Page 1 — ABB GENERAL PURPOSE DRIVES ACS560 drives (0.75 to 160 kW, 1.0 to 215 hp) Hardware manual...
Page 3 ACS560 drives (0.75 to 160 kW, 1.0 to 215 hp) Hardware manual Table of contents 1. Safety instructions 4. Mechanical installation 6. Electrical installation 3AXD50000044998 Rev H Original instructions EFFECTIVE: 2022-11-08...
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 Type designation label .................... Locations of the labels on the drive .............. Type designation key ....................4 Mechanical installation Contents of this chapter ..................Safety ........................Checking the installation site ................Required tools ......................Moving the drive ....................... Unpacking and examining delivery, frames R0…R2 ..........
Page 7: Table Of Contents
Table of contents 7 Routing the cables .................... General guidelines – IEC ..............General guidelines – North America ..........Continuous motor cable shield/conduit or enclosure for equipment on the motor cable ............Separate control cable ducts ............. Implementing thermal overload and short-circuit protection ....Protecting the drive against ground faults ............
Page 8 Connection procedure, frames R5…R8 ............Motor cable .................... Input power cable ................. DC connection ......................Connecting the control cables ................Default control connections of ABB standard macro ........Connection diagram ..................Terminal sizes ..................Notes: ...................... Switches ........................PNP configuration for digital inputs ..............
Page 9 Table of contents 9 Maintenance intervals ..................... Description of symbols ..................Recommended annual maintenance actions by the user ......Recommended maintenance action by the user ........Heatsink ........................Fans ..........................Replacing the cooling fan, frames size R0…R4 ........... Replacing the main cooling fan, frame R5 ........... Replacing the main cooling fan, frames R6…R8 .........
Page 10 10 Table of contents Energy efficiency data (ecodesign) ..............Auxiliary circuit power consumption ..............Degree of protection ....................Ambient conditions ....................Materials ........................Applicable standards ....................CE marking ......................... Compliance with the European Low Voltage Directive ......Compliance with the European EMC Directive ........... Compliance with the European ROHS II Directive 2011/65/EU ....
Page 11: Table Of Contents
Table of contents 11 Resistor braking, frames R4…R8 ................Planning the braking system ................12 The Safe torque off function Contents of this chapter ..................Description ........................ Compliance with the European Machinery Directive and the UK Supply of Machinery (Safety) Regulations ..............Wiring ..........................
Page 12 12 Table of contents Layout ..................... Mechanical installation ..................Electrical installation ..................Start-up ....................... Technical data ....................Control connection data ..............Dimensions .................... CMOD-01 multifunction extension module (external 24 V AC/DC) ....CMOD-01 multifunction extension module (external 24 V AC/DC and digital I/O) ......................
Page 13 Table of contents 13 14 External input choke Contents of this chapter ..................Why external input chokes are required? ............Specification ......................External input choke types ..................Mechanical dimensions ................... 15 d u /d t filters Contents of this chapter ..................d u /d t filters .......................
Page 15: Safety Instructions
Safety instructions 15 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 16: General Safety In Installation, Start-Up And Maintenance
16 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 17 Safety instructions 17 • 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 18: Electrical Safety In Installation, Start-Up And Maintenance
18 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 19: Additional Instructions And Notes
Safety instructions 19 ￭ Additional instructions and notes WARNING! Obey these instructions. 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 or maintenance work. •...
Page 20: Grounding
20 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 21: General Safety In Operation
Safety instructions 21 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 22: Safety In Operation
22 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 23: Introduction To The Manual
This manual provides information needed for planning the installation, installing, and servicing the drive. Categorization by frame (size) The ACS560 is manufactured in frames (frame sizes) R0 to R8. Some instructions and other information which only concern certain frames are marked with the...
Page 24: Quick Installation And Commissioning Flowchart
24 Introduction to the manual symbol of the frame (R0…R8). The frame is marked on the type designation label attached to the drive, see section Type designation label (page 46). Quick installation and commissioning flowchart Task Identify the frame of your drive: R0…R8. Type designation la- bel (page 46) Plan the installation: select the cables, etc.
Page 25: Terms And Abbreviations
Connect the control cables. Electrical installation: Connecting the control cables (page 104) Check the installation. Installation checklist:In- stallation check- list (page 127) ACS560 standard control Commission the drive. program firmware manual (3AXD50000044997 [Eng- lish]) Terms and abbreviations Term/ Description Abbrevi- ation ACS-AP-…...
