and or Phillips as appropriate torque wrench Grounding the motor cable shield at the motor end For minimum radio frequency interference ground the cable shield 360 degrees at the cable entry of the mo...

Page 92: ...ructions of the drive If you ignore them injury or death or damage to the equipment can occur If you are not a qualified electrical professional do not do installation commissioning or maintenance work 1 Do the steps in section Electrical safety precautions page 20 before you start the work 2 Make sure that the motor cable is disconnected from the drive output terminals 3 Measure the insulation re...

Page 93: ...r and disconnected from the drive output terminals 3 At the drive end connect the R and R conductors of the resistor cable together Measure the insulation resistance between the conductors and the PE conductor with a measuring voltage of 1000 V DC The insulation resistance must be more than 1 Mohm R R ohm PE 1000 V DC 1 Mohm Grounding system compatibility check The standard drive can be installed ...

Page 94: ...you install the drive to another system you may need to disconnect the varistor See section When to disconnect EMC filter or ground to phase varistor TN S IT corner grounded delta and midpoint grounded delta systems and TT systems page 94 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...

Page 95: ... Midpoint grounded delta systems 600 V R3 Do not remove EMC or VAR screws PE L3 L2 L1 R6 Remove EMC screw Do not remove VAR screw See Note 1 below R8 Remove EMC DC and VAR screws IT systems ungrounded or high resistance grounded 30 ohms R3 Remove EMC and VAR screws L3 L2 L1 R6 Remove EMC and VAR screws R8 Remove EMC DC and VAR screws TT systems Electrical installation IEC 95 ...

Page 96: ...rge systems the residual current device can trip without a real reason Note 1 Frames R3 and R6 are evaluated for use on corner grounded systems and midpoint grounded delta systems by UL standards They are not evaluated by IEC standards for use on corner grounded or midpoint grounded systems Note 2 These are the EMC filter and varistor screws of different drive frame sizes Ground to phase varistor ...

Page 97: ...e 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 table below shows the line to ground voltages in relation to the line to line voltage for each grounding system Electrical power system type UL3 G UL2 G UL1 G UL L Symmetrically grounded TN system TN S system 0 58 X 0 58 X 0 58 X X Corner grounded delta system nonsym metrical 0 1 0 X 1 0 X X ...

Page 98: ...to phase varistor frame R3 1 Stop the drive and do the steps in section Electrical safety precautions page 20 before you start the work 2 Remove the front cover 3 Remove the EMC screw 4 Remove the VAR screw EMC VAR 3 4 98 Electrical installation IEC ...

Page 99: ...stor frame R6 1 Stop the drive and do the steps in section Electrical safety precautions page 20 before you start the work 2 Remove the front cover and the lower front cover 3 Remove the VAR screw 4 Remove the EMC screw 3 VAR 4 EMC Electrical installation IEC 99 ...

Page 100: ...frame R8 1 Stop the drive and do the steps in section Electrical safety precautions page 20 before you start the work 2 Remove the front cover if it is not already removed 3 Remove the VAR screw 4 Remove the EMC DC screw 3 VAR 4 EMC DC 100 Electrical installation IEC ...

Page 101: ...h a separate PE conductor for the line side if the conductivity of the fourth conductor or shield does not meet the require ments for the PE conductor 2 Use a separate grounding cable for the motor side if the conductivity of the shield is not sufficient or if there is no symmetrically constructed PE conductor in the cable 3 ABB requires 360 grounding of the cable shield for the motor cable ABB al...

Page 102: ...tra wear Connection procedure The procedure of connecting the power cables to the standard drive is described below For the procedure with UK gland plate option H358 see also ACS880 11 ACS880 31 ACH580 31 and ACQ580 31 UK gland plate H358 installation guide 3AXD50000110711 English 1 To remove the R3 front cover R6 and R8 upper front cover lift the cover from the bottom outwards 1a and then up 1b R...

Page 103: ...IP55 R6 R8 IP21 1a 1b 2 3a 3b 4 2 Attach the residual voltage warning sticker in the local language 3 For frames R6 and R8 Remove the shroud on the power cable terminals R8 R6 Electrical installation IEC 103 ...

Page 104: ...cover plates 4a Remove the EMC side plates 4b 4 M5 3 N m 26 lbf in 4b 4b 3 M5 3 N m 26 lbf in 5 M5 3 N m 26 lbf in 4a 4a 5 For frame R8 For easier installation you can remove the side plates 6 M5 3 N m 26 lbf in 6 Remove the rubber grommets from the cable entry plate for the cables you want to install Insert the grommets pointing down in the unused cable entry plate holes 104 Electrical installati...

Page 105: ...own If you use aluminum cables put grease onto the peeled aluminum cable before you connect it to the drive Note The bare shield will be grounded 360 PE PE Only allowed for input cabling with phase conductor cross section less than 10 mm2 8 AWG PE PE 9 Put the cable through the hole of the cable entry plate and attach the grommet to the hole Electrical installation IEC 105 ...

Page 106: ...for ACS880 01 frame R7 and for ACS880 11 ACS880 31 ACH580 31 and ACQ580 31 frame R8 installation instructions 3AXD50000015179 English Connect the phase conductors of the motor cable to the T1 U T2 V and T3 W terminals and the phase conductors of the input cable to the L1 L2 and L3 terminals If the DC cables are present cut off one phase conductor and isolate the end Connect the remaining conductor...

Page 107: ... 7 N m 1 7 N m L1 L2 UDC UDC L3 T1 U T2 V T3 W L1 L2 L3 T1 U T2 V T3 W UDC UDC 1 7 N m R6 2 9 N m 2 9 N m L1 L2 L3 T1 U T2 V T3 W UDC UDC 15 N m 2 N m L1 L2 UDC UDC L3 T1 U T2 V T3 W Electrical installation IEC 107 ...

Page 108: ... power cable connectors can be detached For the instructions see section R8 power cable connection if you detach the cable connectors page 109 11 For frame R8 Install the EMC plates in reverse order See step 4 12 For frame R6 types bigger than 040A x Cut tabs in the shroud for the installed cables 108 Electrical installation IEC ...

Page 109: ...es with cable lugs as follows Remove the nut that attaches the connector to the terminal post and remove the connector Alternative 1 Put the conductor to the connector Tighten to a torque of 30 N m Put the connector back onto the post Tighten the connector to a torque of 16 N m Alternative 2 Attach a cable lug to the conductor Put the cable lug onto the post Tighten the nut to a torque of 16 N m E...

Page 110: ...e default I O connections of the drive Connection procedure WARNING Obey the safety instructions of the drive If you ignore them injury or death or damage to the equipment can occur 1 Stop the drive and do the steps in section Electrical safety precautions page 20 before you start the work 110 Electrical installation IEC ...

Page 111: ...d the pair cable shields and grounding wire at the grounding terminal SCR of the control unit 8 Connect the conductors to the appropriate terminals of the control unit and tighten to 0 5 0 6 N m See Default I O connection diagram page 137 Note Leave the other ends of the control cable shields unconnected or ground them indirectly through a high frequency capacitor with a few nanofarads eg 3 3 nF 6...

Page 112: ...R3 1 7 N m 112 Electrical installation IEC ...

Page 113: ...R6 1 7 N m Electrical installation IEC 113 ...

Page 114: ...R8 1 7 N m 114 Electrical installation IEC ...

Page 115: ...l 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 7 lbf in The screw grounds the module This is necessary for fulfilling the EMC requirements and for correct operation of the module 1 2 3 Electrical installation IEC ...

Page 116: ...SSIS to 0 8 N m 7 lbf in The screw tightens the connections and grounds the module This is necessary for fulfilling the EMC requirements and for correct operation of the module 1 2 Wiring the optional modules See the appropriate option module manual or for I O options the appropriate chapter in this manual 116 Electrical installation IEC ...

