Page 1 — ABB DRIVES FOR HVAC ACH580-01 drives Hardware manual...
Page 3 ACH580-01 drives Hardware manual Table of contents 1. Safety instructions 4. Mechanical installation 6. Electrical installation – IEC 7. Electrical installation – North America 3AXD50000044839 Rev D Original instructions EFFECTIVE: 2022-02-18...
Page 5: Table Of Contents
Table of contents 5 Table of contents 1 Safety instructions Contents of this chapter ..................Use of warnings and notes ................. General safety in installation, start-up and maintenance ........Electrical safety in installation, start-up and maintenance ........Electrical safety precautions ................ Additional instructions and notes ..............
Page 6 6 Table of contents 4 Mechanical installation Contents of this chapter ..................Safety ........................Examining the installation site ................Required tools ..................... Moving the drive ....................Unpacking and examining delivery, frames R1 and R2 ........Frames R1 and R2 cable box (IP21, UL Type 1) ......... Unpacking and examining delivery, frame R3 ............
Page 7 Table of contents 7 Additional requirements for ABB motors of types other than M2_, M3_, M4_, HX_ and AM_ ..............Additional requirements for braking applications ......Additional requirements for the regenerative and low harmonics drives ....................Additional requirements for ABB high-output and IP23 motors ..
Page 8 8 Table of contents Protecting the drive against ground faults ............Residual current device compatibility ............Implementing the emergency stop function ............Implementing the Safe torque off function ............Implementing an ATEX-certified motor thermal protection ......... Using a safety switch between the drive and the motor ........Implementing the Power-loss ride-through function ...........
Page 9 Table of contents 9 Connection procedure, frame R5 ..............IP21 (UL Type 1) ................IP55 (UL Type 12) ................Connection procedure, frames R6…R9 ............Motor cable ..................Input power cable ................Detaching and reinstalling the connectors ........DC connection ....................Connecting the control cables ................
Page 10 10 Table of contents Measuring the insulation ..................Measuring the insulation resistance of the drive .......... Measuring the insulation resistance of the input power cable ..... Measuring the insulation resistance of the motor and motor cable ....Brake resistor assembly for R1…R3 ............Grounding system compatibility check ...............
Page 11 Table of contents 11 Installing option modules ..................Mechanical installation of option modules ........... Option slot 2 (I/O extension modules) ..........Option slot 1 (fieldbus adapter modules) .......... R6…R9 ..................... Wiring the modules ..................Reinstalling grommets ..................Reinstalling covers ....................Reinstalling cover, frames R1…R4 ..............
Page 12 12 Table of contents Replacing the auxiliary cooling fan, IP55 (UL Type 12) frame R4; IP21 and IP55 (UL Type 1 and UL Type 12) frame R5 ..........Replacing the second auxiliary cooling fan, IP55 (UL Type 12) frames R8…R9 ......................Capacitors ......................
Page 13 Table of contents 13 Power cables ...................... Typical power cable sizes, IEC ..............Terminal and entry data for the control cables ............ IEC ....................... UL (NEC) ...................... Electrical power network specification ..............Motor connection data ..................Brake resistor connection data for frames R1…R3 ..........Control connection data ..................
Page 14 14 Table of contents Frame R3, IP55 (UL Type 12) ................Frame R3, IP55+E223 (UL Type 12) ..............Frame R3, IP55+F278/F316 (UL Type 12) ............Frame R4, IP21 (UL Type 1) ................Frame R4, IP55 (UL Type 12) ................Frame R4, IP55+E223 (UL Type 12) ..............Frame R4, IP55+F278/F316 (UL Type 12) ............
Page 15 Table of contents 15 Wiring ........................Connection principle ..................Single ACH580-01 drive, internal power supply ....... Single ACH580-01 drive, external power supply ......Wiring examples ................... Single ACH580-01 drive, internal power supply ....... Single ACH580-01 drive, external power supply ......
Page 16 16 Table of contents CHDI-01 115/230 V digital input extension module ..........Product overview ..................Layout and connection examples ..............Mechanical installation ................. Necessary tools ................Unpacking and examining the delivery ..........Installing the module ................. Electrical installation ..................Necessary tools ................Wiring ....................
Page 17 Table of contents 17 Diagnostics ....................Faults and warning messages ............LEDs ....................Technical data ....................Dimension drawing ..................15 Common mode, du/dt and sine filters Content of this chapter ..................Common mode filters ..................When is a common mode filter needed? ............. Common mode filter types ................
Page 19: Safety Instructions
Safety instructions 19 Safety instructions Contents of this chapter This chapter contains the safety instructions which you must obey when you install, start-up, operate and do maintenance work on the drive. If you ignore the safety instructions, injury, death or damage can occur. Use of warnings and notes Warnings tell you about conditions which can cause injury or death, or damage to the equipment.
Page 20: General Safety In Installation, Start-Up And Maintenance
20 Safety instructions General safety in installation, start-up and maintenance These instructions are for all personnel who do work on the drive. WARNING! Obey these instructions. If you ignore them, injury or death, or damage to the equipment can occur. •...
Page 21 Safety instructions 21 • Before you adjust the drive operation limits, make sure that the motor and all driven equipment can operate throughout the set operation limits. • Before you activate the automatic fault reset or automatic restart functions of the drive control program, make sure that no dangerous situations can occur.
Page 22: Electrical Safety In Installation, Start-Up And Maintenance
22 Safety instructions Electrical safety in installation, start-up and maintenance ￭ Electrical safety precautions These electrical safety precautions are for all personnel who do work on the drive, motor cable or motor. WARNING! Obey these instructions. If you ignore them, injury or death, or damage to the equipment can occur.
Page 23: Additional Instructions And Notes
Safety instructions 23 6. Install temporary grounding as required by the local regulations. 7. Ask for a permit to work from the person in control of the electrical installation work. ￭ Additional instructions and notes WARNING! Obey these instructions. If you ignore them, injury or death, or damage to the equipment can occur.
Page 24: Grounding
24 Safety instructions ￭ Grounding These instructions are for all personnel who are responsible for the grounding of the drive. WARNING! Obey these instructions. If you ignore them, injury or death, or equipment malfunction can occur, and electromagnetic interference can increase. If you are not a qualified electrical professional, do not do grounding work.
Page 25: General Safety In Operation
Safety instructions 25 General safety in operation These instructions are for all personnel that operate the drive. WARNING! Obey these instructions. If you ignore them, injury or death, or damage to the equipment can occur. • If you have a cardiac pacemaker or other electronic medical device, keep away from the area near motor, drive, and the drive power cabling when the drive is in operation.
Page 26: Safety In Operation
26 Safety instructions • Do not do work on the drive when a rotating permanent magnet motor is connected to it. A rotating permanent magnet motor energizes the drive including its input and output power terminals. Before installation, start-up and maintenance work on the drive: •...
Page 27: Introduction To The Manual
Categorization by frame size The ACH580-01 is manufactured in frames (frame sizes) R1…R9. Some instructions and other information that concern only certain frames are marked with the symbol of the frame (R1…R9). The frame is marked on the type designation label of the drive, Type designation label (page 48).
Page 28: Quick Installation And Commissioning Flowchart
28 Introduction to the manual Quick installation and commissioning flowchart Task Identify the frame of your drive: R1…R9. Type designation key (page 50) Plan the installation: select the cables, etc. Guidelines for planning the electrical installa- Examine the ambient conditions, ratings and tion (page 87) required cooling air flow.
Page 29: Terms And Abbreviations
Introduction to the manual 29 Task Check the installation. Installation checklist (page 209) Commission the drive. ACH580 HVAC control program firmware manual (3AXD50000027537 [English]) Terms and abbreviations Term Description ACH-AP-H Assistant control panel with Hand-Off-Auto functionality ACH-AP-W Assistant control panel with Hand-Off-Auto functionality and Bluetooth inter- face BACnet™...
Page 30: Related Documents
30 Introduction to the manual Term Description FCNA-01 Optional ControlNet™ adapter module FDNA-01 Optional DeviceNet™ adapter module FECA-01 Optional EtherCAT® adapter module FEIP-21 Optional Ethernet adapter module for EtherNet/IP™ FENA-21 Optional Ethernet adapter module for EtherNet/IP™, Modbus TCP® and PROFINET IO® protocols, 2-port FEPL-02 Optional Ethernet POWERLINK adapter module FLON-01...
Page 31 Code (English/ Code Multilingual) (Translation) ACH580-01 hardware manual 3AXD50000044839 ACH580-01 quick installation and start-up guide for global 3AXD50000758685 (IEC) product types ACH580-01 quick installation and start-up guide for North 3AXD50000788286 American (NEC) product types ACH580 Installation, Operation, and Maintenance Manual 3AXD50000049127 (I, O &...
Page 32 Main switch and EMC C1 filter options (+F278, +F316, 3AXD50000155132 +E223) installation supplement for ACS580-01, ACH580- 01 and ACH580-01 frames R1 to R5 UL Type 12 hood quick installation guide for ACS580-01, 3AXD50000225972 ACH580-01, ACQ580-01, ACH580-31, ACQ580-31, ACS880-11 and ACS880-31...
Page 33 Introduction to the manual 33 The code below opens an online listing of the manuals applicable to this product. ACH580-01 manuals...
Page 35: Operation Principle And Hardware Description
Operation principle and hardware description 35 Operation principle and hardware description Contents of this chapter This chapter briefly describes the operation principle and construction of the drive.
Page 36: Operation Principle
36 Operation principle and hardware description Operation principle The ACH580-01 is a drive for controlling asynchronous AC induction motors, permanent magnet motors and synchronous reluctance motors (SynRM). The figure below shows the simplified main circuit diagram of the drive. T1/U...
Page 37 Operation principle and hardware description 37 R1 IP21 / UL Type 1 Mounting points (4 pieces) EMC filter grounding screw (EMC (DC)). For disconnecting, see page (IEC) or Cover: upper part (2a), lower part (2b) page (North America). Cover screw Place for storing the removed VAR screw Cable/conduit box Place for storing the removed EMC screw...
Page 38 38 Operation principle and hardware description This is an example of IP55 / UL Type 12 frames. They have one-piece front cover, which has a transparent window to leave the control panel visible. UL Type 12 frames have a hood, whose construction depends on the frame size. R1 IP55 / UL Type 12 Mounting points (4 pieces), top points are under the hood, which is installed last.
Page 39 Operation principle and hardware description 39 Frame R3 R3 IP21 / UL Type 1 20 21 Mounting points (4 pieces) Input power connection (L1, L2, L3), motor connection (T1/U, T2/V, T3/W) and brake Cover connection (R-, R+) Cover screw PE connection (power line) Control panel Grounding connection (motor) Control panel connection...
Page 40 40 Operation principle and hardware description Frame R4 R4 IP21 / UL Type 1 PE 12 Mounting points (4 pieces) Two EMC filter grounding screws (EMC (DC)). For disconnecting, see page Cover (IEC) or page (North America). Cover screw Input power connection (L1, L2, L3), motor Control panel connection (T1/U, T2/V, T3/W) and DC Control panel connection...
Page 41 Operation principle and hardware description 41 R4 v2 IP21 / UL Type 1 PE 12 Mounting points (4 pieces) EMC filter grounding screw (EMC). For disconnecting, see page (IEC) or page Cover (North America). Cover screw Input power connection (L1, L2, L3), motor Control panel connection (T1/U, T2/V, T3/W) and DC Control panel connection...
Page 42 42 Operation principle and hardware description Frame R5 R5 IP21 / UL Type 1 PE 13 Mounting points (6 pieces: 2 at the top, 2 Two EMC filter grounding screws, 11a: at the bottom of the main part of the frame, EMC (DC) and 11b: (EMC (AC).
Page 43 Operation principle and hardware description 43 Frames R6…R9 R6 IP21 / UL Type 1 The layout of a frame R6 drive is presented below. The constructions of frames R6…R9 differ to some extent. Mounting points (6 pieces: 2 at the top, 2 Varistor grounding screw (VAR), under the at the bottom of the main part of the frame, control panel platform.
Page 44: Overview Of Power And Control Connections
44 Operation principle and hardware description Overview of power and control connections The logical diagram below shows the power connections and control interfaces of the drive. T1/U T2/V T3/W UDC+ UDC- Option slot 1 for optional fieldbus adapter modules Option slot 2 for optional I/O extension modules Panel port du/dt or common mode filter (optional), see Common mode, du/dt and sine filters (page...
Page 45: External Control Connection Terminals, Frames R1
Operation principle and hardware description 45 ￭ External control connection terminals, frames R1…R5 The layout of the external control connection terminals of the R1 frame is shown below. Layout of the external control connection terminals is identical in frames R1…R5 but the location of the control unit with the terminals is different in frames R3…R5.
Page 46: External Control Connection Terminals, Frames R6
46 Operation principle and hardware description ￭ External control connection terminals, frames R6…R9 The layout of the external control connection terminals of frames R6…R9 is shown below. Description R6…R9 Analog inputs and outputs Aux. voltage output Digital inputs Safe torque off connection Connection to embedded EIA-485 fieldbus adapter module Relay output 3...
Page 47: Control Panel
Operation principle and hardware description 47 Control panel To remove the control panel, press the retaining clip at the top (1a) and pull the panel forward from the top edge (1b). To reinstall 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).
Page 48: Control Panel Door Mounting Kits
48 Operation principle and hardware description ￭ Control panel door mounting kits You can use a mounting platform to mount the control panel on the cabinet door. Mounting platforms for control panels are available as options from ABB. For more information, see Manual Code (English)
Page 49: Locations Of The Labels On The Drive
Operation principle and hardware description 49 Description Nominal ratings in the supply voltage range, see Ratings (page 231), Electrical power network specification (page 286) Motor connection data (page 288). Link to the product data sheet Valid markings S/N: Serial number of format MYYWWXXXXX, where Manufacturing plant 16, 17, 18, …...
Page 50: Type Designation Key
You find the type designation on the type designation label attached to the drive. The first digits from the left express the basic configuration, for example, ACH580-01-12A7-4. The optional selections are given after that, separated by plus signs, for example, +L501. The main selections are described below. Not all selections are available for all types.