Page 26 26 Introduction to the manual Term/ Description Abbrevi- ation BIO-01 Optional I/O extension module. Can be installed to the drive together with a fieldbus adapter module. Brake chop- Conducts the surplus energy from the intermediate circuit of the drive to the brake resistor when necessary.
Page 27: Related Documents
Manual Code (English) Code (Hindi) Drive manuals and guides ACS560 standard control program firmware manual 3AXD50000044997 3AXD50000045887 ACS560 (0.75 to 160 kW, 1.0 to 215 hp) hardware 3AXD50000044998 3AXD50000045888 manual ACS560 drives quick installation and start-up guide 3AXD50000042620 (Multilingual) Option manuals and guides ACS-AP-x assistant control panels user’s manual...
Page 28 You can find manuals and other product documents in PDF format on the Internet. See section Document library on the Internet on the inside of the back cover. For manuals not available in the Document library, contact your local ABB representative.
Page 29: Operation Principle And Hardware Description
Operation principle and hardware description 29 Operation principle and hardware description Contents of this chapter This chapter briefly describes the operation principle, layout, type designation label and type designation information. It also shows a general diagram of power connections and control interfaces.
Page 30: Operation Principle
30 Operation principle and hardware description Operation principle The ACS560 is a drive for controlling asynchronous AC induction motors. The figure below shows the simplified main circuit diagram of the drive. ACS560 T1/U T2/V T3/W R- UDC+ R+ UDC- T1/U...
Page 31: Layout
Operation principle and hardware description 31 Built-in brake chopper (R-, R+/UDC+, UDC-) in frames R0…R2 and (R-, R+) in frame R3. Conducts the surplus energy from the intermediate DC circuit of the drive to the brake resistor when necessary. The chopper operates when the DC link voltage exceeds a certain maximum limit.
Page 32: Frames R3
32 Operation principle and hardware description For LED of normal power supply and failure, see section LEDs (page 137). I/O connection. See section External control connecting terminal, frames R0…R2 (page 37). Voltage dependent resistor grounding screw (VAR) EMC filter grounding screw (EMC). R0…R2: on the left side of drive.
Page 33 Operation principle and hardware description 33 Installation point (4) Cover plate Cover plate screw Control panel Control panel connection CCA-01 interface For LED of normal power supply and failure, see section LEDs (page 137). I/O connection. See section External control connecting terminal, frames R3...R5 (page 40).
Page 34: Frames R4
34 Operation principle and hardware description ￭ Frames R4…R8 The layout of a frame R6 drive is presented below. The frame sizes R7…R8 is similar but have a different structure. Installation point (2 points on the top and 2 points on the bottom of the frame body) Cover plate Lifting hole...
Page 35 Operation principle and hardware description 35 Mechanical support clamp of I/O cable Voltage dependent resistor ground screw (VAR), arranged below the control tray. Two EMC filter ground screws, one arranged below the control tray bracket and the other arranged on the left and above the protective cover. Protective cover.
Page 36: Overview Of Power And Control Connections
36 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. Panel port Slot 1 Slot 2 T1/U T2/V T3/W UDC+ R+ UDC- Option slot 1 for I/O extension module or/and fieldbus adapter modules Option slot 2 for 24V external power extension CMOD-01 Panel port d u /d t filter, see page 237.
Page 37: External Control Connecting Terminal, Frames R0
Operation principle and hardware description 37 ￭ External control connecting terminal, frames R0…R2 The figure below explains the external control connecting terminal layout of frame R0. The layout of the external control connection terminals is identical to frames R1…R2, but the location of the control board with the terminals is different in frames R3.
Page 38 38 Operation principle and hardware description X1 A…D Analog input and output Auxiliary voltage output X3 A…C Digital signal input X4 A…B Safety torque cancellation...
Page 39 Operation principle and hardware description 39 Modbus built-in fieldbus X6…X8 Relay 1 output +24V DC voltage output The interface is used for CCA-01 adapter configuration...
Page 40: External Control Connecting Terminal, Frames R3
40 Operation principle and hardware description ￭ External control connecting terminal, frames R3...R5 The figure below explains the external control connecting terminal layout of frame...
Page 41 Operation principle and hardware description 41 Analog input and output Auxiliary voltage output Digital input Safety torque cancellation Modbus built-in fieldbus X6…X8 Relay output 1...Relay output 3 Option slot 1 (fieldbus adapter module) Option slot 2 (not used) Panel port (control panel connection) The interface is used for CCA-01 adapter configuration For LED of normal power supply and failure, see section LEDs (page...