Page 117: ...2 frame R8 connect the secondary auxiliary cooling fan power supply wire see section Replacing the auxiliary cooling fan in the IP55 UL Type 12 cover frame R8 page 165 R3 5 5 P I 1 2 P I 2 1 2 1 2 N m 2 N m R6 R8 5 5 P I 1 2 P I 2 N m 2 N m 3 4 1 2 Electrical installation IEC 117 ...

Page 118: ...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 5 See the documentation of the PC tool for setup instructions Start Stop Loc Rem Start Stop Loc Rem USB connected 3a 4 3b 2 2 Connecting a remote panel or chaining one panel to several drives You can connect a...

Page 119: ...install optional modules and connect a PC Safety WARNING If you are not a qualified electrical professional do not do installation or maintenance work Obey the safety instructions of the drive If you ignore them injury or death or damage to the equipment can occur Required tools To do the electrical installation you need these tools wire stripper screwdriver set Torx flat and or Phillips as approp...

Page 120: ...UDC U1 W1 M 3 T1 U T2 V T3 W V1 L1 L2 L3 PE 3 UDC 1 2 3 4 6 7 4 5 A Drive A Insulated ground conductor in a conduit Ground to drive s PE terminal and to the distribution panel ground bus For a VFD cable installation see 4 1 Conduit ground Bond the conduit to the drive s conduit box and to the distribution panel enclosure For a VFD cable installation see 3 2 Shield of a VFD shielded cable Ground th...

Page 121: ...Resistor braking page 243 6 If necessary install an external filter du dt common mode or sine filter Filters are available from ABB 7 Note All openings in the drive enclosure must be closed with UL listed devices having the same Type rating as the drive Type Connection procedure The procedure of connecting the power cables to the standard drive is described below 1 To remove the R3 front cover R6 ...

Page 122: ...6 R8 UL Type 1 1a 1b 2 3a 3b 4 2 Attach the residual voltage warning sticker in the local language 3 For frames R6 and R8 Remove the shroud on the power cable terminals R8 R6 122 Electrical installation North America NEC ...

Page 123: ...the EMC cover plates 4a Remove the EMC side plates 4b 4 M5 3 N m 26 lbf in 4b 4b 3 M5 3 N m 26 lbf in 5 M5 3 N m 26 lbf in 4a 4a 5 For frame R8 For easier installation you can remove the side plates 6 M5 3 N m 26 lbf in 6 Remove the rubber grommets of the cables to be installed from the cable entry plate Install the grommets downwards in unused holes Electrical installation North America NEC 123 ...

Page 124: ...unding wires together with the cable shield and connect them to the grounding terminals Ground the shield 360 at the clamp If you use discrete conductors connect the insulated ground conductor to the grounding terminal EMT 3 Tightening torque for R3 1 7 N m 1 25 lbf ft for R6 and R8 2 N m 1 48 lbf ft 9 For frame R8 Install the common mode filter For instructions see Common mode filter kit for ACS8...

Page 125: ...L3 terminals If DC cables are present use only two phase conductors and the ground conductor Connect the phase conductors to the UDC and UDC terminals EMT Tighten the screws to the torque given in the installation drawing below R3 7 7 7 8 8 L1 L2 L3 T1 U T2 V T3 W UDC UDC PE Ground 1 7 N m 1 2 lbf ft Electrical installation North America NEC 125 ...

Page 126: ...R6 7 7 7 8 8 PE Ground 2 9 N m 2 1 lbf ft L1 L2 L3 T1 U T2 V T3 W UDC UDC 15 N m 11 0 lbf ft 126 Electrical installation North America NEC ...

Page 127: ...t Do not detach the power cable connectors For frame R8 Install the side plates if removed 10 For frame R8 Install the EMC plates in reverse order See step 4 11 For frame R6 types bigger than 040A x Cut tabs in the shroud for the installed cables Electrical installation North America NEC 127 ...

Page 128: ...procedure WARNING Obey the safety instructions of the drive If you ignore them injury or death or damage to the equipment can occur 1 Stop the drive and do the steps in section Electrical safety precautions page 20 before you start the work 2 Remove the front cover s if not already removed 3 For frame R3 Pull the control panel holder up 128 Electrical installation North America NEC ...

Page 129: ...g wire at the grounding terminal SCR of the control unit 9 Connect the conductors to the appropriate terminals of the control unit and tighten to 0 5 0 6 N m 0 4 lbf ft See Default I O connection diagram page 137 Note Leave the other ends of the control cable shields unconnected or ground them indirectly through a high frequency capacitor with a few nanofarads eg 3 3 nF 630 V The shield can also b...

Page 130: ...R3 Max 250 mA 130 Electrical installation North America NEC ...

Page 131: ...R6 Electrical installation North America NEC 131 ...

Page 132: ...R8 Installing optional modules See section Installing option modules page 115 132 Electrical installation North America NEC ...

Page 133: ... cooling fan power supply wire see section Replacing the auxiliary cooling fan in the IP55 UL Type 12 cover frame R8 page 165 UL Type 12 UL Type 1 R3 2 1 2 N m 1 5 lbf ft R3 2 1 2 N m 1 5 lbf ft UL Type 12 UL Type 1 R6 R8 2 N m 1 5 lbf ft 1 2 2 N m 1 5 lbf ft R6 R8 3 2 Electrical installation North America NEC 133 ...

Page 134: ...on Connecting a PC page 118 Connecting a remote panel or chaining one panel to several drives See section Connecting a remote panel or chaining one panel to several drives page 118 134 Electrical installation North America NEC ...

Page 135: ...Control unit Contents of this chapter This chapter contains the default I O connection diagram descriptions of the terminals and technical data for the drive control unit CCU 24 8 Control unit 135 ...

Page 136: ...12 DIGITAL IN Digital inputs 13 18 STO Safe torque off connection 34 38 Internal air temperature NTC sensor connection AIR IN TEMP Internal fan 2 connection FAN2 Internal fan 1 connection FAN1 Panel port control panel connection wired at the factory to the control panel X12 Reserved to internal use X15 EFB EIA RS 485 fieldbus connector Bias resistor switch BIAS End termination switch TERM Connecti...

Page 137: ... mA AO2 8 Analog output circuit common AGND 9 X2 X3 Aux voltage output and programmable digital inputs Aux voltage output 24 V DC max 250 mA 2 24V 10 10 11 12 13 14 15 16 17 18 4 5 Aux voltage output common DGND 11 Digital input common for all DCOM 12 Stop 0 Start 1 DI1 13 Not configured DI2 14 Constant frequency speed selection 3 DI3 15 Start interlock 1 1 allow start DI4 16 Not configured DI5 17...

Page 138: ...14 2 5 mm2 26 14 AWG Tightening torques 0 5 0 6 N m 4 4 5 3 lbf in Wire strip length 7 8 mm 0 3 in Notes Current 0 4 20 mA Rin 100 ohm or voltage 0 2 10 V Rin 200 kohm Change of setting requires changing the corresponding parameter 1 Total load capacity of the Auxiliary voltage output 24V X2 10 is 6 0 W 250 mA 24 V minus the power taken by the option modules installed on the board 2 In scalar cont...

Page 139: ...Must be set to the terminated ON position when the drive or another device is the first or last unit on the link TERM S4 Bus terminated TERM ON Bias off default BIAS ON Switches on the biasing voltages to the bus One and only one device preferably at the end of the bus must have the bias on BIAS S5 Bias on BIAS ON Additional information on I O connections PNP configuration for digital inputs X2 X3...

Page 140: ...DI1 14 DI2 15 DI3 16 DI4 17 DI5 18 DI6 Note DI6 is not supported in the NPN configuration WARNING Do not connect the 24 V AC cable to the control unit ground when the control unit is powered from an external 24 V AC supply Connection for obtaining 0 10 V from analog output 2 AO2 To obtain 0 10 V from analog output AO2 connect a 500 ohm resistor or two 1 kohm resistors in parallel between analog ou...