Page 51: Option Codes
Operation principle and hardware description 51 Code Description 2 = 208…240 V 4 = 380…480 V 6 = 525…600 V See the technical data for further information. ￭ Option codes Code Description B056 IP55 (UL Type 12) C135 Flange mounting Chemical gases contamination class 3C3/C4 level resistance for ammonia, frames C219 R1…R5.
Page 52: Manual Kit Ordering Codes
52 Operation principle and hardware description Code Description P931 Extended warranty 36 months from delivery P932 Extended warranty 60 months from delivery Version for cabinet mounting (drive module with front covers but without cable box) for P944 frames R5…R9. Q971 ATEX-certified safe disconnection function Manual kit ordering codes Hardware and firmware manuals are not included as default.
Page 53: Mechanical Installation
Mechanical installation 53 Mechanical installation Contents of this chapter This chapter tells how to examine the installation site, unpack and examine the delivery and install the drive mechanically. Safety WARNING! Frames R5…R9: Lift the drive with a lifting device. Use the lifting eyes of the drive. Do not tilt the drive.
Page 54: Examining The Installation Site
54 Mechanical installation Examining the installation site The drive must be installed on the wall or an enclosure. There are three alternative ways to install it: • Vertical Note: Do not install the drive upside down. Frame Vertical installation - Free space size IP21 (UL Type 1) IP55 (UL Type 12)
Page 55 Free space between the drive and other objects, e.g. wall. Note: The recommended free space above and below the drive is for installations where the drive is mounted on a wall indoors. For ABB cabinet-built drives, which are thermally tested and approved for a specified temperature range, free space...
Page 56 56 Mechanical installation • Vertical side by side or between walls c = 0 Frame size Vertical installation side by side - Free space, IP21 (UL Type 1) and IP55 (UL Type 12) Above (a) 1) Below (b) 2) Between (c) 3) 7.87 7.87 7.87...
Page 57 Mechanical installation 57 Note: The recommended free space above and below the drive is for installations where the drive is mounted on a wall indoors. For ABB cabinet-built drives, which are thermally tested and approved for a specified temperature range, free space could vary from this recommendation.
Page 58 58 Mechanical installation • Horizontal, IP20 and IP55, R1…R5 only Note 1: You can install IP21/UL Type 1 drives horizontally but the installation meets IP20 requirements only. Note 2: IP55/UL Type 12 drives mounted horizontally meets IP21/UL Type 1 ratings. Note 3: In the horizontal mounting, the drive is not protected from dripping water.
Page 59: Required Tools
Mechanical installation 59 Make sure that the installation site complies with the requirements below: • The installation site is sufficiently ventilated or cooled to remove the heat away from the drive. See Losses, cooling data and noise (page 273). • The operation conditions of the drive meet the specifications given in Ambient conditions (page...
Page 60: Unpacking And Examining Delivery, Frames R1 And R2
60 Mechanical installation Unpacking and examining delivery, frames R1 and R2 The figure below shows the layout of the transport package. 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.
Page 61 Mechanical installation 61 Control panel selected in the order. Cable box North America: Control panel factory in- Note: The cable box is mounted to the stalled. IP55 drive module frame at the factory. Manuals Drive • Europe: Quick installation and start-up Mounting template guide kit (6 languages) Cardboard box...
Page 62 62 Mechanical installation • Remove the mounting template (7) and top cushion (10) • Remove the control panel, option boxes and cable box (1,3,4,5) • Remove the end supports (9) • Remove the plastic bag (12) • Lift the drive (6). WARNING! R1…R2, IP21: Do not lift the drive by holding it from the cover.
Page 63: Frames R1 And R2 Cable Box (Ip21, Ul Type 1)
Mechanical installation 63 ￭ Frames R1 and R2 cable box (IP21, UL Type 1) This illustration shows the contents of the cable box package. The package also includes an assembly drawing which shows how to install the cable box to the drive module frame.
Page 64: Unpacking And Examining Delivery, Frame R3
64 Mechanical installation Unpacking and examining delivery, frame R3 The figure below shows the layout of the transport package. 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.
Page 65 Mechanical installation 65 To unpack: • Open the cardboard box (7) • Remove the mounting template (6) and top cushion (10) • Remove the control panel and option boxes (1,3,4) • Remove the end supports (9) • Remove the plastic bag (12) •...
Page 66: Unpacking And Examining Delivery, Frames R4
66 Mechanical installation Unpacking and examining delivery, frames R4 The figure below shows the layout of the transport package. 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.
Page 67 Mechanical installation 67 Drive Top cushion Cardboard box. Mounting template in the Bottom cushion cardboard box. Bottom cushion Option support: Top cushion • Europe: Quick installation and start-up Note: Hood included with option +B056 guide kit (6 languages) (IP55/UL Type 12) in North America •...
Page 68: Unpacking And Examining Delivery, Frame R5
68 Mechanical installation Unpacking and examining delivery, frame R5 The figure below shows the layout of the transport package. 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.
Page 69: Frame R5 Cable Box (Ip21, Ul Type 1)
Mechanical installation 69 To unpack: • Cut the straps (7). • Remove the cardboard box (4) and option box (3). • Remove the cover protecting film (6). • Lift the drive (2). ￭ Frame R5 cable box (IP21, UL Type 1) This illustration shows the contents of the cable box package.
Page 70: Unpacking And Examining Delivery, Frames R6
70 Mechanical installation Unpacking and examining delivery, frames R6…R9 The figure below shows the layout of the transport package. 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.
Page 71 Mechanical installation 71 Cable box. Power and control cable • North America: English Installation, grounding shelves in a plastic bag, as- Operation, and Maintenance manual sembly drawing. (I, O & M) • Multilingual residual voltage warning Note: The cable box is mounted to the stickers IP55 drive module frame at the factory.
Page 72: Frame R6 Cable Box (Ip21, Ul Type 1)
72 Mechanical installation ￭ Frame R6 cable box (IP21, UL Type 1) The figure below shows the contents of the cable box package. The package also includes an assembly drawing which shows how to install the cable box to the drive frame.
Page 73: Frame R7 Cable Box (Ip21, Ul Type 1)
Mechanical installation 73 ￭ Frame R7 cable box (IP21, UL Type 1) The figure below shows the contents of the cable box package. The package also includes an assembly drawing which shows how to install cable box to the drive frame.
Page 74: Frame R8 Cable Box (Ip21, Ul Type 1)
74 Mechanical installation ￭ Frame R8 cable box (IP21, UL Type 1) The figure below shows the contents of the cable box package. The package also includes an assembly drawing which shows how to install the cable box to the drive frame.
Page 75: Frame R9 Cable Box (Ip21, Ul Type 1)
Mechanical installation 75 ￭ Frame R9 cable box (IP21, UL Type 1) The figure below shows the contents of the cable box package. The package also includes an assembly drawing which shows how to install the cable box to the drive frame.
Page 76: Installing The Drive
76 Mechanical installation Installing the drive ￭ Installing the drive vertically, frames R1…R4 The figures show frame R3 as an example. Select fasteners and their application to meet local requirements appropriate to wall surface materials, drive weight and application. 1. Mark the hole locations using the mounting template included in the package. Do not leave the mounting template under the drive.
Page 77: Installing The Cable Box, Frames R1
Mechanical installation 77 4. Position the drive onto the lower bolts (4a) on the wall to support the weight of the drive. Rotate drive to the wall and place drive over the upper bolts (4b). WARNING! R1…R2, IP21: Do not lift the drive by holding it from the cover. The drive can fall and become damaged or damage the surroundings.
Page 78 78 Mechanical installation 6. Remove the screw (6a) and lift the cover off (6b) from the separate cable box. 7. Attach the cable box cover to the front cover. 8. Install the cable box to the frame. Position the cable box (8a) and tighten the screws (8b).
Page 79: Installing The Drive Vertically, Frame R5
Mechanical installation 79 ￭ Installing the drive vertically, frame R5 Select fasteners and their application to meet local requirements appropriate to wall surface materials, drive weight and application. Mechanical installation 69 1. Mark the hole locations using the mounting template included in the package. Do not leave the mounting template under the drive.
Page 80: Ip21 (Ul Type 1)
80 Mechanical installation IP21 (UL Type 1) 4. Remove the front cover: Remove the fastening screws (4a) with a T20 Torx screwdriver and lift the cover from the bottom upwards (4b) and then to the top side (4c). 5. Attach the cable box to the drive frame. 6.
Page 81: Ip21 (Ul Type 1), Ip55 (Ul Type 12)
Mechanical installation 81 IP21 (UL Type 1), IP55 (UL Type 12) 9. Position the drive onto the lower bolts (9a) on the wall to support the weight of the drive. Rotate drive to the wall and place drive over the upper bolts (9b). Lift the drive with another person or with a lifting device as it is heavy.
Page 82: Installing The Drive Vertically, Frames R6
82 Mechanical installation ￭ Installing the drive vertically, frames R6…R9 Select fasteners and their application to meet local requirements appropriate to wall surface materials, drive weight and application. Mechanical installation 69 1. Mark the hole locations for the six mounting holes using the mounting template Installing the drive vertically, frame included in the package.
Page 83: Ip21 (Ul Type 1)
Mechanical installation 83 R6…R9: M8 (5/16 in) × 2 × 2 ×6 IP21 (UL Type 1) 6. Remove the front cover: Remove the fastening screws (a) with a T20 Torx screwdriver, move the cover to the top side (b) and then up (c). 7.
Page 84: Installing The Drive Vertically Side By Side
84 Mechanical installation Note: Install the hood to UL Type 12 drives after you have installed the drive electrically and reinstalled covers, see Installing UL Type 12 hood (page 207). ￭ Installing the drive vertically side by side Install the drive following the steps in the appropriate section Installing the drive vertically, frames R1…R4 (page 76),...
Page 85: Installation Instructions
Mechanical installation 85 • Upper mounting clip labeled “Top” • Lower mounting clip labeled “Bottom” ￭ Installation instructions Install clips when mounting frame sizes R1…R3 to strut channel. 1. Slide clips onto respective upper and lower mounting flanges of the drive. 2.
Page 87: Guidelines For Planning The Electrical Installation
ABB does not assume any liability whatsoever for any installation which breaches the local laws and/or other regulations. Furthermore, if the recommendations given by ABB are not followed, the drive may experience problems that the warranty does not cover.
Page 88: European Union And United Kingdom
Examining the compatibility of the motor and drive Use asynchronous AC induction motors, permanent magnet synchronous motors or ABB synchronous reluctance motors (SynRM motors) with the drive. Select the motor size and drive type from the rating table on basis of the AC line voltage and motor load.
Page 89: Requirements Table
Guidelines for planning the electrical installation 89 the attenuation and reflection properties of the motor cable and the terminals. This can cause additional stress on the motor and motor cable insulation. Modern variable speed drives with their fast rising voltage pulses and high switching frequencies can generate current pulses that flow through the motor bearings.
Page 90 90 Guidelines for planning the electrical installation This table shows the requirements when an ABB motor is in use. Motor type Nominal AC line Requirement for voltage Motor insu- ABB du/dt and common mode filters, in- lation sys- sulated N-end motor bearings P n <...
Page 91 Guidelines for planning the electrical installation 91 This table shows the requirements when a non-ABB motor is in use. Motor type Nominal AC line Requirement for voltage Motor insu- ABB du/dt and common mode filters, in- lation sys- sulated N-end motor bearings P n <...
Page 92: Availability Of Du/Dt Filter And Common Mode Filter By Drive Type
If you use an explosion-safe (EX) motor, follow the rules in the requirements table above. In addition, consult the motor manufacturer for any further requirements. Additional requirements for ABB motors of types other than M2_, M3_, M4_, HX_ and AM_ Use the selection criteria given for non-ABB motors.
Page 93: 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 bearings in drive systems: •...
Page 94: Additional Data For Calculating The Rise Time And The Peak Line-To-Line Voltage
94 Guidelines for planning the electrical installation Nominal AC supply Requirement for voltage Motor insulation sys- ABB du/dt and common mode filters, insu- lated N-end motor bearings P n < 100 kW or frame 100 kW < P n < 350 kW size < IEC 315 IEC 315 <...
Page 95: Additional Note For Sine Filters
Guidelines for planning the electrical installation 95 Û du/dt -------------(1/ µs) Û -- - - -- - - - - - (1/ µs) l (m) l (m) Drive with du/dt filter Drive without du/dt filter Motor cable length Û LL /U n Relative peak line-to-line voltage (du/dt)/U n Relative du/dt value...
Page 96: Selecting The Power Cables
96 Guidelines for planning the electrical installation Selecting the power cables ￭ General guidelines Select the input power and motor cables according to local regulations. • Current: Select a cable capable of carrying the maximum load current and suitable for the prospective short-circuit provided by the supply network. The method of installation and ambient temperature affect the cable current carrying capacity.
Page 97: Alternate Power Cable Types
Guidelines for planning the electrical installation 97 Cable type Use as input power cabling Use as motor cabling Symmetrical shielded (or ar- mored) cable with three phase conductors and symmetrically constructed PE conductor and a shield (or armor) Symmetrical shielded (or ar- mored) cable with three phase conductors and a shield (or ar- mor), and separate PE conduct-...
Page 98: Not Allowed Power Cable Types
98 Guidelines for planning the electrical installation Cable type Use as input power cabling Use as motor cabling Yes with motors up to 100 kW (135 hp). A potential equaliza- tion between the frames of mo- tor and driven equipment is re- quired.
Page 99: Additional Guidelines, North America
￭ Additional guidelines, North America ABB recommends the use of conduit for power wiring to the drive and between the drive and the motor(s). Due to the variety of application needs, metallic and non-metallic conduit can be used. ABB recommends the use of metallic conduit.
Page 100: Power Cable Shield
100 Guidelines for planning the electrical installation resistor, and control wiring. Do not run motor wiring from more than one drive in the same conduit. ￭ Power cable shield If the cable shield is used as the sole protective earth (PE) conductor, make sure that its conductivity agrees with the PE conductor requirements.
Page 101: Additional Grounding Requirements - Iec
Guidelines for planning the electrical installation 101 in a manner which produces a conductance equivalent to that which results from the application of this table. Cross-sectional area of the phase conduct- Minimum cross-sectional area of the corres- ponding protective earth conductor S (mm 2 ) S p (mm 2 ) S ≤...
Page 102: Additional Grounding Requirements - Ul (Nec)
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.