Page 42: External Control Connection Terminals, Frames R6
42 Operation principle and hardware description ￭ External control connection terminals, frames R6…R8 The figure below explains the external control connecting terminal layout of frames R6...R8.
Page 43 Operation principle and hardware description 43 Analog input and output Auxiliary voltage output Digital input Safety torque cancellation Modbus built-in fieldbus X6…X8 Relay output 1...Relay output 3 Option slot 1 (fieldbus adapter module) Option slot 2 (not used) Panel port (control panel connection) The interface is used for CCA-01 adapter configuration For LED of normal power supply and failure, see section LEDs (page...
Page 44 44 Operation principle and hardware description WARNING! Do not connect the +24 V AC cable to the control board ground when the control board is powered using an external 24 V AC supply.
Page 45: Mounting Option
Operation principle and hardware description 45 Mounting option For information on mounted optional modules, see Installing option modules (page 116): Control panel The drive supports these control panels: • ACS-AP-S • ACS-AP-I • ACS-AP-W • ACS-BP-S • RDUM-01 blank panel with RJ-45 connector. •...
Page 46: Type Designation Label
46 Operation principle and hardware description Type designation label The type designation label includes IEC ratings, appropriate markings and the type designation and serial number, which allow identification of each drive. The type designation label is located on the left side of the drive, see section Layout (page 31).
Page 47: Locations Of The Labels On The Drive
Operation principle and hardware description 47 Frame (size) Degree of protection Nominal ratings in the supply voltage range, see section Ratings (page 139), section Electrical power network specification (page 153) and section Motor connection data (page 153). Input voltage range 3~ 380…480V AC. This is indicated in the type designation label as typical input voltage levels (U1) (3~ 400/480V AC).
Page 48: Type Designation Key
Operation principle and hardware description 37 attached to the drive. The first digits from the left express the basic configuration, for example, ACS560-01-033A-4. The optional selections are given after that, separated by plus signs, for example, +K457. The main selections are described nation key below.
Page 49 Operation principle and hardware description 49 J424 RDUM-01 Blank control panel cover (no control panel) L511 BREL-01 relay output extension module L515 BIO-01 I/O extension module (front option, can be used with fieldbus) L534 BAPO-01 External 24 V DC (side option) L523 CMOD-01 External 24 V AC/DC (only for external power, I/O extensions not applicable)
Page 51: Mechanical Installation
Mechanical installation 51 Mechanical installation Contents of this chapter The chapter tells how to check the installation site, unpack, check the delivery and install the drive mechanically.
Page 52: Safety
Contents of this chapter 52 Mechanical installation The chapter tells how to check the installation site, unpack, check the delivery and Contents of this chapter install the drive mechanically. The chapter tells how to check the installation site, unpack, check the delivery and ￭...
Page 53: Checking The Installation Site
Mechanical installation 53 Checking the installation site The drive must be placed in a cabinet and installed on the wall. Drives of frame sizes R0...R2 have two installation method as follows: • Vertically alone Vertical installation Free space Frame Size Above (a) Below (b) Beside (c)
Page 54: Required Tools
54 Mechanical installation Frame Size Vertical installation side by side - Free space Above (a) Below (b) Between (c) 11.8 11.8 11.8 11.8 11.8 Check the installation site according to the requirements below: • The installation site is sufficiently ventilated or cooled to remove heat from the drives.
Page 55: Moving The Drive
Mechanical installation 55 Moving the drive Frames R5…R8: Move the transport package by pallet truck to the installation site. Unpacking and examining delivery, frames R0…R2 The figure below shows the drive package and its contents. Make sure 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 56: Unpacking And Examining Delivery, Frames R3
56 Mechanical installation Unpacking and examining delivery, frames R3...R4 The figure below shows the drive package and its contents. Make sure 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. See section Type designation label (page 46).
Page 57: Unpacking And Examining Delivery, Frames R5
Mechanical installation 57 User manual (if any, adopt additional code for ordering) Basic panel (provided as default panel) Unpacking and examining delivery, frames 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 58 58 Mechanical installation Stopper Cover protecting film Straps Pallet Control panel selected in the order (in a separate package) in the option box Possible options in separate packages, if they have been ordered with a plus code, such as for example +K457 (FCAN-01 CANopen adapter module) in the option box. Basic panel (provided as default panel)
Page 59: Unpacking And Examining Delivery, Frames R6
Mechanical installation 59 Unpacking and examining delivery, frames R6…R8 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. See section Type designation label (page 46).