Page 141: ...T DI5 as frequency input For setting the parameters for the digital frequency input see the firmware manual DI6 as PTC input If DI6 is used as a PTC input see firmware manual for how to set parameters accordingly Note If DI6 is used as a PTC input the wiring and the PTC sensor need to be double isolated Otherwise the CMOD 02 I O extension module must be used 1 24V DI6 t t t t t t One to six PTC th...

Page 142: ...onnection of the motor temperature sensor requires double or reinforced insulation between motor live parts and the sensor If the assembly does not fulfill this requirement the I O board terminals must be protected against contact and must not be connected to other equipment or the temperature sensor must be isolated from the I O terminals Safe torque off X4 For the drive to start both connections...

Page 143: ...ering 0 04 ms digital filtering 2 ms sampling Note DI6 is not supported in the NPN configuration PTC mode PTC thermistor can be connected between DI6 and 24 V DC 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 rein forced double insulated PTC sensor ...

Page 144: ...1 24 V DC logic levels 0 5 V 1 13 V Rin 2 47 kohm Terminal size 0 14 2 5 mm2 26 14 AWG Safe torque off STO in puts IN1 and IN2 Term 37 and 38 Connector pitch 5 mm maximum wire size 2 5 mm2 14 AWG Physical layer EIA 485 Cable type Shielded twisted pair cable with twisted pair for data and a wire or pair for signal ground nominal impedance 100 165 ohms for example Belden 9842 Transmission rate 9 6 1...

Page 145: ... 5 1 First edition Functional insulation IEC EN 61800 5 1 2007 UL 61800 5 1 First edition The terminals on the control unit fulfill the Protective Extra Low Voltage PELV requirements EN 50178 There is reinforced insulation between the user terminals which only accept ELV voltages and terminals that accept higher voltages relay out puts Note There is functional insulation also between the individua...

Page 146: ...4V 11 DGND 12 DCOM 13 DI1 14 DI2 15 DI3 16 DI4 17 DI5 18 DI6 X6 X7 X8 19 RO1C 20 RO1A 21 RO1B 22 RO2C 23 RO2A 24 RO2B 25 RO3C 26 RO3A 27 RO3B X5 29 B 30 A 31 DGND X4 34 OUT1 35 OUT2 36 SGND 37 IN1 38 IN2 X10 40 24VAC DC in 41 24VAC DC in Slot 1 Slot 2 Jumper installed at factory 146 Control unit ...

Page 147: ...ou ignore them injury or death or damage to the equipment can occur If you are not a qualified electrical professional do not do installation commissioning or maintenance work WARNING Stop 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...

Page 148: ...que Grounding has also been measured according to the regulations The motor cable is connected to the correct terminals the phase order is correct and the terminals are tightened to the correct torque The motor cable is routed away from other cables No power factor compensation capacitors are connected to the motor cable If an external brake resistor is connected to the drive There is an adequatel...

Page 149: ...ling inside the drive The area in front of the drive is clean the drive cooling fan cannot draw any dust or dirt inside Drive covers and cover of the motor connection box are in place The motor and the driven equipment are ready for power up Installation checklist 149 ...

Page 150: ...150 ...

Page 151: ...reforming instructions 3BFE64059629 English Start up procedure 1 Run setup of the drive control program according to the start up instructions given in ACH580 31 drives quick installation and start up guide 3AXD50000803040 English or in the firmware manual For drives with resistor braking See also chapter Resistor braking page 243 For SynRM motor drives Set bit 2 of parameter 95 21 HW options word...

Page 152: ...152 ...

Page 153: ...ance preventive maintenance For more information consult your local ABB Service representative www abb com searchchannels Description of symbols Description Action Inspection visual inspection and maintenance action if needed I Performance of on off site work commissioning tests measurements or other work P Replacement R Recommended maintenance intervals after start up Recommended annual actions b...

Page 154: ...e clock Functional safety I See the maintenance in formation of the safety function Safety function test 20 years Safety component expiry Mission time TM 4FPS10000309652 Note 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 reli...

Page 155: ...intenance work 1 Stop the drive and do the steps in section Electrical safety precautions page 20 before you start the work 2 Clean the exterior of the drive Use vacuum cleaner with an antistatic hose and nozzle soft brush dry or damp not wet cleaning cloth Moisten with clean water or mild detergent pH 5 9 for metal pH 5 7 for plastic WARNING Prevent water from entering the drive Never use excessi...

Page 156: ... s See the separate instructions 3 Blow dry clean and oil free compressed air from bottom to top and simultaneously use a vacuum cleaner at the air outlet to trap the dust If there is a risk of dust entering adjoining equipment do the cleaning in another room 4 Reinstall the cooling fan Fans Parameter 05 04 Fan on time counter indicates the running time of the cooling fan Reset the counter after a...

Page 157: ...hem 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 To release the locking turn clockwise with a screwdriver 3 Turn the fan assembly off 4 Install the new fan in reverse order Maintenance 157 ...

Page 158: ...occur 1 Stop the drive and do the steps in section Electrical safety precautions page 20 before you start the work 2 Lever the fan assembly off the drive frame with for example a screwdriver and pull out the fan assembly 3 Pull the fan assembly down 4 Disconnect the fan power supply wire from the drive 5 Install the new fan in reverse order 158 Maintenance ...

Page 159: ... occur 1 Stop the drive and do the steps in section Electrical safety precautions page 20 before you start the work 2 Undo the mounting screws of the fan assembly 3 Unplug the fan power supply and grounding wires from the drive 4 Pull the fan assembly down 5 Undo the mounting screws of the fan 6 Install the new fan in reverse order 2 2 3 5 Maintenance 159 ...

Page 160: ...ipment can occur 1 Stop the drive and do the steps in section Electrical safety precautions page 20 before you start the work 2 Remove the front cover see Connection procedure page 102 3 Release the retaining clips 4 Lift the fan off 5 Unplug fan power supply wires 6 Install the new fan in reverse order Note Make sure that the arrow on the fan points down Blowing direction down 160 Maintenance ...

Page 161: ...cal safety precautions page 20 before you start the work 2 Remove the upper front covers See section Connection procedure page 102 3 Release the retaining clips 4 Lift the fan off 5 Unplug fan power supply wires 6 Remove the grille from the fan 7 Install the new fan in reverse order Note Make sure that the arrow on the fan points up 8 Reinstall the front covers See section Reinstalling cover s pag...

Page 162: ... frame R6 Another auxiliary cooling fan FAN2 at right hand side of the control panel is included in IP55 UL Type 12 frame R6 types 062A 4 and 052A 4 and bigger For the replacement process see Replacing the auxiliary cooling fan frame R6 page 161 162 Maintenance ...

Page 163: ... the steps in section Electrical safety precautions page 20 before you start the work 2 Remove the upper front covers See section Connection procedure page 102 3 Release the retaining clips 4 Lift the fan off 5 Unplug fan power supply wires 6 Remove the grille 7 Install the new fan in reverse order Note Make sure that the arrow on the fan points up 8 Replace the front covers Maintenance 163 ...

Page 164: ... front cover disconnect the power supply wire of the auxiliary cooling fan in the cover see section Replacing the auxiliary cooling fan the IP55 UL Type 12 cover frame R8 3 Release the retaining clips 4 Lift the fan off 5 Unplug the power supply wire from the branching plug 6 Install the new fan in reverse order Make sure that the arrow on the fan points out 7 Replace the front cover 4 3 164 Maint...

Page 165: ...recautions page 20 before you start the work 2 Remove the IP55 front cover Unplug the auxiliary cooling fan power supply wire 3 Remove the lower front cover from the IP55 cover 4 Pull the fan supply wire through the grommet 5 Remove the fan 6 Install the new fan in reverse order Make sure that the arrow on the fan points up Maintenance 165 ...

Page 166: ... Fan arrow must point up 166 Maintenance ...

Page 167: ...e or unused for a year or more The manufacturing date is on the type designation label For information on reforming the capacitors refer to Capacitor reforming instructions 3BFE64059629 English Control panel See ACS AP I S W and ACH AP H W Assistant control panels user s manual 3AUA0000085685 English For removing the control panel from the drive see Control panel page 37 Drive LEDs There is a gree...