Page 103: Relay Cable
￭ Relay cable The cable type with braided metallic shield (for example ÖLFLEX by LAPPKABEL, Germany) has been tested and approved by ABB. ￭ Control panel to drive cable Use EIA-485, Cat 5e (or better) cable with male RJ-45 connectors. The maximum length of the cable is 100 m (328 ft).
Page 104: General Guidelines - North America
104 Guidelines for planning the electrical installation • 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. •...
Page 105: Continuous Motor Cable Shield/Conduit Or Enclosure For Equipment On The Motor Cable
Guidelines for planning the electrical installation 105 Input power cabling Motor cabling Conduit ￭ Continuous motor cable shield/conduit or enclosure for equipment on the motor cable To minimize the emission level when safety switches, contactors, connection boxes or similar equipment are installed on the motor cable between the drive and the motor: •...
Page 106: Separate Control Cable Ducts
106 Guidelines for planning the electrical installation ￭ Separate control cable ducts Put 24 V DC and 230 V AC (120 V AC) control cables in separate ducts, unless the 24 V DC cable is insulated for 230 V AC (120 V AC) or insulated with an insulation sleeving for 230 V AC (120 V AC).
Page 107: Protecting The Motor And Motor Cable In Short-Circuits
Guidelines for planning the electrical installation 107 ￭ Protecting the motor and motor cable in short-circuits The drive protects the motor cable and motor in a short-circuit situation when the motor cable is sized according to the nominal output current of the drive. ￭...
Page 108: Protecting The Drive Against Ground Faults
108 Guidelines for planning the electrical installation conjunction with UL/IEC 60947-4-1. The standards allow for motor overload protection without external temperature sensors. The protection feature allows the user to specify the class of operation in the same manner as the overload relays are specified in standards UL/IEC 60947-4-1 and NEMA ICS 2.
Page 109: Using A Safety Switch Between The Drive And The Motor
+L537+Q971) user's manual Using a safety switch between the drive and the motor ABB recommends to install a safety switch between the permanent magnet motor and the drive output. The switch is needed to isolate the motor from the drive during maintenance work on the drive.
Page 110: Limiting Relay Output Maximum Voltages At High Installation Altitudes
110 Guidelines for planning the electrical installation Install the protective component as close to the inductive load as possible. Do not install protective components at the relay outputs. 230 V AC 230 V AC + 24 V DC Relay output Varistor RC filter Diode...
Page 111: Connecting Motor Temperature Sensor To The Drive Via An Option Module
Guidelines for planning the electrical installation 111 2. If there is basic insulation between the sensor and the live parts of the motor, you can connect the sensor to the analog/digital inputs of the drive if all circuits connected to the drive’s digital and analog inputs (typically extra-low voltage circuits) are protected against contact and insulated with basic insulation from other low-voltage circuits.
Page 112: Connection Of Motor Temperature Sensor To The Drive Via A Relay
112 Guidelines for planning the electrical installation ￭ Connection of motor temperature sensor to the drive via a relay PTC (IEC 60800-5-1) Class A. This table shows the insulation requirement for a customer’s external relay, and the insulation requirement for the sensor to fulfill decisive voltage class A (double insulation).
Page 113: Electrical Installation - Iec
Electrical installation – IEC 113 Electrical installation – IEC Contents of this chapter This chapter describes how to: • measure the insulation • do the grounding system compatibility check • change the EMC filter or ground-to-phase varistor connection • connect the power and control cables •...
Page 114: Grounding The Motor Cable Shield At The Motor End
Use a measuring voltage of 1000 V DC. The insulation resistance of an ABB motor must be more than 100 Mohm (reference value at 25 °C [77 °F]). For the insulation resistance of other motors, refer to the manufacturer’s instructions.
Page 115: Brake Resistor Assembly For R1
Electrical installation – IEC 115 U1-PE, V1-PE, W1-PE 1000 V DC, > 100 Mohm ￭ Brake resistor assembly for R1…R3 WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. If you are not a qualified electrical professional, do not do installation, commissioning or maintenance work.
Page 116: Ground-To-Phase Varistors
116 Electrical installation – IEC filter. See sections When to disconnect EMC filter or ground-to-phase varistor: TN-S, IT, corner-grounded delta and midpoint-grounded delta systems (page 116), and Guidelines for installing the drive to a TT system (page 117). WARNING! Do not install the drive with the EMC filter connected to a system that the filter is not suitable for.
Page 117: Guidelines For Installing The Drive To A Tt System
Electrical installation – IEC 117 Frame Symmetrically groun- Corner-grounded (B1) and IT systems (ungrounded or size ded TN systems (TN-S midpoint-grounded delta high-resistance grounded systems) ie. center- systems (B2) [>30 ohms]) (C) grounded wye (A) ≤ 600 V Drive Drive Drive Drive 1) Frames R4 and R5 are not evaluated for use on corner-grounded systems or midpoint-grounded delta systems...
Page 118 Because the EMC filter screws have been disconnected, ABB does not guarantee the EMC category. • ABB does not guarantee the functioning of the ground leakage detector built inside the drive. • In large systems the residual current device can trip without a reason.
Page 119: Identifying The Grounding System Of The Electrical Power Network
Electrical installation – IEC 119 ￭ Identifying the grounding system of the electrical power network WARNING! Only a qualified electrical professional may do the work instructed in this section. Depending on the installation site, the work may even be categorized as live working.
Page 120: Disconnecting Internal Emc Filter Or Ground-To-Phase Varistor - Frames R4
120 Electrical installation – IEC 4. To disconnect the ground-to-phase varistor, remove the varistor screw (4a) and place it in the storage place (4b) Screw EMC (DC) ￭ Disconnecting internal EMC filter or ground-to-phase varistor - frames R4…R9 To disconnect the internal EMC filter or ground-to-phase varistor, if needed, do as follows: 1.
Page 121 Electrical installation – IEC 121 3. To disconnect the internal EMC filter, remove the EMC screw(s). 4. To disconnect the ground-to-phase varistor, remove the varistor screw. R4 v2 R6…R9 Screw EMC (DC) EMC (AC)
Page 122: Connecting The Power Cables
122 Electrical installation – IEC Connecting the power cables ￭ Connection diagram ACH580-01 UDC+ T1/U T2/V T3/W 3 ~ M (PE) (PE) For alternatives, see section Selecting the main supply disconnecting device (page 87) Use a separate grounding PE cable (2a) or a cable with a separate PE conductor (2b) if the...
Page 123: Connection Procedure, Frames R1
Electrical installation – IEC 123 ￭ Connection procedure, frames R1…R4 1. Remove the front cover: Loosen the retaining screw with a T20 Torx screwdriver (1a) and lift the cover from the bottom outwards (1b) and then up (1c). IP21 (UL Type 1), IP21 (UL Type 1), IP55 (UL Type 12), IP55 (UL Type 12),...
Page 124: Motor Cable
124 Electrical installation – IEC Note: The drive is shipped with grommet cones pointing up. They must be removed and inserted back pointing down. Motor cable 4. Cut an adequate hole into the rubber grommet. Slide the grommet onto the cable. 5.
Page 125 Electrical installation – IEC 125 6. Slide the cable through the hole in the cable entry and attach the grommet to the hole. 7. Connect the motor cable: • Ground the shield 360 degrees by tightening the clamp of the power cable grounding shelf onto the stripped part of the cable.
Page 126: Input Power Cable
126 Electrical installation – IEC R4 v2 Frame size N·m lbf·ft N·m lbf·ft N·m lbf·ft N·m lbf·ft T1/U, T2/V, T3/W Input power cable 8. Cut an adequate hole into the rubber grommet. Slide the grommet onto the cable. Frame R1: Make sure there is no optional I/O extension module installed in option slot 2 at this point.
Page 127: Grounding Shelf
Electrical installation – IEC 127 • Ground the shield 360 degrees by tightening the clamp of the power cable grounding shelf onto the stripped part of the cable (11a). • Connect the twisted shield of the cable to the grounding terminal (11b). •...
Page 128: Brake Resistor Cable (If Used)
128 Electrical installation – IEC R1…R2 Brake resistor cable (if used) Frames R1…R3 only 13. Repeat steps 4…6 for the brake resistor cable. Cut off one phase conductor. 14. Connect the cable as the motor cable in step 7. Ground the shield 360 degrees (14a).
Page 129: Finalization
Electrical installation – IEC 129 Frame size N·m lbf·ft N·m lbf·ft N·m lbf·ft R+, R- Finalization Note: Frame R1: You have to install any optional I/O extension module, if used, in options slot 2 at this point. See section Installing option modules (page 153).
Page 130 130 Electrical installation – IEC WARNING! If you install the drive on any other system than symmetrically grounded TN-S system, see Grounding system compatibility check (page 115) if you have to disconnect the EMC filter and ground-to-phase varistor. 2. Attach the residual voltage warning sticker in the local language next to the control unit.
Page 131 Electrical installation – IEC 131 5. Prepare the ends of the motor cable as illustrated in figures 5a and 5b (two different motor cable types are shown). If you use aluminum cables, put grease to the peeled aluminum cable before connecting it to the drive. Note: The bare shield will be grounded 360 degrees.
Page 132 132 Electrical installation – IEC Frame size T1/U, T2/V, T3/W N·m lbf·ft N·m lbf·ft N·m lbf·ft Input power cable 8. Repeat steps 4…6 for the input power cable 9. Connect the input power cable. Use terminals L1, L2 and L3. Tighten the screws to the torque given in the table.
Page 133 Electrical installation – IEC 133 10. Install the cable box plate. Position the plate (10a) and tighten the screw (10b). Frame size L1, L2, L3 N·m lbf·ft N·m lbf·ft N·m lbf·ft 11. Reinstall the shroud on the power terminals by putting the tabs at the top of the shroud in their counterparts on the drive frame (11a) and then pressing the shroud in place (11b).
Page 134: Connection Procedure, Frames R6
134 Electrical installation – IEC 13. Ground the motor cable shield at the motor end. For minimum radio frequency interference, ground the motor cable shield 360 degrees at the cable entry of the motor terminal box. ￭ Connection procedure, frames R6…R9 WARNING! If you install the drive on any other system than symmetrically grounded TN-S system, see...
Page 135: Motor Cable
Electrical installation – IEC 135 R6…R9 R6…R9 R8…R9 Motor cable 6. Cut an adequate hole into the rubber grommet. Slide the grommet onto the cable. 7. Prepare the ends of the input power cable and motor cable as illustrated in the figure.
Page 136: Input Power Cable
Note 1 for frames R8…R9: If you connect only one conductor to the connector, ABB recommends that you put it under the upper pressure plate. If you use parallel power cables, put the first conductor under the lower pressure plate and the second under the upper one.
Page 137 Electrical installation – IEC 137 Terminals T1/U, T2/V and T3/W • Remove the nut that attaches the connector to its busbar. • Put the conductor under the connector pressure plate and pre-tighten the conductor. • Put the connector back to its busbar. Start the nut, and turn it at least two rotations by hand.
Page 138 138 Electrical installation – IEC R8…R9 R8…R9 M5×25 M5×12 12. Install the grounding shelf of the control cables. 13. Reinstall the shroud on the power terminals. 14. Secure the cables outside the unit mechanically. 15. Ground the motor cable shield at the motor end. For minimum radio frequency interference, ground the motor cable shield 360 degrees at the cable entry of the motor terminal box.
Page 139: Dc Connection
Electrical installation – IEC 139 DC connection The UDC+ and UDC- terminals (as standard in frames R4…R9) are for using external brake chopper units.
Page 140: Connecting The Control Cables
140 Electrical installation – IEC Connecting the control cables Default I/O connection diagram (HVAC default configuration) (page 141) for the default I/O connections of the HVAC default configuration. Connect the cables as described under Control cable connection procedure R1…R9 (page 147).
Page 141: Default I/O Connection Diagram (Hvac Default Configuration)
Electrical installation – IEC 141 ￭ Default I/O connection diagram (HVAC default configuration) R1…R5 Reference voltage and analog inputs and outputs Signal cable shield (screen) Output frequency/speed reference: 0…10 V 1…10 kohm AGND Analog input circuit common +10V Reference voltage 10 V DC Actual feedback: 0…20 mA AGND Analog input circuit common...
Page 142 142 Electrical installation – IEC R6…R9 Reference voltage and analog inputs and outputs Signal cable shield (screen) Output frequency/speed reference: 0…10 V 1…10 kohm AGND Analog input circuit common +10V Reference voltage 10 V DC Actual feedback: 0…20 mA AGND Analog input circuit common Output frequency: 0…10 V max.
Page 143: Switches
Electrical installation – IEC 143 Notes: Current [0(4)…20 mA, R = 100 ohm] or voltage [ 0(2)…10 V, R > 200 kohm]. Change of setting requires changing the corresponding parameter. Total load capacity of the Auxiliary voltage output +24 V (X2:10) is 6.0 W (250 mA / 24 V).
Page 144: Additional Information On I/O Connections
144 Electrical installation – IEC ￭ Additional information on I/O connections PNP configuration for digital inputs Internal and external +24 V power supply connections for PNP configuration are shown in the figure below. Internal +24 V power supply External +24 V power supply PNP connection (source) PNP connection (source) X2 &...
Page 145: Connection For Obtaining 0
Electrical installation – IEC 145 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 the analog output 2 AO2 and analog common ground AGND.
Page 146: Di5 As Frequency Input
146 Electrical installation – IEC (0)4…20 mA AGND … 10 +24V 11 DGND Process actual value measurement or reference, 0(4)…20 mA, R in = 100 ohm AGND +24V Auxiliary voltage output, non-isolated, +24 V DC, max. 250 mA DGND DI5 as frequency input For setting the parameters for the digital frequency input, see ACH580 HVAC control program firmware manual (3AXD50000027537 [English]).
Page 147: Safe Torque Off (X4)
Electrical installation – IEC 147 AGND AGND 1…3 × (Pt100 or Pt1000) or 1 × (Ni1000 or KTY83 or KTY84) Select the input type to voltage for analog input AI1 or AI2 with parameters. Set the appro- priate analog input unit to V (volt) in parameter group 12 Standard AI. Select the excitation mode in parameter group 13 Standard AO.
Page 148 148 Electrical installation – IEC Analog signals The figures for frames R1…R2 and R3 (page 150), R4 (page 151), R5 (page 152) and R6…R9 (page 153) show an example of connecting a cable. Make the connections according to the default configuration. 3.