Page 60 60 Mechanical installation In the option tray • Multilingual quick installation and start-up guide • User’s manual (if ordered with a plus code) • Residual voltage warning stickers Control panel selected in the order (in a separate package) in the option tray Possible options in separate packages, if they are ordered with a plus code Mounting template on top of the option tray Basic panel (provided as default panel)
Page 61: Installing The Drive
Mechanical installation 61 Installing the drive ￭ Installing the drive vertically, frames R0…R2 The figures show frame R0 as an example. Mark the hole locations with the mounting template included in the package. Do not leave the mounting template behind the drive. The drive dimensions and hole locations are also shown in the drawings, see chapter Dimension drawings (page...
Page 62: Installing The Drive Vertically, Frames R3
62 Mechanical installation 4. Position the drive onto the screws on the wall. Tighten the screws in the wall securely. Mechanical installation ￭ Installing the drive vertically, frames R3...R4 Installing the drive vertically, frame size R3...R4 Mark the hole locations with the mounting template included in the package. Do not leave the mounting template behind the drive.
Page 63: Installing The Drive Vertically, Frames R5
Mechanical installation 63 6.30 6.30 6.30 6.30 18.62 24.37 18.62 24.37 Weight Weight 14.9 32.84 19.0 41.89 14.86 32.77 23.0 50.72 ￭ Installing the drive vertically, frames R5…R8 Mark the punch positions for the six mounting holes with the mounting template included in the package.
Page 64 64 Mechanical installation × 4 10.4 22.9 20.9 22.9 25.9 24.1 22.5 24.5 27.6 11.8 11.8 11.8 11.8 2. Drill the mounting holes. 3. Start the screws or bolts into the mounting holes. 4. Position the drive onto the screws on the wall. Lift the drive with another person as it is heavy.
Page 65: Installing The Drive Vertically Side By Side
Mechanical installation 65 × 2 × 2 Mechanical installation 51 Mechanical installation 51 6. Remove the front cover as follows: 6. Remove the front cover as follows: 6. Remove the front cover as follows: • Remove the fastening screws (a). •...
Page 67: Planning The Electrical Installation
Planning the electrical installation 67 Planning the electrical installation Contents of this chapter This chapter contains instructions for planning the electrical installation of the drive, for example, for checking the compatibility of the motor and drive, selecting cables, protections, and cable routing. Note: The installation must always be designed and made according to applicable local laws and regulations.
Page 68: Other Regions
68 Planning the electrical installation • disconnector that has an auxiliary contact that in all cases causes switching devices to break the load circuit before the opening of the main contacts of the disconnector (EN 60947-3) • circuit breaker suitable for isolation in accordance with EN 60947-2. ￭...
Page 69: Typical Power Cable Sizes
The table below gives copper cable types with concentric copper shield for the drives with nominal current. The value separated by the plus sign means the diameter of the PE conductor. Drive type Framesize ACS560 Cu cable type Cu cable type AI cable AI cable...
Page 70: Alternative Power Cable Types
70 Planning the electrical installation Drive type Framesize ACS560 Cu cable type Cu cable type AI cable AI cable type type mm 2 mm 2 AWG/kcmil AWG/kcmil 293A-4 2 x (3 x 95 + 2 x (3 x 120) 2 x 3/0 1) The cable sizing is based on maximum parallel layout of 6 cables laid on a cable ladder side by side, ambient temperature 30 °C, PVC insulation, surface temperature 70 °C (EN 60204-1 and IEC...
Page 71: Not Allowed Power Cable Types
Planning the electrical installation 71 Corrugated or EMT cable with three phase conductors and a protective conductor is allowed for motor cabling with phase conductor cross section less than 10 mm 2 (8 AWG) or motors ≤ 30 kW (40 hp). Not allowed power cable types Symmetrical shielded cable with individual shields for each phase con- ductor is not allowed on any cable size for input or motor cabling.
Page 72: Armored Cable / Shielded Power Cable
72 Planning the electrical installation to the drive enclosure and motor frame. Use separate conduits for input power, motor, and control wiring. When conduit is employed, type MC continuous corrugated aluminum armor cable or shielded cable is not required. A dedicated ground cable is always required.
Page 73: Signals Allowed To Be Run In The Same Cable
100 m (330 ft). If multiple drives are connected, the total length of the panel bus must not exceed 100 m (330 ft). The cable type tested and approved by ABB is used in control panel option kits. Suitable cables are CAT 5e unshielded or shielded twisted pair cables.