Page 168: ... to the components of the standard Safe torque off circuit as well as any modules relays and typically any other components that are part of functional safety circuits The expiry of mission time terminates the certification and SIL PL classification of the safety function The following options exist Renewal of the whole drive and all optional functional safety module s and components Renewal of th...

Page 169: ...se Light duty use Nominal use PHd IHd PLd ILd Pn I2 Sn Imax I1 kW A kW A kW A kVA A A 3 phase Un 400 V 3 0 7 2 4 0 8 9 4 0 9 4 6 5 12 2 8 0 R3 09A5 4 4 0 9 4 5 5 12 0 5 5 12 6 8 7 16 1 10 0 R3 12A7 4 5 5 12 6 7 5 16 2 7 5 17 0 11 8 21 4 14 0 R3 018A 4 7 5 17 0 11 23 8 11 25 0 17 3 28 8 20 0 R3 026A 4 11 25 15 30 4 15 32 0 22 2 42 5 27 R6 033A 4 15 32 18 5 36 1 18 5 38 0 26 3 54 4 33 R6 039A 4 18 5...

Page 170: ...VA A A 3 phase Un 480 V 3 5 2 5 7 6 6 3 12 2 7 0 R3 09A5 4 5 7 6 7 5 12 10 0 16 1 9 0 R3 12A7 4 7 5 12 0 10 14 11 6 21 4 12 0 R3 018A 4 10 14 0 15 23 19 1 28 8 17 0 R3 026A 4 15 23 20 27 22 4 42 5 24 R6 033A 4 20 27 25 34 28 3 54 4 29 R6 039A 4 25 34 30 44 36 6 64 6 34 R6 046A 4 30 44 40 52 43 2 77 5 44 R6 062A 4 40 52 50 65 54 0 105 4 54 R6 073A 4 50 65 60 77 64 0 124 1 66 R6 088A 4 60 77 75 96 7...

Page 171: ...ltage boost levels and drive type specific derating curves The rise in input current can heat the input cable and fuses To avoid heating select an input cable and fuses according to the increased input current caused by the DC voltage boost For more information refer to ACH580 31 ACQ580 31 ACH580 34 and ACQ580 34 drives product note on DC voltage boost 3AXD50000769407 English Definitions Nominal i...

Page 172: ...regardless of the supply voltage within one voltage range Note ABB recommends the DriveSize dimensioning tool available from http new abb com drives software tools drivesize for selecting the drive motor and gear combination Deratings The load capacity I2 ILd IHd note that Imax is not derated decreases for certain situations as defined below In such situations where full motor power is required ov...

Page 173: ...range All drives except IP55 UL Type 12 drive type 206A 4 No derating up to 40 C up to 104 F Derate 1 for every 1 C 1 8 F Calculate the output by multiplying the current given in the rating table by the derating factor k in the diagram below 40 50 C 104 122 F T 1 00 0 90 40 C 104 F 50 C 122 F k 0 80 15 C 5 F 0 85 0 95 Technical data 173 ...

Page 174: ...F 40 50 C 104 131 F Note For ambient temperatures above 40 C 104 F the power cables must be rated for 90 C 194 F minimum Altitude derating At altitudes above 1000 m 3281 ft above sea level the output current derating is 1 percentage point for every added 100 m 328 ft For example the derating factor for 1500 m 4921 ft is 0 95 The maximum permitted installation altitude is given in the technical dat...

Page 175: ... tool To calculate the output current multiply the current given in the rating table by derating factor k which for x meters 1000 m x 4000 m is Switching frequency derating To calculate the output current multiplying the current given in the rating table by the derating factor given in the table below Note If you change the minimum switching frequency with parameter 97 02 Minimum switching frequen...

Page 176: ... 1 0 1 0 1 0 169A 4 3 phase Un 480 V R3 0 52 0 74 1 0 1 0 1 0 09A5 4 R3 0 52 0 74 1 0 1 0 1 0 12A7 4 R3 0 52 0 74 1 0 1 0 1 0 018A 4 R3 0 52 0 74 1 0 1 0 1 0 026A 4 R6 0 52 0 67 1 0 1 0 1 0 033A 4 R6 0 52 0 67 1 0 1 0 1 0 039A 4 R6 0 52 0 67 1 0 1 0 1 0 046A 4 R6 0 52 0 67 1 0 1 0 1 0 062A 4 R6 0 52 0 67 1 0 1 0 1 0 073A 4 R6 0 52 0 67 1 0 1 0 1 0 088A 4 R8 1 00 1 0 1 0 1 0 106A 4 R8 0 84 1 0 1 0 ...

Page 177: ...her motor voltage than the supply voltage This can require derating of the drive output power depending on the difference between the supply voltage and the output voltage to the motor for continuous operation 400 V and 480 V drive types This graph shows the required derating for 400 V and 480 V drive types 0 80 0 85 0 90 0 95 1 00 1 10 1 05 1 00 0 95 0 90 0 85 0 80 0 75 0 70 P Pn U Un 0 875 0 975...

Page 178: ...ost the output voltage to correspond the nominal supply voltage 480 V increase the DC voltage to 480 V 2 679V Fuses IEC Fuses protect the input cable in short circuit situations They also restrict drive damage and prevent damage to adjoining equipment in case of a short circuit inside the drive ABB recommends the high speed aR fuses specified below The gG fuses can be used for frame R3 if they ope...

Page 179: ...8A 4 000 170M1311 690 130 25 20 0 100 026A 4 000 170M1313 690 460 40 27 0 110 033A 4 000 170M1315 690 1450 63 33 0 210 039A 4 000 170M1315 690 1450 63 40 0 300 046A 4 000 170M1316 690 2550 80 51 0 300 062A 4 000 170M1317 690 4650 100 63 0 400 073A 4 000 170M1318 690 8500 125 76 0 700 088A 4 000 170M1319 690 16000 160 94 700 106A 4 000 170M3015 690 15000 200 128 970 145A 4 00 170M3016 690 28500 250...

Page 180: ...88A 4 000 170M1569 690 16500 160 94 700 106A 4 000 170M3817 690 46500 315 128 900 145A 4 2 170M5808 690 79000 400 154 1900 169A 4 2 170M5809 690 155000 450 188 2200 206A 4 1 Minimum short circuit current of the electrical power system gG fuses DIN 43620 blade style gG fuses can be used for frame R3 if they operate rapidly enough max 0 1 seconds ABB recommends however aR fuses gG fuses are not allo...

Page 181: ...uit Ik2 ph Network line to line voltage V U Cable resistance ohm Rc Zk zk Un 2 Sn transformer impedance ohm Zk Transformer impedance zk Transformer rated voltage V Un Nominal apparent power of the transformer kVA Sn Cable reactance ohm Xc Calculation example Drive ACH580 31 145A 4 supply voltage 410 V Transformer rated power Sn 600 kVA rated secondary voltage supply for drive supply Un 430 V trans...

Page 182: ...protected by the fuses described below ABB recommends Class T fuses listed below Also allowed are UL Listed 248 8 Class J fast acting time delay and high speed fuses 248 4 Class CC fast acting fuses and 248 17 Class CF fast acting and time delay fuses of the same nominal voltage and current rating Refer to notes below the tables UL one fuse per phase Input current ACH580 31 UL class Bussmann type ...

Page 183: ... fuses recommended by ABB are the required branch circuit protection per NEC Circuit breakers listed in section Circuit breakers UL are also acceptable as branch circuit protection 4 The recommended size or smaller UL listed 248 fast acting time delay or high speed fuses must be used to maintain the UL listing of the drive Additional protection can be used Refer to local codes and regulations 5 A ...

Page 184: ...tings are also allowed Using a circuit breaker with a lower KAIC rating is not allowed even if the available short circuit current is less than 65kA For the ABB circuit breaker configurator refer to https lowvoltage configurator tnb com configurator config tmax_xt You can use the circuit breakers listed below Other circuit breakers can be used with the drive if they provide the same electrical cha...