Page 149 Electrical installation – IEC 149 Note: • Leave the other ends of the control cable shields unconnected or ground them indirectly via a high-frequency capacitor with a few nanofarads, eg, 3.3 nF / 630 V. The shield can also be grounded directly at both ends if they are in the same ground line with no significant voltage drop between the end points.
Page 150 150 Electrical installation – IEC R1…R2 INPUT BRAKE RES MOTOR INPUT BRAKE RES MOTOR UDC+ UDC+ R3: 0.5…0.6 N·m (0.4 lbf·ft) R1…R2: 0.5…0.6 N·m (0.4 lbf·ft)
Page 151 Electrical installation – IEC 151...
Page 152 152 Electrical installation – IEC 0.5...0.6 N·m (0.4 lbf·ft)
Page 153: Installing Option Modules
Electrical installation – IEC 153 R6…R9 0.5...0.6 N·m (0.4 lbf·ft) 0.5...0.6 N·m (0.4 lbf·ft) M4×20 Installing option modules WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. 1.
Page 154: Option Slot 2 (I/O Extension Modules)
154 Electrical installation – IEC ￭ 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.
Page 155: Option Slot 1 (Fieldbus Adapter Modules)
Electrical installation – IEC 155 ￭ Option slot 1 (fieldbus adapter modules) 1. Put the module carefully into its position on the control unit. 2. Tighten the mounting screw (CHASSIS) to 0.8 N·m (7 lbf·in). The screw tightens the connections and grounds the module. It is necessary for fulfilling the EMC requirements and for correct operation of the module.
Page 156: Reinstalling Grommets
156 Electrical installation – IEC Reinstalling grommets UL Type 12: To maintain UL Type 12, reinstall grommets (top of the grommets downwards) to all cable entry holes without conduits.
Page 157: Reinstalling Covers
Electrical installation – IEC 157 Reinstalling covers ￭ Reinstalling cover, frames R1…R4 1. Reinstall the cover: Put the tabs on the cover top in their counterparts on the housing (1a) and the press the cover (1b). 2. Tighten the retaining screw at the bottom with a T20 Torx screwdriver. IP21 (UL Type 1) R1…R2 IP21 (UL Type 1) R3…R4 IP55 (UL Type 12) R1…R3...
Page 158: Reinstalling Covers, Frame R5
158 Electrical installation – IEC ￭ Reinstalling covers, frame R5 IP21 (UL Type 1) 1. Reinstall the box cover: Slide the cover upwards (1a) and tighten the retaining screws (1b) with a T20 Torx screwdriver. 2. Reinstall the module cover: Press the cover at the bottom (2a) and tighten the retaining screws (2b).
Page 159: Reinstalling Side Plates And Covers, Frames R6
Electrical installation – IEC 159 ￭ Reinstalling side plates and covers, frames R6…R9 IP21 (UL Type 1) 1. Reinstall the side plates of the cable box. Tighten the retaining screws with a T20 Torx screwdriver. 2. Slide the cover of the cable box on the module from below until the cover snaps into place.
Page 160: Connecting A Pc
160 Electrical installation – IEC IP21 (UL Type 1) IP55 (UL Type 12) Connecting a PC WARNING! Do not connect the PC directly to the control panel connector of the control unit as this can cause damage.
Page 161: Connecting A Remote Panel, Or Chaining One Panel To Several Drives
Electrical installation – IEC 161 A PC (with eg, the Drive composer PC tool) can be connected as follows: 1. Connect a ACS-AP-… or ACH-AP-… control panel to the unit either • by inserting the control panel into the panel holder or platform, or •...
Page 163: Electrical Installation - North America
Electrical installation – North America 163 Electrical installation – North America Contents of this chapter This chapter describes how to: • measure the insulation • do the grounding system compatibility check • change the EMC filter or ground-to-phase varistor connection •...
Page 164: Required Tools
164 Electrical installation – North America 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 motor terminal box.
Page 165: Brake Resistor Assembly For R1
Use a measuring voltage of 1000 V DC. The insulation resistance of an ABB motor must be more than 100 Mohm (reference value at 25 °C [77 °F]). For the insulation resistance of other motors, refer to the manufacturer’s instructions.
Page 166: Grounding System Compatibility Check
166 Electrical installation – North America Grounding system compatibility check The standard drive can be an be installed to a symmetrically grounded TN-S system. For other systems, see sections EMC filter Ground-to-phase varistors below. ￭ EMC filter To connect the drive to symmetrically grounded TN-S systems, you should connect the internal EMC filter if you are concerned with EMC issues.
Page 167 Electrical installation – North America 167 Frame Screw la- Factory Symmetrically Corner-grounded IT systems (un- size default grounded TN sys- (B1) and midpoint- grounded or high- screw tems (TN-S sys- grounded delta resistance groun- material tems) ie. center- systems (B2) ded [>30 ohms]) grounded wye (A) ≤...
Page 168: Guidelines For Installing The Drive To A Tt System
Plastic EMC (DC), plastic EMC (AC) Metal VAR Drive Note: • ABB does not guarantee the EMC category because the EMC filter screws have been disconnected. • ABB does not guarantee the functioning of the ground leakage detector built inside the drive.
Page 169: Identifying The Grounding System Of The Electrical Power Network
Electrical installation – North America 169 ￭ Identifying the grounding system of the electrical power network WARNING! Only a qualified electrical professional may do the work instructed in this section. Depending on the installation site, the work may even be categorized as live working.
Page 170: Frames R4
170 Electrical installation – North America 3. The internal DC EMC filter is disconnected by default with a plastic screw (3a). 4. To disconnect the ground-to-phase varistor, replace the metal varistor screw (4a) with the plastic screw provided in the package, and place it in the storage place (4b) Screw Default material...
Page 171 Electrical installation – North America 171 1. Switch off the power from the drive. 2. Open the cover, if not already opened. Frame R4: see page 174, frame R5: see page 178, frames R6…R9: see page 182. 3. To disconnect the internal EMC filters: The DC EMC filter is disconnected by default with a plastic screw (3a).
Page 172: Connecting The Power Cables
172 Electrical installation – North America Connecting the power cables ￭ Connection diagram ACH580-01 UDC+ T1/U T2/V T3/W 3 ~ M (PE) (PE) For alternatives, see Selecting the main supply disconnecting device (page 87) With a conduit: Use a separate grounding PE cable (2a) or a PE conductor (2b) inside the...
Page 173 96)) or there is no grounding conductor inside the conduit. Note: ABB prefers the use of a symmetrical shielded motor cable (VFD cable), see the note at the bottom of the table. With a shielded cable: Use a separate grounding cable if the shield does not meet the re-...
Page 174: Connection Procedure, Frames R1
174 Electrical installation – North America ￭ Connection procedure, frames R1…R4 1. Remove the front cover: Loosen the retaining screw with a T20 Torx screwdriver (1a) and lift the cover from the bottom outwards (1b) and then up (1c). IP21 (UL Type 1), IP21 (UL Type 1), IP55 (UL Type 12), IP55 (UL Type 12),...
Page 175: Motor Cabling
Electrical installation – North America 175 Note: The drive is shipped with grommet cones pointing up. They must be removed and inserted back pointing down. Motor cabling 5. Strip the ends of the conductors. Conduit 6. Slide the conductors through the conduit. 7.
Page 176: Input Power Cabling
176 Electrical installation – North America BRAKE RES INPUT MOTOR UDC+ INPUT MOTOR BRAKE RES T1/U T2/V T3/W UDC+ Frame size N·m lbf·ft N·m lbf·ft N·m lbf·ft N·m lbf·ft T1/U, T2/V, T3/W Input power cabling 8. Strip the ends of the conductors as for the motor cabling. 9.
Page 177: Brake Resistor Cabling (If Used)
Electrical installation – North America 177 BRAKE RES INPUT MOTOR UDC+ INPUT BRAKE RES MOTOR T1/U T2/V T3/W UDC+ Frame size N·m lbf·ft N·m lbf·ft N·m lbf·ft N·m lbf·ft L1, L2, L3 Brake resistor cabling (if used) Frames R1…R3 only: 11.
Page 178: Finalization
178 Electrical installation – North America 12. Connect the grounding conductor to the grounding terminal (12a) and the other conductors to the R+ and R- terminals (12b). Tighten the screws to the torque given in the table. R1…R2 BRAKE RES INPUT MOTOR UDC+...
Page 179 Electrical installation – North America 179 IP21 (UL Type 1) IP21 (UL Type 1) IP55 (UL Type 12) WARNING! If you install the drive on any other system than symmetrically grounded TN-S system, see see Grounding system compatibility check (page 166) if you have to disconnect the EMC filter and ground-to-phase varistor.
Page 180 180 Electrical installation – North America Motor cabling 6. Strip the ends of the conductors. Conduit 7. Slide the conductors through the conduit. 8. Connect the conductors: • Connect the grounding conductor to the grounding terminal. (8a) • Connect the phase conductors to the T1/U, T2/V and T3/W terminals (8b). Tighten the screws to the torque given in the table.
Page 181 Electrical installation – North America 181 Frame T1/U, T2/V, T3/W size N·m lbf·ft N·m lbf·ft Input power cabling 9. Repeat steps 6…7 for the conductors. 10. Connect the conductors as for the motor cabling. Use terminals L1, L2 and L3. Tighten the screws to the torque given in the table.
Page 182: Connection Procedure, Frames R6
182 Electrical installation – North America 12. Reinstall the shroud on the power terminals by putting the tabs at the top of the shroud in their counterparts on the drive frame (12a) and then pressing the shroud in place (12b). Finalization 13.
Page 183: Motor Cabling
Electrical installation – North America 183 3. Remove the shroud on the power cable terminals by releasing the clips with a screwdriver (3a) and pulling the shroud out (3b). 4. Knock out holes in the shroud for the cabling to be installed. 5.
Page 184: Input Power Cabling
Note 1 for frames R8…R9: If you connect only one conductor to the connector, ABB recommends that you put it under the upper pressure plate. If you use parallel power cabling, put the first conductor under the lower pressure plate and the second under the upper one.
Page 185: Detaching And Reinstalling The Connectors
Electrical installation – North America 185 Frame L1, L2, L3, T1/U, size T2/V, T3/W N·m lbf·ft N·m lbf·ft Detaching and reinstalling the connectors This is possible but not recommended. Terminals T1/U, T2/V and T3/W • Remove the nut that attaches the connector to its busbar. •...
Page 186: Dc Connection
186 Electrical installation – North America • Tighten the combi screw to a torque of 30 N·m (22 lbf·ft). • Tighten the conductor(s) to 40 N·m (30 lbf·ft) for frame R8 or to 70 N·m (52 lbf·ft) for frame R9. 12.
Page 187: Connecting The Control Cables
Electrical installation – North America 187 Connecting the control cables See section i1369542 for the default I/O connections of the HVAC default configuration. Connect the cables as described under Control cable connection procedure R1…R9 (page 194).
Page 188: Default I/O Connection Diagram (Hvac Default Configuration)
188 Electrical installation – North America ￭ Default I/O connection diagram (HVAC default configuration) R1…R5 Reference voltage and analog inputs and outputs Signal cable shield (screen) Output frequency/speed reference: 0…10 V 1…10 kohm AGND Analog input circuit common +10V Reference voltage 10 V DC Actual feedback: 0…20 mA AGND Analog input circuit common...
Page 189 Electrical installation – North America 189 R6…R9 Reference voltage and analog inputs and outputs Signal cable shield (screen) Output frequency/speed reference: 0…10 V 1…10 kohm AGND Analog input circuit common +10V Reference voltage 10 V DC Actual feedback: 0…20 mA AGND Analog input circuit common Output frequency: 0…10 V...
Page 190: Switches
190 Electrical installation – North America Current [0(4)…20 mA, R = 100 ohm] or voltage [ 0(2)…10 V, R > 200 kohm]. Change of setting requires changing the corresponding parameter. 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 installedon the board.
Page 191: Additional Information On I/O Connections
Electrical installation – North America 191 ￭ Additional information on I/O connections PNP configuration for digital inputs Internal and external +24 V power supply connections for PNP configuration are shown in the figure below. Internal +24 V power supply External +24 V power supply PNP connection (source) PNP connection (source) X2 &...
Page 192: Connection For Obtaining 0
192 Electrical installation – North America WARNING! Do not connect the +24 V AC cable to the control unit ground when the control unit is powered using an external 24 V AC supply. 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 the analog output 2 AO2 and analog common ground AGND.
Page 193: Di5 As Frequency Input
Electrical installation – North America 193 Note: The sensor is supplied through its current output and the drive feeds the supply voltage (+24 V DC). Thus the output signal must be 4…20 mA, not 0…20 mA. (0)4…20 mA AGND … 10 +24V 11 DGND Process actual value measurement or reference, 0(4)…20 mA, R in = 100 ohm...
Page 194: Safe Torque Off (X4)
194 Electrical installation – North America AGND AGND 1…3 × (Pt100 or Pt1000) or 1 × (Ni1000 or KTY83 or KTY84) Select the input type to voltage for analog input AI1 or AI2 with parameters. Set the appro- priate analog input unit to V (volt) in parameter group 12 Standard AI. Select the excitation mode in parameter group 13 Standard AO.
Page 195 Electrical installation – North America 195 2. Remove the front cover(s) if not already removed. See page (R1…R4), page (R5) or page (R6…R9). Analog signals The figures for frames R1…R2 and R3 (page 197), R4 (page 198), R5 (page 199) and R6…R9 (page 200) show an example of connecting a cable.
Page 196 196 Electrical installation – North America Note: • Leave the other ends of the control cable shields unconnected or ground them indirectly via a high-frequency capacitor with a few nanofarads, eg, 3.3 nF / 630 V. The shield can also be grounded directly at both ends if they are in the same ground line with no significant voltage drop between the end points.
Page 197 Electrical installation – North America 197 R1…R2 INPUT BRAKE RES MOTOR UDC+ INPUT BRAKE RES MOTOR UDC+ R3: 0.4 lbf·ft R1…R2: 0.4 lbf·ft...
Page 198 198 Electrical installation – North America R4: 0.4 lbf·ft...
Page 199 Electrical installation – North America 199 R5: 0.4 lbf·ft...