Page 74: General Guidelines - North America
74 Planning the electrical installation min. 300 mm (12 in) min. 300 mm (12 in) min. 500 mm (20 in) 90° min. 200 mm (8 in) min. 500 mm (20 in) Motor cable Input power cable Control cable Brake resistor or chopper cable (if any) General guidelines –...
Page 75: Continuous Motor Cable Shield/Conduit Or Enclosure For Equipment On The Motor Cable
Planning the electrical installation 75 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 76: Separate Control Cable Ducts
76 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 77: Protecting The Drive Against Ground Faults
Planning the electrical installation 77 monitors a calculated temperature value (based on a motor thermal model) or an actual temperature indication given by motor temperature sensors. The motor thermal protection model supports thermal memory retention and speed sensitivity. The user can tune the thermal model further by feeding in additional motor and load data.
Page 78: Implementing The Undervoltage Control (Power-Loss Ride-Through)
78 Planning the electrical installation Implementing the undervoltage control (power-loss ride-through) See ACS560 standard control program firmware manual (3AXD50000044997 [English]. Using a contactor between the drive and the motor Implementing the control of the output contactor depends on how you select the drive to operate.
Page 79: Example Bypass Connection
Planning the electrical installation 79 ￭ Example bypass connection An example bypass connection is shown below. Main switch for the drive Bypass circuit breaker Drive main contactor Bypass contactor Drive output contactor Drive main contactor on/off control...
Page 80: Switching The Motor Power Supply From Drive To Direct-On-Line
80 Planning the electrical installation S 4 0 Motor power supply selection (drive or direct-on-line) Start when the motor is connected direct-on-line S 4 2 Stop when the motor is connected direct-on-line Drive Switching the motor power supply from drive to direct-on-line Stop the drive and the motor with the drive control panel (drive in local control mode) or with the external stop signal (drive in remote control mode).
Page 81 Planning the electrical installation 81 230 V AC 230 V AC + 24 V DC Relay outputs Varistor RC filter Diode...
Page 83: Electrical Installation
Electrical installation 83 Electrical installation Contents of this chapter The chapter describes how to check the insulation of the assembly and the compatibility with IT (ungrounded) and corner-grounded TN systems. It then shows how to connect the power and control cables, install optional modules and connect a PC.
Page 84: Checking The Insulation Of The Assembly
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 85: Brake Resistor Assembly R0
Electrical installation 85 ￭ Brake resistor assembly R0...R3 Check the insulation of the brake resistor assembly (if present) as follows: Check that the resistor cable is connected to the resistor, and disconnected from the drive output terminals R+ and R-. 2.
Page 86: Ground-To-Phase Varistor
86 Electrical installation ￭ Ground-to-phase varistor The ground-to-phase varistor is not suitable for use on an IT (ungrounded) system. Disconnect the ground-to-phase varistor before connecting the drive to the supply network. Check the table below. WARNING! WARNING! Do not install the drive with the ground-to-phase varistor connected on an IT system (an ungrounded power system or a high-resistance-grounded [over 30 ohms] power system), otherwise the varistor circuit can be damaged.
Page 87: Frames R0
Electrical installation 87 ￭ Frames R0…R3 To disconnect the internal EMC filter or ground-to-phase varistor, if needed, do as follows: Switch off the power from the drive. 2. Open the front cover, if not already opened. For R0...R2, see Connection procedure: frames R0…R2 (page 91) and for R3 see section Connection...
Page 88 88 Electrical installation...
Page 89 Electrical installation 89 R6...R8...
Page 90: Connecting The Power Cables
90 Electrical installation Connecting the power cables ￭ Connection diagram For alternatives, see section Selecting the supply disconnecting device (page 67). Use a separate grounding PE cable (2a) or a cable with a separate PE conductor (2b) if the conductivity of the shield does not meet the requirements for the PE conductor (see Selecting the power cables (page 68)).
Page 91: Connection Procedure: Frames R0
Electrical installation 91 ￭ Connection procedure: frames R0…R2 WARNING! If the drive is connected on an IT (ungrounded) system, make sure that the EMC filter and Varistor (VAR) is disconnected. See EMC filter (page 85). 1. Remove the front cover as follows: •...
Page 92 92 Electrical installation 3. Connect the motor cable as follows: • Ground the shield 360° by tightening the clamp of the power cable grounding shelf onto the stripped part of the cable (3a). • Connect the twisted shield of the cable to the grounding terminal (3b). •...