Page 185: ... R6 033A 4 65 XT2H 160 EKIP DIP LS I IN 100 R6 039A 4 65 XT2H 160 EKIP DIP LS I IN 100 R6 046A 4 65 XT2H 160 EKIP DIP LS I IN 160 R6 062A 4 65 XT2H 160 EKIP DIP LS I IN 160 R6 073A 4 65 XT2H 160 EKIP DIP LS I IN 160 R6 088A 4 65 XT4H 250 EKIP DIP LS I In 250A R8 106A 4 65 XT4H 250 EKIP DIP LS I In 250A R8 145A 4 65 XT4H 250 EKIP DIP LS I In 250A R8 169A 4 65 XT4H 250 EKIP DIP LS I In 250A R8 206A ...

Page 186: ... XT4Hαβ225 6602 480 225 111 R8 124A 4 30 0 98 106 XT4Hαβ250 6602 480 250 134 R8 156A 4 30 0 98 106 XT4Hαβ250 6602 480 250 163 R8 180A 4 Notes 1 Drives that have an enclosure minimum volume listed must be mounted in an enclosure enclosure minimum volume specified in the tables above 2 When multiple drives that have an enclosure minimum volume specified are installed in the same enclosure minimum vo...

Page 187: ...ndicated with an represent accessories for the breakers and have no impact on the drive UL listing or performance or rating of the breaker For the ABB circuit breaker configurator refer to https lowvoltage configurator tnb com configurator config tmax_xt 8 Ratings in the tables are maximum for the given circuit breaker frame size Breakers of the same frame size and interrupting rating with lower c...

Page 188: ... 205 19 49 495 47 21 3 R3 17 65 448 9 92 252 30 35 771 139 63 R6 19 53 496 11 81 300 38 965 273 124 R8 IP20 option P940 13 74 349 7 99 203 19 490 40 34 18 3 R3 14 358 9 92 252 30 35 771 131 59 R6 16 93 430 11 81 300 38 965 254 115 R8 1 Hood not included Drive weight with flange kit option C135 Frame size UL Type 12 IP55 UL Type 1 IP21 lb kg lb kg 56 25 35 56 89 25 35 R3 152 68 88 148 66 80 R6 291 ...

Page 189: ... Package dimensions and weights R6 R3 R8 26 61 11 38 16 65 23 54 25 74 39 06 15 75 45 59 19 76 Technical data 189 ...

Page 190: ...Frame Noise Air flow Heat dissipation ACH580 31 Main cir cuit and control boards Control circuit maxim um Control circuit minim um Main cir cuit at rated I1 at I2 dB A ft3 min m3 h W W W W Un 400 V R3 57 212 361 226 36 4 1 190 09A5 4 R3 57 212 361 329 36 4 1 293 12A7 4 R3 57 212 361 395 36 4 1 359 018A 4 R3 57 212 361 579 36 4 1 543 026A 4 R6 71 324 550 625 36 4 1 589 033A 4 R6 71 324 550 751 36 4...

Page 191: ...9131 1678 36 4 1 1642 106A 4 R8 68 506 5371 860 9131 2237 36 4 1 2201 145A 4 R8 68 506 5371 860 9131 2796 36 4 1 2760 169A 4 R8 68 506 5371 860 9131 3356 36 4 1 3320 206A 4 1 IP21 IP55 These losses are not calculated according to the ecodesign standard IEC 61800 9 2 UL NEC Frame Noise Air flow Heat dissipation ACH580 31 Main cir cuit and control boards Control circuit maxim um Control circuit mini...

Page 192: ...g to the ecodesign standard IEC 61800 9 2 Cooling air flow and heat dissipation for flange mounting option C135 IEC Frame Air flow option C135 Heat dissipation op tion C135 ACH580 31 Front Heatsink Front Heatsink ft3 min m3 h ft3 min m3 h W W Un 400 V R3 0 0 212 361 40 150 09A5 4 R3 0 0 212 361 41 252 12A7 4 R3 0 0 212 361 42 317 018A 4 R3 0 0 212 361 46 497 026A 4 R6 31 52 293 498 47 542 033A 4 R...

Page 193: ...573 106A 4 R8 66 113 471 800 84 2117 145A 4 R8 66 113 471 800 100 2660 169A 4 R8 66 113 471 800 118 3201 206A 4 Un 480 V R3 0 0 212 361 39 144 07A6 4 R3 0 0 212 361 40 202 012A 4 R3 0 0 212 361 41 244 014A 4 R3 0 0 212 361 44 393 023A 4 R6 31 52 293 498 47 542 027A 4 R6 31 52 293 498 48 627 034A 4 R6 31 52 293 498 50 721 044A 4 R6 31 52 293 498 53 871 052A 4 R6 31 52 293 498 59 1128 065A 4 R6 31 5...

Page 194: ...or the terminals of the main circuit Frame Flat blade 0 6 x 3 5 mm R3 UL Input motor and DC cable entries maximum wire sizes per phase and terminal screw sizes and tightening torques are given below PE terminal L1 L2 L3 T1 U T2 V T3 W UD UDC terminals Cable entries Frame T Wire screw Wire size T Wire screw Max wire size solid stranded Min wire size solid stran ded 2 Ø1 pcs lbf ft M AWG kcmil lbf f...

Page 195: ... tightening torques T are given below Control cable entries and terminal sizes Cable entries Frame size DI AI O AGND RO STO terminals 24V DCOM DGND EXT 24V terminals Max cable size Holes T Wire size T Wire size lbf ft AWG lbf ft AWG in pcs 0 4 26 14 0 4 24 14 0 67 4 R3 0 4 26 14 0 4 26 14 0 67 4 R6 0 4 26 14 0 4 26 14 0 67 4 R8 Typical power cables The table below gives typical copper and aluminum...

Page 196: ...169A 4 300 MCM 3 240 3 150 R8 206A 4 Un 480 V IEC 14 3 2 5 R3 09A5 4 14 3 2 5 R3 12A7 4 14 3 2 5 R3 018A 4 10 3 6 R3 026A 4 8 3 16 3 10 R6 033A 4 8 3 16 3 10 R6 039A 4 6 3 25 3 16 R6 046A 4 4 3 35 3 25 R6 062A 4 2 3 50 3 35 R6 073A 4 1 0 3 70 3 50 R6 088A 4 2 0 3 70 3 70 R8 106A 4 3 0 3 120 3 95 R8 145A 4 250 MCM 3 150 3 120 R8 169A 4 300 MCM 3 240 3 150 R8 206A 4 Un 480 V NEC 14 3 2 5 R3 07A6 4 1...

Page 197: ...e R3 3 The cable sizing is based on NEC Table 310 16 for copper wires 75 C 167 F wire insulation at 40 C 104 F ambient temperature Not more than three current carrying conductors 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 4 In the USA aluminum cables must not be ...

Page 198: ... by the fuses given in the fuse table Rated conditional short circuit current IEC 61439 1 The drive is suitable for use on a circuit capable of delivering not more than 100 000 rms symmetrical amperes at 480 V maximum when protected by the fuses given in the fuse table Short circuit current protection UL 61800 5 1 47 5 63 Hz This is indicated in the type designation label as typical input frequenc...

Page 199: ... sidered installation PCC Indicates the total harmonic current distortion of the wave form This value is defined as the ratio in of the harmonic currenttothefundamental non harmonic currentmeasured at a load point at the particular moment when the measure ment is taken THDi 40 2 n 2 I I1 100 THDi Indicates the total magnitude of the voltage distortion This value is defined as the ratio in of the h...

Page 200: ...rive operates with optimum performance with the following maximum motor cable lengths Longer motor cables cause a motor voltage decrease which limits the available motor power The de crease depends on the motor cable length and characteristics Contact ABB for more information Note that a sine filter optional at the drive output also causes a voltage decrease Note Conducted and radiated emissions o...