Page 200 200 Electrical installation – North America R6…R9 R6…R9: 0.4 lbf·ft...
Page 201: Installing Option Modules
Electrical installation – North America 201 Installing option modules Note: In North American deliveries, options may also be ordered as factory installed. Note: If you will install the FPBA-01 module, see section FPBA-01 PROFIBUS DP adapter module connectors (page 103) for suitable connector types.
Page 202 202 Electrical installation – North America R1…R2 R3…R5...
Page 203: Wiring The Modules
Electrical installation – North America 203 R6…R9 ￭ Wiring the modules For the optional I/O extension modules CHDI-01, CMOD-01 and CMOD-02, see chapter Optional I/O extension and adapter modules for specific installation and wiring instructions. For other option modules, for example, CPTC-02, see the appropriate option module manual.
Page 204: Reinstalling Grommets
204 Electrical installation – North America Reinstalling grommets UL Type 12: To maintain UL Type 12, reinstall grommets (top of the grommets downwards) to all cable entry holes without conduits. Reinstalling covers ￭ Reinstalling cover, frames R1…R4 1. Reinstall the cover: Put the tabs on the cover top in their counterparts on the housing (1a) and the press the cover (1b).
Page 205: Reinstalling Covers, Frame R5
Electrical installation – North America 205 IP55 (UL Type 12) R1…R3 IP55 (UL Type 12) R4 ×6 ×2 ￭ Reinstalling covers, frame R5 IP21 (UL Type 1) 1. Reinstall the box cover: Slide the cover upwards (1a) and tighten the retaining screws (1b) with a T20 Torx screwdriver.
Page 206: Reinstalling Side Plates And Covers, Frames R6
206 Electrical installation – North America IP21 (UL Type 1) IP21 (UL Type 1) IP55 (UL Type 12) ￭ Reinstalling side plates and covers, frames R6…R9 IP21 (UL Type 1) 1. Reinstall the side plates of the cable box (1a). Tighten the retaining screws with a T20 Torx screwdriver (1b).
Page 207: Ip55 (Ul Type 12)
IP21 (UL Type 1) IP21 (UL Type 1) IP55 (UL Type 12) Installing UL Type 12 hood See UL Type 12 hood quick installation guide for ACS580-01, ACH580-01 and ACQ580-01 frames R1 to R9 (3AXD50000196067 [English]) which is included in the hood package.
Page 208: Connecting A Pc
208 Electrical installation – North America Connecting a PC WARNING! Do not connect the PC directly to the control panel connector of the control unit as this can cause damage. A PC (with eg, the Drive composer PC tool) can be connected as follows: 1.
Page 209: Installation Checklist
Installation checklist 209 Installation checklist Contents of this chapter This chapter contains a checklist of the mechanical and electrical installation of the drive. Checklist Examine the mechanical and electrical installation of the drive before start-up. Go through the checklist together with another person. WARNING! Obey the safety instructions of the drive.
Page 210 210 Installation checklist Make sure that … The insulation resistance of the input power cable, motor cable and motor is measured according to local regulations and the manuals of the drive. The drive is attached securely on an even, vertical and non-flammable wall. The cooling air flows freely in and out of the drive.
Page 211 Installation checklist 211 Make sure that … 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.
Page 213: Maintenance
Maintenance intervals The tables below show the maintenance tasks which can be done by the end user. The complete maintenance schedule is available on the Internet (https://new.abb.com/drives/services/maintenance/preventive-maintenance). For more information, consult your local ABB Service representative (www.abb.com/searchchannels). ￭ Description of symbols...
Page 214: Recommended Maintenance Intervals After Start-Up
214 Maintenance ￭ Recommended maintenance intervals after start-up Action Description Quality of supply voltage Spare parts Capacitor reforming for spare modules and spare capacitors, see Capacit- ors (page 227) Tightness of terminals Dustiness, corrosion or temperature Heatsink cleaning, see Cleaning the heatsink (page 216) Component Years from start-up Cooling...
Page 215: Cleaning The Exterior Of The Drive
• Maintenance and component replacement intervals are based on the assumption that the equipment is operated within the specified ratings and ambient conditions. ABB recommends annual drive inspections to ensure the highest reliability and optimum performance. • Long term operation near the specified maximum ratings or ambient conditions may require shorter maintenance intervals for certain components.
Page 216: Cleaning The Heatsink
216 Maintenance Cleaning the heatsink The drive module heatsink fins pick up dust from the cooling air. The drive runs into overtemperature warnings and faults if the heatsink is not clean. When necessary, clean the heatsink as follows. WARNING! Use the required personal protective equipment. Wear protective gloves and long sleeves.
Page 217: Fans
Maintenance 217 Fans Maintenance intervals (page 213) for the fan replacement interval in average operation conditions. Parameter 05.04 Fan on-time counter indicates the running time of the cooling fan. Reset the counter after a fan replacement. See the firmware manual. In a speed-controlled fan, the speed of the fan matches the cooling needs.
Page 218: Replacing The Main Cooling Fan, Ip21 And Ip55 (Ul Type 1 And Ul Type 12) Frames R1
218 Maintenance ￭ Replacing the main cooling fan, IP21 and IP55 (UL Type 1 and UL Type 12) frames R1…R4 WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. 1.
Page 219 Maintenance 219 1. Lever the fan assembly off the drive frame with for example a screwdriver (2a) and pull out the fan assembly (2b). 2. Install the fan assembly in reverse order.
Page 220: Replacing The Main Cooling Fan, Ip21 And Ip55 (Ul Type 1 And Ul Type 12) Frames R5
220 Maintenance ￭ Replacing the main cooling fan, IP21 and IP55 (UL Type 1 and UL Type 12) frames R5…R8 WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. 1.
Page 221: Replacing The Main Cooling Fans, Ip21 And Ip55 (Ul Type 1 And Ul Type 12) Frame R9
Maintenance 221 ￭ Replacing the main cooling fans, IP21 and IP55 (UL Type 1 and UL Type 12) frame R9 WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. 1.
Page 222: Replacing The Auxiliary Cooling Fan, Ip21 And Ip55 (Ul Type 1 And Ul Type 12) Frames R6
222 Maintenance ￭ Replacing the auxiliary cooling fan, IP21 and IP55 (UL Type 1 and UL Type 12) frames R6…R9 WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. 1.
Page 223: Replacing The Auxiliary Cooling Fan, Ip55 (Ul Type 12) Frames R1
Maintenance 223 ￭ Replacing the auxiliary cooling fan, IP55 (UL Type 12) frames R1…R2 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 disconnect it from the power line. Wait for 5 minutes and then make sure by measuring that there is no voltage.
Page 224: Replacing The Auxiliary Cooling Fan, Ip55 (Ul Type 12) Frame R3
224 Maintenance ￭ Replacing the auxiliary cooling fan, IP55 (UL Type 12) frame R3 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 disconnect it from the power line. Wait for 5 minutes and then make sure by measuring that there is no voltage.
Page 225: Replacing The Auxiliary Cooling Fan, Ip55 (Ul Type 12) Frame R4; Ip21 And Ip55 (Ul Type 1 And Ul Type 12) Frame R5
Maintenance 225 ￭ Replacing the auxiliary cooling fan, IP55 (UL Type 12) frame R4; IP21 and IP55 (UL Type 1 and UL Type 12) frame R5 WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur.
Page 226: Replacing The Second Auxiliary Cooling Fan, Ip55 (Ul Type 12) Frames R8
226 Maintenance ￭ Replacing the second auxiliary cooling fan, IP55 (UL Type 12) frames R8…R9 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 disconnect it from the power line. Wait for 5 minutes and then make sure by measuring that there is no voltage.
Page 227: Capacitors
Capacitor failure is usually followed by damage to the unit and an input cable fuse failure, or a fault trip. If you think that any capacitors in the drive have failed, contact ABB. ￭...
Page 228: Control Panel Leds
228 Maintenance ￭ Control panel LEDs The control panel has one LED. The table below describes the control panel LED indications. For more information see ACS-AP-I, -S, -W and ACH-AP-H, -W assistant control panels user’s manual (3AUA0000085685 [English]). Control panel LED, at the left edge of the control panel LED off LED lit and steady LED blinking/flickering...
Page 229: Functional Safety Components
Note that some of the components may already have been renewed earlier, restarting their mission time. The remaining mission time of the whole circuit is however determined by its oldest component. Contact your local ABB service representative for more information.
Page 231: Technical Data
Technical data 231 Technical data Contents of this chapter This chapter contains the technical specifications of the drive including the ratings, sizes and technical requirements, provisions for fulfilling the requirements for CE, UL and other approval marks. Ratings ￭ ACH580- Input Output ratings Frame...
Page 232 232 Technical data ACH580- Input Output ratings Frame rating Max. Nominal use Light-duty use Heavy-duty use current I max I Ld P Ld I Hd P Hd 115A-2 88.0 144A-2 171A-2 213A-2 276A-2 ACH580- Input rating Output ratings Frame A 1) 1-phase U n = 230 V 04A7-2 0.37...
Page 233 Technical data 233 ACH580- Input Output ratings Frame rating Max. Nominal use Light-duty use Heavy-duty use current I max I Ld P Ld I Hd P Hd 02A7-4 0.75 0.75 03A4-4 04A1-4 05A7-4 07A3-4 10.1 09A5-4 13.0 12A7-4 12.6 15.3 12.6 12.0 018A-4...
Page 234: Definitions
234 Technical data ACH580- Input Output ratings Frame rating Max. Nominal use Heavy-duty use current I max I Ld P Ld I Hd P Hd 04A1-4 05A7-4 07A3-4 09A5-4 12A7-4 11.0 13.7 12.0 018A-4 14.0 19.8 14.0 10.0 11.0 026A-4 21.0 25.2 23.0...
Page 235: Ul (Nec)
Technical data 235 Nominal output current. Maximum continuous rms output current allowed (no overload). Nominal power of the drive. Typical motor power (no overload). The kilowatt ratings apply to most IEC 4-pole motors. The horsepower ratings apply to most NEMA 4- pole motors.
Page 236 236 Technical data ACH580- Input rating Output ratings Frame size A 1) 1-phase U 1 = 208…240 V, P n at U n = 208/230 V, 60 Hz 04A6-2 06A6-2 0.75 07A5-2 10A6-2 017A-2 11.8 024A-2 17.3 031A-2 30.4 15.2 046A-2 059A-2 075A-2...
Page 237 Technical data 237 ACH580- Input rating Output ratings Frame size Max. current Light-duty use I max I Ld P Ld 052A-4 065A-4 077A-4 078A-4 096A-4 124A-4 156A-4 180A-4 240A-4 260A-4 302A-4 361A-4 414A-4 ACH580- Input rating Output ratings Frame size Max.
Page 238: Definitions
1) Maximum current with 40% overload, allowed for one minute every ten minutes. Typical motor power in heavy-duty use (50% overload). ￭ Conversion tables for IEC and North American type codes IEC type North American type Frame size ACH580-01 ACH580-01 3-phase U n = 230 V 04A7-2 04A6-2 06A7-2 06A6-2...
Page 239: Sizing
Technical data 239 IEC type North American type Frame size ACH580-01 ACH580-01 213A-2 211A-2 276A-2 273A-2 346A-2 343A-2 400A-2 396A-2 IEC type North American type Frame size ACH580-01 ACH580-01 3-phase U n = 480 V 02A7-4 02A1-4 03A4-4 03A0-4 04A1-4...
Page 240: Deratings
Note: The motor may have a derating on it too. Example 1, IEC: How to calculate the derated current The IP21 / UL Type 1 drive type is ACH580-01-01-062A-4, which has drive output current of 62 A. Calculate the derated drive output current (I ) at 4kHz switching frequency, at 1500 m altitude and at 50 °C ambient temperature as follows:...
Page 241 No derating needed for 35 °C ambient temperature. Referring to I in the ratings tables (starting from page 232), drive type ACH580-01-01-026A-4 exceeds the I requirement of 19.43 A. Example 2, UL (NEC): How to calculate the required drive If your application requires continuous maximum current with 10% overload 12.0 A of...
Page 242: Surrounding Air Temperature Derating, Ip21 (Ul Type 1)
242 Technical data Surrounding air temperature derating, IP21 (UL Type 1) IP21 (UL Type 1) drive types, other than the exceptions below In the temperature range +40…50 °C (+104…122 °F), the rated output current is derated by 1% for every added 1 °C (1.8 °F). The output current can be calculated by multiplying the current given in the rating table by the derating factor (k, in the diagram below).
Page 243: Surrounding Air Temperature Derating, Ip55 (Ul Type 12)
Technical data 243 The output current can be calculated by multiplying the current given in the rating table by the derating factor (k): 1.00 0.95 0.90 0.90 0.85 0.80 0.75 … -15 °C +40 °C +45 °C +50 °C +5 °F +104 °F +113 °F +122 °F...
Page 244 244 Technical data 1.00 0.95 0.90 0.85 0.85 0.80 0.75 … -15 °C +40 °C +45 °C +50 °C +5 °F +104 °F +113 °F +122 °F -260A-4, -293A-4; -273A-2, -276A-2: In the temperature range +40…45 °C (+104…113 °F), the rated output current is derated by 1% for every added 1 °C (1.8 °F). In the temperature range +45…50 °C (+113…122 °F), the rated output current is derated by 2.5% for every added 1 °C (1.8 °F).
Page 245: Altitude Derating
100 m (330 ft). Note: There are special considerations in corner-grounded installations above 2000 m. Contact your local ABB representative for further information. The output current is calculated by multiplying the current given in the rating table by the derating factor k, which for x meters (1000 m <= x <= 4000 m) is: Altitude and surrounding air temperature At altitudes from 1000…4000 m (3281…13123 ft) above sea level and temperature...
Page 246: Switching Frequency Derating By Derating Factor
246 Technical data 4000 m 13123 ft 0.80 3500 m 11429 ft 0.85 3000 m 0.90 9842 ft 0.95 2500 m 8202 ft 1.00 2000 m 6562 ft 1500 m 4921 ft 1000 m 3300 ft +20 °C +25 °C +30 °C +35 °C +40 °C...
Page 247 Technical data 247 Frame ACH580-01- Derating factor (k) for the minimum switching frequen- size cies at 40 °C (+104 °F) 1 kHz 2 kHz 4 kHz 8 kHz 12 kHz 3-phase U n = 230 V 04A7-2…18A2-2 0.89 0.80 025A-2…032A-2 0.86...