Page 93: Input Power Cable
Electrical installation 93 Input power cable 4. Prepare the ends of the cable as illustrated in the figure. Note: The bare shield will be grounded 360°. Mark the pigtail made from the shield as a PE conductor with yellow-and-green color 5.
Page 94: Finalization
94 Electrical installation 8. Connect the twisted shield to the grounding terminal (6b) and the conductors to the UDC+/R+ and R- terminals (6c). 9. Tighten the screws to the torque given below. Frame size R0…R1 N·m lbf·ft N·m lbf·ft UDC+/R+, R- 0.5…0.6 1.2…1.5 0.9…1.1...
Page 95: Connection Procedure, Frames R3
Electrical installation 95 ￭ Connection procedure, frames R3...R4 WARNING! If the drive is connected on an IT (ungrounded) system, make sure you have disconnected the EMC filter and Varistor (VAR). See EMC filter (page 85). 1. Remove the front cover as follows: •...
Page 96: Notes
96 Electrical installation 3. Connect the motor cable as follows: If the power cable is temporarily removed from the grounding shelf, connect the motor and input power cables except the 360° grounding, and then reinstall the grounding shelf. • Ground the shield 360° by tightening the clamp of the power cable grounding shelf onto the stripped part of the cable (4a).
Page 97 Electrical installation 97 Note: The bare shield is grounded 360°. Mark the pigtail made from the shield as a PE conductor with yellow-and-green color. 5. Connect the input power cable as follows: • Ground the shield 360° by tightening the clamp of the power cable grounding shelf onto the stripped part of the cable (6a).
Page 98: Finalization
98 Electrical installation 8. Connect the twisted shield to the grounding terminal (7b). 9. For R3, connect the conductors to the R+ and R- terminals (7c). 10. Tighten to the torque given below. Frame size lbf.ft R+, R- 2.5...4.5 1.8...3.3 Electrical installation Finalization Finalization...
Page 99 Electrical installation 99 12. Ground the motor cable shield at the motor end. For minimum radio frequency interference, ground the motor cable shield 360° at the lead-through of the motor terminal box.
Page 100: Connection Procedure, Frames R5
100 Electrical installation ￭ Connection procedure, frames R5…R8 WARNING! If the drive will be connected on an IT (ungrounded) system, make sure you 86 Electrical installation have disconnected the EMC filter and Varistor (VAR). See EMC filter (page 85). 86 Electrical installation Connection procedure, frames R6…R8 Attach the residual voltage warning sticker next to the control board.
Page 101: Motor Cable
Electrical installation 101 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. If you use aluminum cables, put grease on the peeled aluminum cable before connecting it to the drive.
Page 102: Input Power Cable
102 Electrical installation Note: Frame R8 only: • If you connected the connector to only one conductor, ABB recommends to put the conductor under the upper pressure plate. • The connectors are detachable, but ABB recommends not to detach them. If you do, detach and reinstall the connectors as follows.
Page 103 Electrical installation 103 • Tighten the nut 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 R8. Terminals L1, L2 and L3 •...
Page 104: Dc Connection
The UDC+ and UDC- terminals (as standard in frames R4…R8) are for using external brake chopper units. Connecting the control cables Connect the cables as described in section Control cable connection procedure R0…R8 (page 111). See the below default I/O connections of ABB standard macro. See other macro connections in the firmware manual.
Page 105: Default Control Connections Of Abb Standard Macro
Electrical installation 105 Default control connections of ABB standard macro ￭ Connection diagram...
Page 106: Terminal Sizes
106 Electrical installation Note: For information of parameter indexes marked in this diagram, see chapter Parameters in the firmware manual Terminal sizes • (frames R0…R8): 0.14…1.5 mm (all terminals) • tightening torques: 0.5…0.6 N·m (0.4 lbf·ft) Notes: Current [0(4)…20 mA, R <...
Page 107: Switches
Electrical installation 107 Input signal Output signal Switches Switch Description Position S100 Modbus link termination and biasing Term & BIAS off (TERM voltages to the bus. (default) & BIAS) Set to ON position when the drive is the Term & BIAS on last unit on the link.
Page 108: Npn Configuration For Digital Inputs
WARNING! Do not connect the +24 V AC cable to the control board ground when the 108 Electrical installation control board is powered using an external 24 V AC supply. NPN configuration for digital inputs NPN configuration for digital inputs Internal and external +24 V power supply connections for NPN configuration are Internal and external +24 V power supply connections for NPN configuration are shown in the figure below.