Page 201: ...e by case Radi ated emissions are according to Category C2 with integrated EMC filter Note 2 The integrated EMC filter must be connected Note 3 Radiated and conducted emissions are according to category C3 with an integrated filter and these cable lengths Note 4 Category C2 meets requirements for connecting equipment to the public low voltage networks CCU 24 control unit connection data See chapte...

Page 202: ...9002 PMS 653 C Materials Drive Refer to Recycling instructions and environmental information ACS880 11 ACS880 31 ACH580 31 and ACQ580 31 drives 3AXD50000137671 English Package materials for small wall mounted drives and converter modules Cardboard Molded pulp EPP foam PP strapping PE plastic bag Package materials for large wall mounted drives and converter modules Cardboard heavy duty quality with...

Page 203: ...rds and large electrolytic capacitors need selective treatment according to IEC 62635 guidelines To aid recycling plastic parts are marked with an appropriate identification code Contact your local ABB distributor for further information on environmental aspects and recycling instructions for professional recyclers End of life treatment must follow international and local regulations Applicable st...

Page 204: ... motor starters IEC 61800 9 2 2017 Standard for Adjustable Speed Electrical Power Drive Systems Part 5 1 Safety Requirements Electrical Thermal and Energy UL 61800 5 1 First edition 2012 Insulation coordination for equipment within low voltage systems Part 1 Principles requirements and tests IEC EN 60664 1 2007 Enclosures for Electrical Equipment 1000 Volts Maximum NEMA 250 2014 Industrial control...

Page 205: ...68 2 6 Constantpeakacceler ation 10 m s 1 gn 57 56 150 Hz R3 Displacement 25 mm peak to peak 14200 vibratory impacts Vibration ISTA R6 R8 ISTA 3E Random overall Grms level of 0 54 R3 ISTA 1A Drop 6 faces 3 edges and 1 corner 460 mm 18 1 in Not allowed Shock Drop ISTA R6 R8 ISTA 3E Shock incline impact 1 2 m s 3 94 ft s Shock rotational edge drop 230 mm 9 1 in 1 For neutral grounded TN and TT syste...

Page 206: ...quirements see the additional information concerning the drive EMC compliance IEC EN 61800 3 EAC Eurasian Conformity mark Product complies with the technical regulations of the Eurasian Customs Union EAC mark is required in Russia Belarus and Kazakhstan KC mark Product complies with Korean Registration of Broadcasting and Communications Equipment Clause 3 Article 58 2 of Radio Waves Act Electronic...

Page 207: ...ive of category C3 drive of rated voltage less than 1000 V and intended for use in the second environment and not intended for use in the first environment Drive of category C4 drive of rated voltage equal to or above 1000 V or rated current equal to or above 400 A or intended for use in complex systems in the second environment Category C2 The emission limits are complied with the following provi...

Page 208: ...e length with 4 kHz switching frequency see section Motor connection data page 200 WARNING A drive of category C3 is not intended 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 Note Do not install a drive with the integrated EMC filter connected to a system that the filter is not suitable f...

Page 209: ... The drive is installed according to its installation instructions The EMC recommendations are obeyed WARNING A drive of category C4 is not intended 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 checklist WARNING Operation of this drive requires detailed installation and operation instr...

Page 210: ...or at least 75 C in UL compliant installations The input cable must be protected with fuses or circuit breakers These protective devices provide branch circuit protection in accordance with the national regulations National Electrical Code NEC or Canadian Electrical Code Obey also any other applicable local or provincial codes WARNING The opening of the branch circuit protective device may be an i...

Page 211: ...r and the product is an unsecured protocol For independent and continuous operation of product such connection via network to commissioning tool is not necessary However it is Customer s sole responsibility to provide and continuously ensure a secure connection between the product and Customer network or any other network as the case may be Customer shall establish and maintain any appropriate mea...

Page 212: ...212 ...

Page 213: ...dimension drawings of the drive The dimensions are given in millimeters and inches For dimension drawings of option P940 refer to ACS580 ACH580 and ACQ580 P940 and P944 drive modules supplement 3AXD50000210305 English 13 Dimension drawings 213 ...

Page 214: ...R3 IP21 UL Type 1 3AXD50000028643 214 Dimension drawings ...

Page 215: ...R3 Option B056 IP55 UL Type 12 3AXD50000045321 Dimension drawings 215 ...

Page 216: ...R6 IP21 UL Type 1 3AXD50000037446 216 Dimension drawings ...

Page 217: ...R6 Option B056 IP55 UL Type 12 3AXD50000045351 Dimension drawings 217 ...

Page 218: ...R8 IP21 UL Type 1 3AXD50000147052 218 Dimension drawings ...

Page 219: ...R8 Option B056 IP55 UL Type 12 3AXD50000147052 Dimension drawings 219 ...

Page 220: ...220 ...

Page 221: ...o the drive When activated the Safe torque off function disables the control voltage for the power semiconductors of the drive output stage thus preventing the drive from generating the torque required to rotate the motor If the motor is running when Safe torque off is activated it coasts to a stop The Safe torque off function has a redundant architecture that is both channels must be used in the ...

Page 222: ...ic programmableelectronicsafety related systems IEC 61508 2 2010 Functional safety Safety instrumented systems for the process industry sector IEC 61511 1 2017 Adjustable speed electrical power drive systems Part 5 2 Safety requirements Functional IEC 61800 5 2 2016 EN 61800 5 2 2007 Safety of machinery Functional safety of safety related control systems EN IEC 62061 2021 Safety of machinery Safet...

Page 223: ...hnical data of the control unit Connection principle Single ACH580 31 drive internal power supply OUT1 24 V DC SGND STO UDC UDC K 2 1 3 4 OUT2 24 V DC IN1 IN2 34 35 36 37 38 Drive 1 Control unit 2 Control logic 3 To motor 4 Activation switch K The Safe torque off function 223 ...

Page 224: ... IN2 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 Single ACH580 31 drive internal power supply 24 14 23 13 Y1 A2 Y2 A1 31 32 OUT GND OUT1 34 OUT2 35 SGND 36 IN1 37 IN2 38 STO 1 K 2 Drive 1 Safety PLC 2 224 The Safe torque off function ...

Page 225: ...ay K Single ACH580 31 drive external power supply 24 14 23 13 Y1 A2 Y2 A1 31 32 OUT GND K 2 24 V DC 1 OUT1 34 OUT2 35 SGND 36 IN1 37 IN2 38 STO Drive 1 Safety PLC 2 Safety relay K The Safe torque off function 225 ...

Page 226: ...r supply 34 35 36 37 38 OUT1 OUT2 SGND IN1 IN2 34 35 36 37 38 OUT1 OUT2 SGND IN1 IN2 STO K 24 V DC 24 V DC 2 1 STO 2 1 34 35 36 37 38 OUT1 OUT2 SGND IN1 IN2 STO 2 1 Drive 1 Control unit 2 Activation switch K 226 The Safe torque off function ...

Page 227: ...pply 34 35 36 37 38 OUT1 OUT2 SGND IN1 IN2 34 35 36 37 38 OUT1 OUT2 SGND IN1 IN2 STO K 24 V DC 24 V DC 2 1 STO 2 1 34 35 36 37 38 OUT1 OUT2 SGND IN1 IN2 STO 2 1 24 V DC Drive 1 Control unit 2 Activation switch K The Safe torque off function 227 ...

Page 228: ...300 m 1000 ft between activation switch K and drive control unit 60 m 200 ft between multiple drives 60 m 200 ft between external power supply and first control unit Note A short circuit in the wiring between the switch and an STO terminal causes a dangerous fault Therefore it is recommended to use a safety relay including wiring diagnostics or a wiring method shield grounding channel separation w...

Page 229: ... 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 230: ...e documented and signed by this person Validation test reports Signed validation test reports must be 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 validation tests performed due to changes or maintenance shall be logged into the logbook Validation test procedure A...