Page 248: Switching Frequency Derating With Actual Output Current Values
248 Technical data Frame ACH580-01- Derating factor (k) for the minimum switching frequen- size cies at 40 °C (+104 °F) 1 kHz 2 kHz 4 kHz 8 kHz 12 kHz 3-phase U 1 = 440…480 V, P n at U n = 480 V, 60 Hz 02A1-4…012A-4...
Page 249 Technical data 249 Frame ACH580- Nominal Nominal output current (I 2 ) for the minimum switching fre- size output quencies at 40 °C (+104 °F) 1 kHz 2 kHz 4 kHz 8 kHz 12 kHz 16 kHz 018A-2 18.0 16.9 16.9 16.9 15.0...
Page 250 250 Technical data Frame ACH580- Nominal Nominal output current (I 2 ) for the minimum switching fre- size output quencies at 40 °C (+104 °F) 1 kHz 2 kHz 4 kHz 8 kHz 12 kHz 16 kHz 145A-4 169A-4 206A-4 246A-4 293A-4 363A-4...
Page 251 Technical data 251 UL (NEC) Frame ACH580- Nominal Nominal output current (I 2 ) for the minimum switching fre- size output quencies at 40 °C (+104 °F) 1 kHz 2 kHz 4 kHz 8 kHz 12 kHz 16 kHz 3-phase U 1 = 200…240 V, P n at U n = 208/230 V, 60 Hz 04A6-2 06A6-2 07A5-2...
Page 252 252 Technical data Frame ACH580- Nominal Nominal output current (I 2 ) for the minimum switching fre- size output quencies at 40 °C (+104 °F) 1 kHz 2 kHz 4 kHz 8 kHz 12 kHz 16 kHz 044A-4 45.0 45.0 45.0 45.0 29.3...
Page 253: Output Frequency Derating
242A-6 271A-6 Output frequency derating Output frequency derating applies for ratings up to ACH580-01-106A-4 (R5). Inverter output current is limited by the following factor k below 5 Hz absolute inverter output frequency f_abs. k = 2/3 + 1/3 · (f_abs / 5 Hz)
Page 254 254 Technical data ACH580- Input gG (IEC 60269) Min. current I 2 t short- Nominal Voltage ABB type circuit current rating 60269 current size A 2 s 012A-2 12.0 2500 OFAF000H25 018A-2 16.9 2500 OFAF000H25 025A-2 24.5 7700 OFAF000H40 032A-2 31.2...
Page 255: Ur And Ar Fuses
Technical data 255 ACH580- Input gG (IEC 60269) Min. current I 2 t short- Nominal Voltage ABB type circuit current rating 60269 current size A 2 s 430A-4 10200 2800000 OFAF3H630 1) Minimum short-circuit current of the installation ￭ uR and aR fuses...
Page 256 256 Technical data ACH580- Input uR or aR (DIN 43620 blade style) Min. current I 2 t short- Nominal Voltage Buss- IEC 60269 circuit current rating mann type size current A 2 s 033A-4 32.0 1450 170M1565 039A-4 38.0 1450 170M1565 046A-4 45.0...
Page 257: Circuit Breakers (Iec)
You can use the circuit breakers listed below. Other circuit breakers can be used with drive if they provide the same electrical characteristics. ABB does not assume any liability whatsoever for the correct function and protection with circuit breakers not listed below.
Page 258 258 Technical data ACH580- MCBs and MCCBs Max. T max T max Electronic SACE ordering ABB type short- frame rating release code for breaker circuit XT / T and release unit class I sc 3-phase U n = 400 or 480 V...
Page 259: Fuses (Ul)
Technical data 259 Fuses (UL) Fuses for branch circuit protection per NEC are listed below. ABB recommends fast acting class T or faster fuses in the USA. Obey local regulations. ACH580-01- Input current Maximum current Voltage rating Bussmann type class 3-phase U 1 = 200…240 V, P n at U n = 208/230 V, 60 Hz...
Page 260 260 Technical data ACH580-01- Input current Maximum current Voltage rating Bussmann type class 078A-4 JJS-110 096A-4 JJS-150 124A-4 JJS-200 156A-4 JJS-225 180A-4 JJS-300 240A-4 JJS-350 260A-4 JJS-400 302A-4 JJS-500 JJS-500 361A-4 JJS-600 414A-4 3-phase U 1 = 500…600 V, P n at U n = 575 V, 60 Hz...
Page 261: Circuit Breakers (Ul)
Technical data 261 3. The UL listed 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.
Page 262 262 Technical data ACH580- Frame Input Enclosure Drive ABB circuit breaker size current maximum voltage minimum volume current volume in 3 in 3 65 kA @ 240 V 059A-2 59.4 6480 1011 XT2Nαβ100#******** 075A-2 74.8 6480 1669 XT2Nαβ100#******** 088A-2 88.0...
Page 263 Technical data 263 ACH580- Frame Input Enclos- Drive ABB circuit breaker Maximum Maximum size current maxim- voltage volume peak um cur- minim- rent volume 65 kA @ 240 V 240A-4 53703 3858 XT5Hαβ40A#******** 47.9 4.2×10 260A-4 53703 3858 XT5Hαβ40A#******** 47.9 4.2×10...
Page 264 Use drive volume for all three types listed in the table when installing multiple drives in the enclosure. 7. The ABB circuit breaker part number listed in the table is a base part number. • Symbol α represents 80% or 100% allowable continuous current. Options allowed are U, Q, C and D.
Page 265: Dimensions, Weights And Free Space Requirements
10. Other manufacturers' inverse time circuit breakers can be used if they are UL 489 listed, they are 240V or higher, they have a 65kA or higher interrupting rating and they have the same or lower nominal current rating than the ABB specified circuit breaker.
Page 266 266 Technical data Frame Dimensions and weights size IP21 UL Type 1 W e i g h t W e i g h t - *) - *) - *) - *) 11.8 17.87 19.29 7.99 9.02 26.0 - *) - *) - *) - *)
Page 267 Technical data 267 IP21 (UL Type 1), R1…R2, R5…R9 Symbols IP21 / UL Type 1 R5.…R9: Height back without cable/con- duit box R5.…R9: Height front without cable/conduit R3.…R4: Height front, R1…R2, R5.…R9: Height front with cable/conduit box R3.…R4: Height back, R1…R2, R5.…R9: Height back with cable/conduit box Width Depth...
Page 268 268 Technical data IP55 (UL Type 12) , R3…R4 IP55 (UL Type 12) , R1…R2, R5…R9 UL Type 12, R1…R3 UL Type 12, R1…R3 UL Type 12, R4…R5 UL Type 12, R6…R9 Symbols R3.…R4: Height front, R1…R2 and R5.…R9: Height front with cable/conduit box R3.…R4: Height back, R1…R2 and R5.…R9: Height back with cable/conduit box Width...
Page 269 Technical data 269 Frame Dimensions and weights with main switch and EMC C1 filter options (+F278, +F316, size +E223), IP55 Weight 18.87 13.03 5.04 10.03 11.8 19.80 17.01 5.04 10.12 16.4 28.86 20.43 8.15 10.16 15.0 33.1 34.61 26.18 8.11 11.26 23.3 51.5...
Page 270 270 Technical data R1…R3 IP21 (UL Type 1) R1…R3 IP55 (UL Type 12) R4…R9 IP21 (UL Type 1) R4…R9 IP55 (UL Type 12)
Page 271 Technical data 271 Note: 1. For the actual degree of protection that can be achieved with flange for each frame size (on the back and front sides of the drive), see Flange mounting kit installation supplement (3AXD50000019100 [English]). 2. Regarding flange mounting: •...
Page 272 272 Technical data Frame Free space, IP21 (UL Type 1) size Horizontal mounting Above Below Between 5.91 3.39 30/200 1.18/7.87 7.87 2.09 30/200 1.18/7.87 1.18 7.87 30/200 1.18/7.87 1.18 7.87 30/200 1.18/7.87 1) Note: Horizontal installation meets IP20 requirements only. 2) For definition, see the figure on page 3) Free space below is always measured from the drive frame, not from the cable box.
Page 273: Losses, Cooling Data And Noise
54). Note: IP55 (UL Type 12) does not imply that the drive can be installed outside/outdoors. To install outside, contact your local ABB representative directly for specific instructions (3AXD10000425906). The warranty will be void if installed outdoors without using these special instructions.
Page 274: Ul (Nec)
274 Technical data ACH580-01- Air flow Noise Frame size Typical heat dissipation m 3 /h BTU/h dB(A) 07A3-4 09A5-4 12A7-4 018A-4 026A-4 1303 033A-4 1658 039A-4 1764 046A-4 2276 062A-4 2958 062A-4 2740 R4 v2 073A-4 1114 3801 073A-4 3010...
Page 275 Technical data 275 ACH580-01- Air flow Noise Frame size Typical heat dissipation m 3 /h BTU/h dB(A) 075A-2 2760 088A-2 2938 114A-2 1268 4327 143A-2 1916 6538 169A-2 1965 6705 211A-2 2809 9585 273A-2 3518 12004 343A-2 2547 8691 1150...
Page 276: Cooling Air Flow And Heat Dissipation For Flange Mounting (Option +C135)
276 Technical data ACH580-01- Air flow Noise Frame size Typical heat dissipation m 3 /h BTU/h dB(A) 06A1-6 09A0-6 011A-6 017A-6 1099 022A-6 1467 027A-6 1788 032A-6 2112 041A-6 2849 052A-6 1024 3494 062A-6 1240 4231 077A-6 1510 5152 099A-6...
Page 277: Ul (Nec)
Technical data 277 ACH580- Heat dissipation Air flow (+C135) Frame (+C135) size Heatsink Front Heatsink Front m 3 /h m 3 /h 033A-4 039A-4 046A-4 062A-4 062A-4 R4 v2 073A-4 073A-4 R4 v2 089A-4 R4 v2 088A-4 106A-4 1099 145A-4 1733 169A-4 1758...
Page 278: Terminal And Entry Data For The Power Cables
278 Technical data ACH580- Heat dissipation (with Air flow (with flange kit) Frame flange kit) size Heatsink Front Heatsink Front m 3 /h m 3 /h 052A-4 052A-4 R4 v2 065A-4 065A-4 R4 v2 077A-4 R4 v2 078A-4 096A-4 1099 124A-4 1733 156A-4...
Page 279 Technical data 279 Frame Cable L1, L2, L3, T1/U, T2/V, T3/W terminals Grounding terminals size entries Max wire size Max wire size Ø Min wire size cable (solid/stranded) (solid/stran- type ded) mm 2 mm 2 mm 2 N·m N·m 0.20/0.25 16/16 0.5/0.5 16/16...
Page 280: Ul (Nec)
280 Technical data Frame Cable entries R+, R-, UDC+ and UDC- terminals size Per cable Max wire size T (Wire screw) Ø Min wire size type (solid/stranded) (solid/stran- ded) mm 2 mm 2 Screw/Bolt N·m 0.5/0.5 16/16 0.5/0.5 35/25 0.5/0.5 R4 v2 1.5/1.5 2×50...
Page 281 Technical data 281 Frame Cable L1, L2, L3, T1/U, T2/V, T3/W terminals Grounding terminals size entries Wire range (stranded/sol- Ø Wire range (stranded/solid cable type lbf·ft lbf·ft 2.13 500 MCM 29.5 350 MCM 1.77 2×1/0 2×300 MCM 29.5 2×350 MCM 2.13 2×3/0 2×500 MCM...
Page 282 282 Technical data Frame Cable entries R+, R-, UDC+ and UDC- terminals size Per cable Ø Wire range size (stranded/solid) type Screw/Bolt lbf·ft 3-phase U 1 = 200…240 V, P n at U n = 208/230 V, 60 Hz 0.91 0.91 1.18 1.54...
Page 283: Power Cables
The value separated by the plus sign means the diameter of the PE conductor. See page for the cable entry sizes allowed for the selected drive frame size. ACH580-01- Frame size Cu cable type AI cable type...
Page 284: Terminal And Entry Data For The Control Cables
284 Technical data ACH580-01- Frame size Cu cable type AI cable type mm 2 mm 2 033A-4 3×10 + 10 039A-4 3×10 + 10 046A-4 3×10 + 10 062A-4 3×25 + 16 073A-4 3×35 + 16 089A-4 R4 v2 3×50 + 25 088A-4 3×50 + 25...
Page 285: Ul (Nec)
Technical data 285 Frame Cable entries Control cable entries and terminal sizes size Holes Max cable +24V, DCOM, DGND, EXT. DI, AI/O, AGND, RO, STO size 24V terminals terminals Wire size Wire size mm 2 mm 2 N·m N·m 0.2…2.5 0.5…0.6 0.14…1.5 0.5…0.6...
Page 286: Electrical Power Network Specification
26…16 Electrical power network specification Voltage (U 1 ) • ACH580-01-xxxx-2 drives: Input voltage range 3~ 208…240 V AC +10%…. -15%. IEC: This is indicated in the type designation label as typical input voltage levels 3~ 230 V AC. North America: This is indicated in the type designation label as typical input voltage levels 1~ 208/230 V AC and 3~ 208/230 V AC.
Page 287 Technical data 287 Network type Public low voltage networks. Symmetrically grounded TN-S system, IT (ungrounded), corner-grounded delta, midpoint- grounded delta and TT systems, see sections: IEC: When to disconnect EMC filter or ground-to-phase varistor: TN-S, IT, corner-grounded delta and midpoint-grounded delta systems (page 116) Guidelines for installing the drive to a TT system (page...
Page 288: Motor Connection Data
288 Technical data Minimum short-circuit power The minimum short-circuit power Sce given for each drive type (IEC/EN 61000-3-12) for the Rsce (transformer short circuit ratio) value of 350. ACH580- Input rat- Min. short circuit Frame power size 400 V 480 V 3-phase U n = 400 V and 480 V, IEC ratings 02A7-4 03A4-4...
Page 289 The decrease depends on the motor cable length and characteristics. Contact your local ABB representative for more information. When using longer motor cables than 50 m (165 ft), 8 and 12 kHz switching frequencies are not allowed. With motor cable length over 100 m, disconnect EMC DC screw if ap- plicable.