Page 109: Connection Examples Of Two-Wire And Three-Wire Sensors
Connection examples of two-wire and three-wire sensors Connection examples of two-wire and three-wire sensors PID macros (see ACS560 firmware manual (3AXD50000016097 [English])) use PID macros (see ACS560 firmware manual (3AXD50000016097 [English])) use analog input 2 (AI2). The macro wiring diagrams on these pages use an externally analog input 2 (AI2).
Page 110: Di5 As Frequency Input
For setting the parameters for the digital as a frequency input in the drive.For setting the parameters for the digital frequency frequency input, see ACS560 standard control program firmware manual input, see ACS560 standard control program firmware manual (3AXD50000044997 (3AXD50000044997 [English]).
Page 111: Safe Torque Off (X4)
Electrical installation 111 WARNING! As the inputs pictured above are not insulated according to IEC 60664, the connection of the motor temperature sensor requires double or reinforced insulation between motor live parts and the sensor. If the assembly does not fulfill the requirement, the I/O board terminals must be protected against contact and must not be connected to other equipment or the temperature sensor must be isolated from the I/O terminals.
Page 112 112 Electrical installation 6. Connect the conductors to the appropriate terminals of the control board and tighten to 0.5…0.6 N·m (0.4 lbf·ft). Digital signals The figures for frames R0...R2 (page 113), R3...R5 (page 114) R6...R8 (page 115) show an example of connecting a cable. Make the connections according to the macro in use.
Page 113 Electrical installation 113 ￭ R0...R2...
Page 114 114 Electrical installation ￭ R3...R5...
Page 115: Auxiliary Voltage Connection (For R0
Electrical installation 115 ￭ R6...R8 0.5...0.6 N·m (0.4 lbf·ft) 0.5...0.6 N·m (0.4 lbf·ft) M4×20 Auxiliary voltage connection (For R0...R2 frames with optional BAPO-01 module) The drive has an auxiliary 24 V DC (±10%) voltage connection. Depending on the application, you can use the connection, •...
Page 116: Installing Option Modules
116 Electrical installation Connect the external supply or module to the +24V and DGND terminals (40 and 41). For more information on how to feed auxiliary power to the drive, see BAPO-01 auxiliary power extension module (page 222). Power supply inside BAPO-01 works alongside the main power supply of the drive and only takes over when the main power supply shuts down.
Page 117 Electrical installation 117 Module Option slot Applicable frames Power extension - CMOD-1 Front option slot 2 R3...R5 I/O extension - BIO-01 Front option slot 1 R0...R2 Fieldbus (In R0...R2 frames, Front option slot1 R0...R8 fieldbus module can be also used with BIO-01 module) Before you install the BIO-01 option module, make sure that the chassis screw slider is in the top position.
Page 118: To Install A Front Option
118 Electrical installation Note: If you power up the drive before you install the BIO-01 option module or a fieldbus module, the drive gives a warning. ￭ To install a front option WARNING! Obey the instructions in chapter Safety instructions (page 15).
Page 119: Front Option Slot 1
18). Front option slot 1 By default, RIIO-01 module is provided in ACS560 standard R0...R2 drives. You can remove the RIIO-01 module and can install BIO-01 and/or fieldbus adapter module (+fxxx). If you are installing any of the fieldbus module, see section...
Page 120: Front Option Slot 2 (Applicable For R3
120 Electrical installation 6. Tighten the locking screw. Note: The optional fieldbus module can also be installed on top of the BIO-01 module. See BIO-01 I/O extension module (page 213). 7. For BIO-01, connect the applicable control cables. See Electrical installation (page 214).
Page 121: To Remove A Front Option
Electrical installation 121 ￭ To remove a front option Loosen the locking screw. 2. Pull the locking tab out to unlock the option module. 3. Pull the option module to disconnect and remove it. Note: The option module can be tightly in position. ￭...
Page 122: To Remove A Side Option
122 Electrical installation ￭ To remove a side option Disconnect the control cables from the side option. 2. Open the grounding bar screws. 3. Loosen the locking screw. Carefully remove the side option from the drive. Note that the option module can be tightly in position.
Page 123: Reinstalling Covers, Frame Size
Electrical installation 123 ￭ Reinstalling covers, frame size R3, R4 Reinstall the module cover. Put the tabs on the cover top in their counterparts on the housing and then press the cover. (1a.1b). 2. Tighten the two retaining screws with a screwdriver. ￭...