Page 231: ...ribed above in testing the 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 input channel of the STO circuit If the motor was running it should coast to a stop The drive generates an FA81 fault indication...

Page 232: ...m the supply and all other voltage sources WARNING The drive cannot detect or memorize any changes in the STO circuitry when the drive control unit is not powered If both STO circuits are closed and a level type start signal is active when the power is restored it is possible that the drive starts without a fresh start command Take this into account in the risk assessment of the system This is als...

Page 233: ... other functions of the drive The Safe torque off function is ineffective against deliberate sabotage or misuse The Safe torque off function has been designed to reduce the recognized hazardous conditions In spite of this it is not always possible to eliminate all potential hazards The assembler of the machine must inform the final user about the residual risks The Safe torque off function 233 ...

Page 234: ...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 235: ...ion function is performed and the drive trips on an FA81 or FA82 fault An attempt to use the STO in a non redundant manner for example activating only one channel will trigger the same reaction See the firmware manual of the drive control program for the indications generated by the drive and for details on directing fault and warning indications to an output on the control unit for external diagn...

Page 236: ...ety data The safety data for the Safe torque off function is given below Note The safety data is calculated for redundant use and applies only if both STO channels are used 236 The Safe torque off function ...

Page 237: ... Frame size 1 40E 10 6 43E 08 1 40E 12 20 80 1 3 87 99 90 27033 1 63E 04 8 15E 05 3 26E 05 3 91E 09 e 3 3 R3 1 40E 10 6 43E 08 1 40E 12 20 80 1 3 87 99 90 27033 1 63E 04 8 15E 05 3 26E 05 3 91E 09 e 3 3 R6 1 40E 10 1 96E 07 1 40E 12 20 80 1 3 99 90 8792 1 85E 04 9 24E 05 3 69E 05 4 22E 09 e 3 3 R8 3AXD10001613538 A The Safe torque off function 237 ...

Page 238: ...mes STO reaction time shortest detectable break 1 ms STO response time Frames R3 and R6 2 ms typical 10 ms maximum Frame R8 2 ms typical 15 ms maximum Fault detection time Channels in different states for longer than 200 ms Fault reaction time Fault detection time 10 ms Indication delays STO fault indication parameter 31 22 delay 500 ms STO warning indication parameter 31 22 delay 1000 ms Terms an...

Page 239: ... repair can restore the system to an as new condition or as close as practical to this condition IEC 61508 IEC 62061 Proof test Systematic capability 1 3 IEC 61508 SC Safe failure fraction IEC 61508 SFF Safety integrity level 1 3 IEC 61508 SIL 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 ...

Page 240: ... 2 Safety requirements Functional The product s referred in this Declaration of conformity fulfil s the relevant provisions of other European Union Directives which are notified in Single EU Declaration of conformity 3AXD10000497691 Authorized to compile the technical file ABB Oy Hiomotie 13 00380 Helsinki Finland Hiomotie 13 00380 Helsinki Finland 358 10 22 11 declare under our sole responsibilit...

Page 241: ...e the technical file ABB Limited Daresbury Park Cheshire United Kingdom WA4 4BT Functional safety of electrical electronic programmable electronic safety related systems Adjustable speed electrical power drive systems Part 5 2 Safety requirements Functional Safety of machinery Safety related parts of control systems Part 1 General requirements Safety of machinery Safety related parts of the contro...

Page 242: ...242 ...

Page 243: ...s the voltage until the resistor can be disconnected Planning the braking system The drive needs external brake chopper and resistors Selecting the default brake system components 1 Calculate the maximum power generated by the motor during braking 2 Select a suitable drive brake chopper and brake resistor combination for the application from the brake ratings table in the technical data The brakin...

Page 244: ...the custom resistor does not restrict the braking capability needed ie where Maximum power generated by the motor during braking Pmax Drive intermediate DC circuit voltage UDC 1 35 1 2 415 V when supply voltage is 380 415 V AC 1 35 1 2 500 V when supply voltage is 440 500 V AC or Resistance of the custom resistor R 3 make sure that the resistor can dissipate the energy transferred to it during the...

Page 245: ...ompletely either by using shielded cable or a metallic enclosure Unshielded single core cable can only be used if it is routed inside a cabinet that efficiently suppresses the radiated emissions Install the cables away from other cable routes Avoid long parallel runs with other cables The minimum parallel cabling separation distance is 0 3 meters 1 ft Cross the other cables at 90 degree angles Kee...

Page 246: ...ding to the nominal current of the drive The drive control program includes a resistor and resistor cable thermal protection function which can be tuned by the user See the firmware manual ABB requires that the resistor has a thermal switch standard in ABB resistors which is wired to the chopper for safety reasons The thermal switch cable must be shielded and may not be longer than the resistor ca...

Page 247: ...stor thermal switch 4 Digital input Monitors the brake resistor thermal switch 5 Protecting the resistor cable against short circuits The input fuses will also protect the resistor cable when it is identical with the input cable Mechanical installation The brake chopper and brake resistors must be installed outside the drive Obey the resistor manufacturer s instructions Electrical installation Mea...

Page 248: ...per operates for the first time the grease burns off and may produce some smoke Make sure there is sufficient ventilation Set the following parameters HVAC control program Disable the overvoltage control of the drive by parameter 30 30 Overvoltage control Set parameter 31 01 External event 1 source to point to the digital input where the thermal switch of the brake resistor is wired Set parameter ...

Page 249: ...rmal protection of the drive against resistor overheating is not in use In this case the brake resistor must be disconnected Technical data Ratings Contact ABB for the brake chopper and resistor specifications Terminals and cable entry data See section Terminal and entry data for the power cables page 194 Resistor braking 249 ...

Page 250: ...250 ...

Page 251: ...y includes the common mode filter installation kit which the customer needs to install For installation instructions refer to Common mode filter kit for ACS880 01 frame R7 and for ACS880 11 ACS880 31 ACH580 31 and ACQ580 31 frame R8 installation instructions 3AXD50000015179 English du dt filters When is a du dt filter needed See section Examining the compatibility of the motor and drive page 59 16...

Page 252: ...CH0260 70 169A 4 FOCH0260 70 206A 4 IEC ratings Un 480 V NOCH0016 6x 09A5 4 NOCH0016 6x 12A7 4 NOCH0016 6x or NOCH0030 6x 1 018A 4 NOCH0030 6x 026A 4 NOCH0070 6x 033A 4 NOCH0070 6x 039A 4 NOCH0070 6x 046A 4 NOCH0070 6x 062A 4 NOCH0070 6x or NOCH0120 6x 2 073A 4 NOCH0120 6x 088A 4 NOCH0120 6x 106A 4 FOCH0260 7X 145A 4 FOCH0260 7X 169A 4 FOCH0260 7X 206A 4 3AXD00000586715 1 NOCH0016 6x can be used i...

Page 253: ...X 156A 4 FOCH0260 7X 180A 4 3AXD00000586715 1 NOCH0016 6x can be used if full load current is not needed 2 NOCH0070 6x can be used if full load current is not needed Description installation and technical data of the filters See AOCH and NOCH du dt filters hardware manual 3AFE58933368 English or FOCHxxx xx du dt filters hardware manual 3AFE68577519 English Sine filters See section Examining the co...

Page 254: ...254 ...

Page 255: ...IO 01 bipolar analog I O module expands the inputs and outputs of the drive control unit It has three bipolar current voltage inputs and two unipolar current voltage outputs The inputs can handle positive and negative signals The way the drive interprets the negative range of the inputs depends on the parameter settings of the drive The voltage current selection of the inputs is done with a parame...

Page 256: ... signal AI3 82 Cable shield connection SHIELD 93 Cable shield connection SHIELD 83 Analog output 4 signal AO4 94 Analog input 4 positive signal AI4 84 Analog ground potential AGND 95 Analog input 4 negative signal AI4 85 Cable shield connection SHIELD 86 Analog input 5 positive signal AI5 87 Analog input 5 negative signal AI5 88 Control unit slot interface 6 Grounding hole 7 Diagnostic LED 8 Mount...