Page 290 290 Technical data EMC compatibility and motor cable length To comply with the European EMC Directive (standard EN 61800-3), use the following maximum motor cable lengths at 4 kHz switching frequency. See the table below. Frame size Maximum motor cable length, 4 kHz EMC limits for Category C2 Standard drive with an internal EMC filter.
Page 291: Brake Resistor Connection Data For Frames R1
Technical data 291 Brake resistor connection data for frames R1…R3 Short-circuit protection The brake resistor output is conditionally short-circuit proof by (IEC/EN 61800-5-1, IEC 61439- IEC/EN 61800-5-1. Rated conditional short-circuit current as defined in IEC 61439-1. Control connection data External power supply Maximum power: Frames R1…R5: 25 W, 1.04 A at 24 V AC/DC ±10% with an option module...
Page 292 292 Technical data Digital inputs DI1…DI6 Input type: NPN/PNP (Term. 13…18) Terminal size: Frames R1…R5: 0.14…1.5 mm 2 (26...16 AWG) Frames R6…R9: 0.14…2.5 mm 2 (26...14 AWG) DI1…DI4 (Term.13…16) 12/24 V DC logic levels: "0" < 4 V, "1" > 8 V, 10…24 V AC R in : 3 kohm Hardware filtering: 0.04 ms, digital filtering: 2 ms sampling...
Page 293 Technical data 293 Reference voltage output for Max. 20 mA output analog inputs +10V DC Inaccuracy: ±1% (Term. 4) Connector pitch 5 mm, wire size 2.5 mm 2 Embedded fieldbus (Term. 29…31) 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 Baud rate: 4.8…115.2 kbit/s...
Page 294 294 Technical data Isolation areas, R1…R5 AI/AO 24 V SLOT1 SLOT2 Symbol Description Panel port Power unit connection I/O extension Reinforced insulation (IEC/EN 61800-5-1:2007) Functional insulation (IEC/EN 61800-5-1:2007) Below altitudes 4000 m (13123 ft): The terminals on the control unit fulfill the Protective Extra Low Voltage (PELV) requirements (EN 50178): There is adequate insulation between the user terminals which only accept ELV voltages and terminals that accept higher voltages (relay outputs).
Page 295 Technical data 295 Isolation areas, R6…R9 SLOT1 X1:1…3 X1:4…6 X1:7…8 24 V GND X3:1…3 X3:4…6 Ext. 24 V SLOT2 X18 X16 AIR IN FAN1 FAN2 TEMP Symbol Description Power unit connection I/O extension Reinforced insulation (IEC/EN 61800-5-1:2007) Functional insulation (IEC/EN 61800-5-1:2007) 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 outputs).
Page 296 296 Technical data Grounding of frames R1…R5 Slot 1 Slot 2 AGND +10V AGND AGND X2 & X3 +24V DGND DCOM X6, X7, X8 RO1C RO1A RO1B RO2C RO2A RO2B RO3C RO3A RO3B DGND OUT1 OUT2 SGND...
Page 297 Technical data 297 Grounding of frames R6…R9 Slot 1 Slot 2 AGND +10V AGND AGND X2 & X3 +24V DGND DCOM X6, X7, X8 RO1C RO1A RO1B RO2C RO2A RO2B RO3C RO3A RO3B DGND OUT1 OUT2 SGND 24VAC/DC+in 24VAC/DC-in...
Page 298: Auxiliary Circuit Power Consumption
Approximately 98% at nominal power level. The efficiency is not calculated according to IEC 61800-9-2. Energy efficiency data (ecodesign) Energy efficiency data according to IEC-61800-9-2 is available from the ecodesign tool (https://ecodesign.drivesmotors.abb.com). Protection classes for module Degrees of protection IP21 (standard)
Page 299: Materials
IEC 62635 guidelines. To aid recyc- ling, plastic parts are marked with an appropriate identification code. Contact your local ABB distributor for further information on environ- mental aspects and recycling instructions for professional recyclers. End of life treatment must follow international and local regulations.
Page 300: Ambient Conditions
300 Technical data IEC/EN 61800-3:2017 Adjustable speed electrical power drive systems. Part 3: EMC re- quirements and specific test methods IEC/EN 61800-5-1:2007 Adjustable speed electrical power drive systems. Part 5-1: Safety requirements – electrical, thermal and energy IEC/EN 61800-9-2:2017 Adjustable speed electrical power drive systems. Part 9-2: Ecodesign for power drive systems, motor starters, power electronics and their driven applications –...
Page 301 Technical data 301 Contamination levels IEC 60721-3-3: IEC 60721-3-1: 1997 IEC 60721-3-2: 1997 (IEC 60721-3-x) 2002: Classification of envir- onmental conditions - Part 3-3: Classifica- tion of groups of en- vironmental paramet- ers and their severit- ies - Stationary use of weather protected locations Chemical gases...
Page 302: Markings
302 Technical data Note: There are special considerations in corner-grounded installations above 2000 m. Contact your local ABB representative for further information. Markings These markings are attached to the drive: CE mark Product complies with the applicable European Union legislation. For fulfilling the EMC requirements, see the additional information concerning the drive EMC compliance (IEC/EN 61800-3).
Page 303: Ce Marking
At the end of life the product should enter the recycling system at an appropriate col- lection point and not placed in the normal waste stream. Note: The ACH580-01 230 V 3-phase R9 drives have NOT been verified to comply with CSA, CE or IEC directives or any other world standards outside of North America.
Page 304: Compliance With The European Weee Directive 2002/96/Ec
304 Technical data ￭ Compliance with the European WEEE Directive 2002/96/EC The WEEE Directive defines the regulated disposal and recycling of electric and electrical equipment. ￭ Compliance with the European Machinery Directive 2006/42/EC 2nd Edition – June 2010 The drive is a machinery component that can be integrated into a wide range of machinery categories as specified in European Commission’s Guide to application of the Machinery Directive 2006/42/EC 2nd Edition –...
Page 305: Category C2
1. The optional EMC C1 filter is selected according to the documentation and installed as specified in the EMC C1 filter manual. See Main switch and EMC C1 filter options (+F278, +F316, +E223) installation supplement for ACS580-01, ACH580-01 and ACQ580-01 frames R1 to R5 (3AXD50000155132 [Multilingual]).
Page 306: Category C4
306 Technical data 3. For the maximum motor cable length with 4 kHz switching frequency, see page Maximum recommended motor cable length (page 289) WARNING! A drive of category C3 is not intended to be used on a low-voltage public network which supplies domestic premises.
Page 307: Ul Checklist
Technical data 307 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 instructions provided in the hardware and software manuals.
Page 308: Disclaimers
Notwithstanding any other provision to the contrary and regardless whether the contract is terminated or not, ABB and its affiliates are under no circumstances liable for damages and/or losses related to such security breaches, any unauthorized access, interference,...
Page 309: Dimension Drawings
Dimension drawings 309 Dimension drawings Contents of this chapter This chapter shows the dimension drawings of the ACH580-01. Note: The dimensions are given in millimeters and [inches].
Page 310: Frame R1, Ip21 (Ul Type 1)
310 Dimension drawings Frame R1, IP21 (UL Type 1)
Page 311: Frame R1, Ip55 (Ul Type 12)
Dimension drawings 311 Frame R1, IP55 (UL Type 12)
Page 312: Frame R1, Ip55+F278 (Ul Type 12)
312 Dimension drawings Frame R1, IP55+F278 (UL Type 12)
Page 313: Frame R2, Ip21 (Ul Type 1)
Dimension drawings 313 Frame R2, IP21 (UL Type 1)
Page 314: Frame R2, Ip55 (Ul Type 12)
314 Dimension drawings Frame R2, IP55 (UL Type 12)
Page 315: Frame R2, Ip55+F278 (Ul Type 12)
Dimension drawings 315 Frame R2, IP55+F278 (UL Type 12)
Page 316: Frame R3, Ip21 (Ul Type 1)
316 Dimension drawings Frame R3, IP21 (UL Type 1)
Page 317: Frame R3, Ip55 (Ul Type 12)
Dimension drawings 317 Frame R3, IP55 (UL Type 12)
Page 318: Frame R3, Ip55+E223 (Ul Type 12)
318 Dimension drawings Frame R3, IP55+E223 (UL Type 12)
Page 319: Frame R3, Ip55+F278/F316 (Ul Type 12)
Dimension drawings 319 Frame R3, IP55+F278/F316 (UL Type 12)
Page 320: Frame R4, Ip21 (Ul Type 1)
320 Dimension drawings Frame R4, IP21 (UL Type 1)
Page 321: Frame R4, Ip55 (Ul Type 12)
Dimension drawings 321 Frame R4, IP55 (UL Type 12)
Page 322: Frame R4, Ip55+E223 (Ul Type 12)
322 Dimension drawings Frame R4, IP55+E223 (UL Type 12)
Page 323: Frame R4, Ip55+F278/F316 (Ul Type 12)
Dimension drawings 323 Frame R4, IP55+F278/F316 (UL Type 12)
Page 324: Frame R5, Ip21 (Ul Type 1)
324 Dimension drawings Frame R5, IP21 (UL Type 1)
Page 325: Frame R5, Ip55 (Ul Type 12)
Dimension drawings 325 Frame R5, IP55 (UL Type 12)
Page 326: Frame R5, Ip55+E223 (Ul Type 12)
326 Dimension drawings Frame R5, IP55+E223 (UL Type 12)
Page 327: Frame R5, Ip55+F278/F316 (Ul Type 12)
Dimension drawings 327 Frame R5, IP55+F278/F316 (UL Type 12)
Page 328: Frame R6, Ip21 (Ul Type 1)
328 Dimension drawings Frame R6, IP21 (UL Type 1)
Page 329: Frame R6, Ip55 (Ul Type 12)
Dimension drawings 329 Frame R6, IP55 (UL Type 12)
Page 330: Frame R7, Ip21 (Ul Type 1)
330 Dimension drawings Frame R7, IP21 (UL Type 1)
Page 331: Frame R7, Ip55 (Ul Type 12)
Dimension drawings 331 Frame R7, IP55 (UL Type 12)
Page 332: Frame R8, Ip21 (Ul Type 1)
332 Dimension drawings Frame R8, IP21 (UL Type 1)
Page 333: Frame R8, Ip55 (Ul Type 12)
Dimension drawings 333 Frame R8, IP55 (UL Type 12)
Page 334: Frame R9, Ip21 (Ul Type 1)
334 Dimension drawings Frame R9, IP21 (UL Type 1)
Page 335: Frame R9, Ip55 (Ul Type 12)
Dimension drawings 335 Frame R9, IP55 (UL Type 12)
Page 337: Resistor Braking
Resistor braking 337 Resistor braking Contents of this chapter This chapter describes how to select, protect and wire brake choppers and resistors. The chapter also contains technical data. Operation principle and hardware description The brake chopper handles the energy generated by a decelerating motor. The chopper connects the brake resistor to the intermediate DC circuit whenever the voltage in the circuit exceeds the limit defined by the control program.
Page 338 = energy conducted into the resistor during a single braking pulse (J) t on = length of the braking pulse (s) = length of the braking cycle (s). The tables below show reference resistor types for the maximum braking power. ACH580-01- R min R max P BRmax Reference resistor types...
Page 339 Resistor braking 339 ACH580-01- R min R max P BRmax Reference resistor types 03A4-4 Danotherm CBH 360 C T 406 210R 04A1-4 Danotherm CBH 360 C T 406 210R 05A7-4 Danotherm CBH 360 C T 406 210R 07A3-4 Danotherm CBR-V 330 D T 406 78R UL...
Page 340: Selecting And Routing The Brake Resistor Cables
340 Resistor braking ACH580-01- R min R max P BRmax Reference resistor types 3-phase U 1 = 525…600 V, P n at U n = 575 V 02A7-6 2.09 Danotherm CBR-V 330 D T 406 78R UL 03A9-6 Danotherm CBR-V 330 D T 406 78R UL...
Page 341: Placing The Brake Resistor
ABB recommends to enable the thermal model at start up. ABB recommends to equip the drive with a main contactor for safety reasons even when you have enabled the resistor thermal model. Wire the contactor so that it opens in case the resistor overheats.
Page 342: Mechanical Installation
342 Resistor braking ABB recommends that you also wire the thermal switch to a digital input of the drive, and configure the input to cause a fault trip at resistor overtemperature indication. Θ +24V Drive input power connection with a main contactor...
Page 343: Start-Up
Frames R4…R9 need external brake choppers and resistors. The table below lists suitable choppers and resistors. For more information, see NBRA-6xx Braking Choppers Installation and start-up guide (3AFY58920541 [English]) and ACS-BRK Brake Units Installation and start-up guide (3AFY61514309 [English]). ACH580-01- Brake chop- R min R max P BRmax...
Page 344: Ul (Nec)
344 Resistor braking ACH580-01- Brake chop- R min R max P BRmax Reference resistor types 076A-2 NBRA-658 089A-2 NBRA-658 SAFUR125F500 115A-2 NBRA-658 SAFUR125F500 144A-2 NBRA-658 SAFUR125F500 171A-2 NBRA-658 SAFUR125F500 213A-2 NBRA-658 2xSAFUR210F575 276A-2 NBRA-658 2xSAFUR210F575 3-phase U n = 400 or 480 V (380…415 V, 440…480 V)
Page 345: Parameter Settings For External Braking Chopper And Resistor
Resistor braking 345 ACH580-01- R min R max P BRmax Reference resistor types 078A-4 10.7 Built in with the brake chopper 096A-4 SAFUR125F500 124A-4 SAFUR125F500 156A-4 SAFUR200F500 180A-4 SAFUR200F500 240A-4 2xSAFUR125F500 260A-4 2xSAFUR210F575 302A-4 361A-4 2xSAFUR200F500 414A-4 2xSAFUR200F500 3-phase U 1 = 525…600 V, P n at U n = 575 V...
Page 347: The Safe Torque Off Function
The Safe torque off function 347 The Safe torque off function Contents of this chapter This chapter describes the Safe torque off (STO) function of the drive and gives instructions for its use. Description The Safe torque off function can be used, for example, as the final actuator device of safety circuits that stop the drive in case of danger (such as an emergency stop circuit).
Page 348: Compliance With The European Machinery Directive And The Uk Supply Of Machinery (Safety) Regulations
348 The Safe torque off function Standard Name IEC 61000-6-7:2014 Electromagnetic compatibility (EMC) – Part 6-7: Generic stand- ards – Immunity requirements for equipment intended to perform functions in a safety-related system (functional safety) in indus- trial locations IEC 61326-3-1:2017 Electrical equipment for measurement, control and laboratory use –...
Page 349: Wiring
The Safe torque off function 349 Wiring For the electrical specifications of the STO connection, see the technical data of the control unit. ￭ Connection principle Single ACH580-01 drive, internal power supply OUT1 + 24 V DC OUT2 + 24 V DC SGND...
Page 350: Single Ach580-01 Drive, External Power Supply
350 The Safe torque off function Single ACH580-01 drive, external power supply 24 V DC OUT1 + 24 V DC OUT2 + 24 V DC SGND UDC+ UDC- Drive Control unit Control logic To motor Activation switch ￭ Wiring examples...
Page 351: Single Ach580-01 Drive, External Power Supply
The Safe torque off function 351 Safety relay Single ACH580-01 drive, external power supply 24 V DC OUT1 OUT2 SGND Drive Safety PLC Safety relay...
Page 352: Multiple Ach580-01 Drives, Internal Power Supply
352 The Safe torque off function Multiple ACH580-01 drives, internal power supply OUT1 + 24 V DC OUT2 + 24 V DC SGND OUT1 OUT2 SGND OUT1 OUT2 SGND Drive Control unit Activation switch...
Page 353: Multiple Ach580-01 Drives, External Power Supply
The Safe torque off function 353 Multiple ACH580-01 drives, external power supply 24 V DC – OUT1 + 24 V DC OUT2 + 24 V DC SGND OUT1 OUT2 SGND OUT1 OUT2 SGND Drive Control unit Activation switch...
Page 354: Activation Switch
354 The Safe torque off function ￭ Activation switch In the wiring diagrams, the activation switch has the designation [K]. This represents a component such as a manually operated switch, an emergency stop push button switch, or the contacts of a safety relay or safety PLC. •...
Page 355: Operation Principle
The Safe torque off function 355 Operation principle 1. The Safe torque off activates (the activation switch is opened, or safety relay contacts open). 2. The STO inputs of the drive control unit de-energize. 3. The control unit cuts off the control voltage from the output IGBTs. 4.
Page 356: Start-Up Including Validation Test
356 The Safe torque off function Start-up including validation test To ensure the safe operation of a safety function, validation is required. The final assembler of the machine must validate the function by performing a validation test. The test must be performed •...
Page 357 The Safe torque off function 357 Action Test the operation of the STO function when the motor is stopped. • Give a stop command for the drive (if running) and wait until the motor shaft is at a standstill. Make sure that the drive operates as follows: •...
Page 358: Use
358 The Safe torque off function 1. Open the activation switch, or activate the safety functionality that is wired to the STO connection. 2. The STO inputs on the drive control unit de-energize, and the control unit cuts off the control voltage from the output IGBTs. 3.
Page 359 The Safe torque off function 359 or is not otherwise acceptable, stop the drive and machinery using the appropriate stop mode before activating the Safe torque off function. • The Safe torque off function overrides all other functions of the drive. •...
Page 360: Maintenance
If any wiring or component change is needed after start-up, or the parameters are restored, do the test given in section Validation test procedure (page 356). Use only spare parts approved by ABB. Record all maintenance and proof test activities in the machine logbook. ￭ Competence...
Page 361: Fault Tracing
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 diagnostics. Any failures of the Safe torque off function must be reported to ABB.
Page 362: Safety Data
362 The Safe torque off function Safety data The safety data for the Safe torque off function is given below. Note: The safety data is calculated for redundant use, and does not apply if both STO channels are not used. PFD avg PFD avg MTTF D...
Page 363: Terms And Abbreviations
The Safe torque off function 363 • 32 °C board temperature at 2.0% of time • 60 °C board temperature at 1.5% of time • 85 °C board temperature at 2.3% of time. • The STO is a type A safety component as defined in IEC 61508-2. •...
Page 364: Tüv Certificate
After the mission time elapses, the safety device must be replaced. Note that any T M values given cannot be regarded as a guarantee or warranty. ￭ TÜV certificate The TÜV certificate is available on the Internet at www.abb.com/drives/documents.
Page 365: Declarations Of Conformity
Name and address: Jussi Vesti, Hiomotie 13, 00380 Helsinki, Finland. Helsinki, March 30, 2021 Signed for and on behalf of: Tuomo Tarula Harri Mustonen Local Division Manager, ABB Oy Product Unit Manager, ABB Oy Document number 3AXD10000437229 Page 1 of 1...
Page 366 Name and address: Jussi Vesti, Hiomotie 13, 00380 Helsinki, Finland. Helsinki, March 30, 2021 Signed for and on behalf of: Tuomo Tarula Harri Mustonen Local Division Manager, ABB Oy Product Unit Manager, ABB Oy Document number 3AXD10001329521 Page 1 of 1...
Page 367: Optional I/O Extension And Adapter Modules
Optional I/O extension and adapter modules 367 Optional I/O extension and adapter modules Contents of this chapter This chapter describes how to install and start up the optional CAIO-01, CHDI-01, CMOD-01 and CMOD-02 IO multifunction extension modules. The chapter also contains diagnostics and technical data.
Page 368: Layout
368 Optional I/O extension and adapter modules ￭ Layout 1, 2, Analog inputs 4, 5 Analog outputs SHIELD Cable shield connection SHIELD Cable shield connection AI3+ Analog input 3 positive signal Analog output 3 signal AI3- Analog input 3 negative sig- AGND Analog ground potential SHIELD...
Page 369: Mechanical Installation
Optional I/O extension and adapter modules 369 ￭ Mechanical installation Necessary tools • Screwdriver and a set of suitable bits. Unpacking and examining the delivery 1. Open the option package. Make sure that the package contains: • the option module •...
Page 370: Start-Up
370 Optional I/O extension and adapter modules CAIO-01 SHIELD 90 80 SHIELD AI-3 AO-3 AI +VE AO + 91 AI -VE GND 92 SHIELD 93 83 SHIELD AI-4 AO-4 AI +VE AO + 94 AI -VE GND 95 86 SHIELD 0-11 V, 0-22 mA AI +VE AI-5...
Page 371: Diagnostics
Optional I/O extension and adapter modules 371 ￭ Diagnostics LEDs The adapter module has one diagnostic LED. Color Description Green The adapter module is powered up. There is no communication with the drive control unit or the adapter module has detected an error.
Page 372: Technical Data
372 Optional I/O extension and adapter modules ￭ Technical data Installation Into slot 2 of drive control unit Degree of protection IP20 / UL Type 1 Ambient conditions See the drive technical data. Package Cardboard Analog inputs (80..82, 83..85, 86..88) 1.5 mm 2 Maximum wire size Input voltage ( AI+ and AI-)
Page 373: Dimension Drawings
Optional I/O extension and adapter modules 373 ￭ Dimension drawings The dimensions are in millimeters.
Page 374: Chdi-01 115/230 V Digital Input Extension Module
374 Optional I/O extension and adapter modules CHDI-01 115/230 V digital input extension module ￭ 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.
Page 375: Layout And Connection Examples
Optional I/O extension and adapter modules 375 ￭ Layout and connection examples 3-pin terminal blocks for 115/230 V in- Relay outputs puts RO4C 115/230 V AC HDI7 RO4A 24 V DC HDI8 RO4B NEUTRAL HDI7 115/230 V input 1 RO4C Common, C HDI8 115/230 V input 2...
Page 376: Mechanical Installation
376 Optional I/O extension and adapter modules ￭ Mechanical installation Necessary tools • Screwdriver and a set of suitable bits. Unpacking and examining the delivery 1. Open the option package. Make sure that the package contains: • the option module •...
Page 377: Fault And Warning Messages
Optional I/O extension and adapter modules 377 • set parameter 15.01 value to CHDI-01. You can now see the parameters of the extension module in parameter group 15 I/O extension module. 3. Set the parameters of the extension module to applicable values. Parameter setting example for relay output This example shows how make the relay output RO4 of the extension module indicate the reverse direction of rotation of the motor with a one-second delay.
Page 378: Dimension Drawing
378 Optional I/O extension and adapter modules CHDI-01 Plugged to drive SLOT2 Reinforced insulation (IEC 61800-5-1:2007) Functional insulation (IEC 61800-5-1:2007) ￭ Dimension drawing The dimensions are in millimeters and [inches].
Page 379: Cmod-01 Multifunction Extension Module (External 24 V Ac/Dc And Digital I/O)
Optional I/O extension and adapter modules 379 CMOD-01 multifunction extension module (external 24 V AC/DC and digital I/O) ￭ Product overview The CMOD-01 multifunction extension module (external 24 V AC/DC and digital I/O) expands the outputs of the drive control unit. It has two relay outputs and one transistor output, which can function as a digital or frequency output.
Page 380: Mechanical Installation
380 Optional I/O extension and adapter modules 24 V AC/DC - in External 24 V (AC/DC) input RO4A Normally closed, NC 3-pin terminal block for for transistor output RO4B Normally open, NO DO1 SRC 24 V DC DO1 OUT DO1 SGND DO1 SRC DO1 OUT DO1 SGND...
Page 381: Necessary Tools
Optional I/O extension and adapter modules 381 Stop the drive and do the steps in section Electrical safety precautions (page 22) 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 cables 360 degrees under a grounding clamp on the grounding shelf of the control cables.
Page 382: Diagnostics
382 Optional I/O extension and adapter modules Parameter setting example for digital output This example shows how to make digital output DO1 of the extension module indicate the reverse direction of rotation of the motor with a one-second delay. Parameter Setting 15.22 DO1 configuration Digital output...
Page 383: Dimension Drawing
Optional I/O extension and adapter modules 383 Package Cardboard Reley outputs (50…52, 53…55) 1.5 mm 2 Maximum wire size Minimum contact rating 12 V / 10 mA Maximum contact rat- 250 V AC / 30 V DC / 2 A Maximum breaking ca- 1500 VA pacity...
Page 384 384 Optional I/O extension and adapter modules...
Page 385: Cmod-02 Multifunction Extension Module (External 24 V Ac/Dc And Isolated Ptc Interface)
Optional I/O extension and adapter modules 385 CMOD-02 multifunction extension module (external 24 V AC/DC and isolated PTC interface) ￭ Product overview The CMOD-02 multifunction extension module (external 24 V AC/DC and isolated PTC interface) has a motor thermistor connection for supervising the motor temperature and one relay output, which indicates the thermistor status.
Page 386: Mechanical Installation
386 Optional I/O extension and adapter modules CMOD-02 RO PTC C 24V AC/DC + in 24 V AC/DC 24V AC/DC - in PTC B OUT1 OUT2 SGND 24 V AC/DC External 24 V (AC/DC) input RO PTC C Common, C + in 24 V AC/DC External 24 V (AC/DC) input...
Page 387: Necessary Tools
Optional I/O extension and adapter modules 387 Stop the drive and do the steps in section Electrical safety precautions (page 22) 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 cables 360 degrees under a grounding clamp on the grounding shelf of the control cables.
Page 388: Technical Data
388 Optional I/O extension and adapter modules ￭ Technical data Installation Into option slot 2 on the drive control unit Degree of protection IP20 / UL Type 1 Ambient conditions See the drive technical data. Package Cardboard Motor thermistor connection (60…61) 1.5 mm 2 Maximum wire size Supported standards...
Page 389: Dimension Drawing
Optional I/O extension and adapter modules 389 Functional insulation (IEC 61800-5-1:2007) ￭ Dimension drawing The dimensions are in millimeters and [inches].
Page 391: Common Mode, Du/Dt And Sine Filters
See section Examining the compatibility of the motor and drive (page 88). Common mode filter kits are available from ABB, see the table on page Common mode filter types (page 391). A kit includes three wound cores. For installation instructions of the cores, see the instruction included in the core package.
Page 392: Du/Dt Filters
392 Common mode, du/dt and sine filters IEC type Common mode filters Frame size North Americ- ACH580-01- ABB drives an type ACH580-01- 145A-4 3AXD50000017269 124A-4 169A-4 3AXD50000017270 156A-4 206A-4 3AXD50000017270 180A-4 246A-4 3AXD50000018001 240A-4 293A-4 3AXD50000018001 363A-4 3AXD50000017940 361A-4 430A-4...
Page 393: Ul (Nec) Ratings At U
Common mode, du/dt and sine filters 393 IEC ratings at U = 400 and 480 V, UL (NEC) ratings at U = 480 V IEC type Frame size du/dt filters North Americ- ACH580-01- ABB drives an type ACH580-01- 02A7-4 NOCH0016-6x 02A1-4 03A4-4...
Page 394: Description, Installation And Technical Data Of The Foch Filters
394 Common mode, du/dt and sine filters North American type Frame size du/dt filters ACH580-01- ABB drives 041A-6 FOCH0070-6x 052A-6 FOCH0070-6x 062A-6 FOCH0070-6x 077A-6 FOCH0120-6x 099A-6 FOCH0260-70 125A-6 FOCH0260-70 144A-6 FOCH0260-70 192A-6 FOCH0260-70 242A-6 FOCH0260-70 271A-6 FOCH0260-70 ￭ Description, installation and technical data of the FOCH filters See FOCH du/dt filters hardware manual (3AFE68577519 [English]).
Page 395: Description, Installation And Technical Data
Common mode, du/dt and sine filters 395 026A-4 B84143V0038R231 B84143V0025R229 + 023A-4 B84143Q0008R229 033A-4 B84143V0038R231 B84143V0033R229 + 027A-4 B84143Q0008R229 039A-4 B84143V0038R231 B84143V0050R229 + 034A-4 B84143Q0010R229 046A-4 B84143V0043R231 B84143V0050R229 + 044A-4 B84143Q0010R229 062A-4 B84143V0064R231 B84143V0066R229 + 052A-4 B84143Q0010R229 073A-4 B84143V0064R231 B84143V0066R229 + 065A-4 B84143Q0010R229 088A-4...
Page 397: Further Information
Product and service inquiries Address any inquiries about the product to your local ABB representative, quoting the type designation and serial number of the unit in question. A listing of ABB sales, support and service contacts can be found by navigating to www.abb.com/searchchannels.

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