Page 257: ...ption modules page 115 Electrical installation WARNING Obey the safety instructions of the drive If you ignore them injury or death or damage to the equipment can occur Stop the drive and do the steps in section Electrical safety precautions page 20 before you start the work Necessary tools Screwdriver and a set of suitable bits Wiring Connect the external cables to the applicable module terminals...

Page 258: ...e of 15 02 is CAIO 01 set the value of parameter 15 01 to CAIO 01 You can now see the parameters of the extension module in group 15 I O extension module 3 Set the parameters of analog inputs AI3 AI4 AI5 or analog outputs AO3 or AO4 to applicable values see the firmware manual Example To connect supervision 1 to AI3 of the extension module Select the mode of the supervision function 32 05 Supervis...

Page 259: ... conditions Cardboard Package Analog inputs 80 82 83 85 86 88 1 5 mm2 Maximum wire size 11 V 11 V Input voltage AI and AI 22 mA 22 mA Input current AI and AI 200 kohm voltage mode 100 ohm current mode Input resistance Optional cable shield connections Analog outputs 90 92 93 95 1 5 mm2 Maximum wire size 0 V 11 V Output voltage AO and AO 0 mA 22 mA Output current AO and AO 20 ohm Output resistance ...

Page 260: ... Isolation areas 2 2 2 Plugged to drive control unit SLOT 2 1 Reinforced insulation IEC 61800 5 1 2007 260 CAIO 01 bipolar analog I O adapter module ...

Page 261: ...Dimension drawings The dimensions are in millimeters CAIO 01 bipolar analog I O adapter module 261 ...

Page 262: ...262 ...

Page 263: ... optional CHDI 01 multifunction extension module The chapter also contains diagnostics and technical data Product overview The CHDI 01 115 230 V digital input extension module expands the inputs of the drive control unit It has six high voltage inputs and two relay outputs 18 CHDI 01 115 230 V digital input extension module 263 ...

Page 264: ...ormally open NO RO4A 52 Neutral point NEUTRAL 1 72 Common C RO5C 53 115 230 V input 3 HDI9 73 Normally closed NC RO5B 54 115 230 V input 4 HDI10 74 Normally open NO RO5A 55 Neutral point NEUTRAL 1 75 Grounding screw 1 115 230 V input 5 HDI11 76 Hole for mounting screw 2 115 230 V input 5 HDI12 77 Diagnostic LED Green The extension module is powered up 5 Neutral point NEUTRAL 1 78 1 Neutral points ...

Page 265: ...section Electrical safety precautions page 20 before you start the work Necessary tools Screwdriver and a set of suitable bits Wiring Connect the external control cables to the applicable module terminals Ground the outer shield of the control cables 360 under the grounding clamp on the grounding shelf Start up Setting the parameters 1 Power up the drive 2 If no warning is shown make sure that the...

Page 266: ...09 RO4 OFF delay Fault and warning messages Warning A7AB Extension I O configuration failure Technical data Into an option slot on the drive control unit Installation IP20 UL Type 1 Degree of protection See the drive technical data Ambient conditions Cardboard Package Reley outputs 50 52 53 55 1 5 mm2 Maximum wire size 12 V 10 mA Minimum contact rat ing 250 V AC 30 V DC 2 A Maximum contact rating ...

Page 267: ...DI 1 Plugged to drive SLOT2 1 Reinforced insulation IEC 61800 5 1 2007 Functional insulation IEC 61800 5 1 2007 Dimension drawing The dimensions are in millimeters and inches CHDI 01 115 230 V digital input extension module 267 ...

Page 268: ...268 ...

Page 269: ...sistor output which can operate as a digital or frequency output In addition the extension module has an external power supply interface which can be used to power up the drive control unit in case the drive power supply is not on If you do not need the backup power supply you do not have to connect it because the module is powered from the drive control unit by default With CCU 24 control unit a ...

Page 270: ...V AC DC in 24V AC DC in 24 V AC DC Common C RO4C 50 External 24 V AC DC in put 24 V AC DC in 40 Normally closed NC RO4A 51 External 24 V AC DC in put 24 V AC DC in 41 Normally open NO RO4B 52 3 pin terminal block for for transistor output 4 24 V DC 42 43 44 DO1 SRC DO1 OUT DO1 SGND 1 42 43 44 DO1 SRC DO1 OUT DO1 SGND 2 Common C RO5C 53 Source input DO1 SRC 42 270 CMOD 01 multifunction extension mo...

Page 271: ...contains the option module a mounting screw 2 Make sure that there are no signs of damage Installing the module See section Installing option modules page 115 Electrical installation WARNING Obey the safety instructions of the drive If you ignore them injury or death or damage to the equipment can occur Stop the drive and do the steps in section Electrical safety precautions page 20 before you sta...

Page 272: ...odule 3 Set the parameters of the extension module to applicable values Examples are given below 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 Setting Parameter Reverse 15 07 RO4 source 1 s 15 08 RO4 ON delay 1 s 15 09 RO4 OFF delay Parameter setting exa...

Page 273: ...g 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 Into an option slot on the drive control unit Installation IP20 UL Type 1 Degree of protection See the drive technical data Ambient conditions Cardboard Package Reley outputs 50 52 53 55 1 5 mm2 Maximum wire size 12 V...

Page 274: ...Maximum wire size 24 V AC V DC 10 GND user potential Input voltage 25 W 1 04 A at 24 V DC Maximum power con sumption Isolation areas DO1 CMOD 01 RO5 RO4 24 Vin 1 Plugged to drive SLOT2 1 Reinforced insulation IEC 61800 5 1 2007 Functional insulation IEC 61800 5 1 2007 Dimension drawing The dimensions are in millimeters and inches 274 CMOD 01 multifunction extension module external 24 V AC DC and d...

Page 275: ...CMOD 01 multifunction extension module external 24 V AC DC and digital I O 275 ...

Page 276: ...276 ...

Page 277: ...utput which indicates the thermistor status In case the thermistor overheats the drive trips on motor overtemperature If Safe torque off tripping is required the user must wire the overtemperature indication relay to the certified Safe torque off input of the drive In addition the extension module has an external power supply interface which can be used to power up the drive control unit in case t...

Page 278: ...ected directly to terminals 40 and 41 on the control unit Layout and example connections 1 2 5 4 3 6 2 pin terminal block for relay output 4 2 pin terminal block for external power supply 3 62 63 CMOD 02 CCU 34 35 X4 36 37 38 OUT1 OUT2 SGND IN1 IN2 RO PTC C RO PTC B 40 41 24V AC DC in 24V AC DC in 24 V AC DC Common C RO PTC C 62 External 24 V AC DC in put 24 V AC DC in 40 Normally open NO RO PTC B...

Page 279: ... signs of damage Installing the module See section Installing option modules page 115 Electrical installation WARNING Obey the safety instructions of the drive If you ignore them injury or death or damage to the equipment can occur Stop the drive and do the steps in section Electrical safety precautions page 20 before you start the work Necessary tools Screwdriver and a set of suitable bits Wiring...

Page 280: ...s 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 Into option slot 2 on the drive control unit Installation IP20 UL Type 1 Degree of protection See the drive technical d...

Page 281: ...d CMOD 02 PTC terminal Relay output 62 63 1 5 mm2 Maximum wire size 250 V AC 30 V DC 5 A Maximum contact rating 1000 VA Maximum breaking capacity External power supply 40 41 1 5 mm2 Maximum wire size 24 V AC V DC 10 GND user potential Input voltage 25 W 1 04 A at 24 V DC Maximum power con sumption Isolation areas CMOD 02 PTCin RO PTC 24 Vin 1 Plugged to drive SLOT2 1 Reinforced insulation IEC 6180...

Page 282: ...282 CMOD 02 multifunction extension module external 24 V AC DC and isolated PTC interface ...

Page 283: ... 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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