Page 124: Connecting A Pc
124 Electrical installation 2. Tighten the two retaining screws with a screwdriver. 106 Electrical installation 106 Electrical installation 106 Electrical installation Connecting a PC Connecting a PC Connecting a PC Connecting a PC To be able to connect a PC to the drive, you need a control panel To connect a PC to the drive, there are two alternatives: To be able to connect a PC to the drive, you need a control panel To be able to connect a PC to the drive, you need a control panel...
Page 125 Electrical installation 125 • You can connect a remote ACS-AP-I, ACS-AP-S or ACS-AP-W control panel to the drive with a CDPI-02 or RDUM-01 module. You can also chain the control panel or a PC to several drives on a panel bus with a CDPI-02 communication adapter module.
Page 127: Installation Checklist
Installation checklist 127 Installation checklist Contents of this chapter This chapter contains a checklist for 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 128 128 Installation checklist Make sure that … The insulation resistance of the input power cable, motor cable and motor is meas- ured 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 can flow freely in and out of the drive.
Page 129: Maintenance And Hardware Diagnostics
Maintenance and component replacement intervals are based on the assumption that the equipment is operated within the specified ratings and ambient conditions. ABB recommends annual drive inspections to ensure the highest reliability and optimum performance. Note: Long term operation near the specified maximum ratings or ambient conditions may require shorter maintenance intervals for certain components.
Page 130: Recommended Annual Maintenance Actions By The User
Recommended maintenance action by the user The table below shows the intervals for the preventive maintenance tasks allowed for the customer. For other maintenance tasks, consult your local ABB Service representative, or see the complete maintenance schedule on the Internet.
Page 131: Heatsink
(full) load. To maintain the best possible performance and reliability of the drive, inspect the drive annually. Contact ABB Service at least once in three years for replacement of aging compon- ents. Note: Recommended maintenance intervals and component replacements are based on operation in specified ambient conditions.
Page 132: Fans
132 Maintenance and hardware diagnostics 3. Blow clean, dry and oil free compressed air from bottom to top and simultaneously use a vacuum cleaner at the air outlet to trap the dust. Note: If there is a risk of dust entering adjoining equipment, perform the cleaning in another room.
Page 133: Replacing The Main Cooling Fan, Frame R5
Maintenance and hardware diagnostics 133 ￭ Replacing the main cooling fan, frame R5 WARNING! Obey the instructions in chapter Safety instructions (page 15). Ignoring the instructions can cause physical injury or death, or damage to the equipment. 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 134: Replacing The Main Cooling Fan, Frames R6
134 Maintenance and hardware diagnostics ￭ Replacing the main cooling fan, frames R6…R8 116 Maintenance and hardware diagnostics WARNING! Obey the instructions in chapter Safety instructions (page 15). Ignoring the Replacing the main cooling fan, frames size R6…R8 instructions can cause physical injury or death, or damage to the equipment. WARNING! Obey the instructions in chapter Safety instructions on page 11.
Page 135: Replacing The Auxiliary Cooling Fan, Frames R5
Maintenance and hardware diagnostics 135 ￭ Replacing the auxiliary cooling fan, frames R5...R8 Maintenance and hardware diagnostics 115 WARNING! Obey the instructions in chapter Safety instructions (page 15). Ignoring the instructions can cause physical injury or death, or damage to the equipment. Replacing the auxiliary cooling fan, frames R5 WARNING! Obey the instructions in chapter Safety instructions...
Page 136: Reforming The Capacitors
For information on reforming the capacitors, see Converter module capacitor reforming instructions (3BFE64059629 [English]), available on the Internet (go to 118 Maintenance and hardware diagnostics http://www.abb.com and enter the code in the Search field). Control panel Control panel Cleaning the control panel ￭...
Page 137: Leds
Maintenance and hardware diagnostics 137 LEDs ￭ Drive LEDs (R3...R8) There is a green POWER and a red FAULT LED on the front of the drive. They are visible through the panel cover but invisible if a control panel is attached to the drive.
Page 138 138 Maintenance and hardware diagnostics Control panel LED, at the left edge of the control panel LED off LED lit and steady LED blinking/flickering Panel has Green Drive functioning normally. Green Blinking: no power. Connection between the Active warning in the drive drive and control panel Flickering: may be faulty or lost, or...
Page 139: Technical Data
￭ IEC ratings Drive Nom- Max. Output ratings Frame Type inal cur- size Nominal use Light overload Heavy-duty use ACS560 rent I 1N I max I Ld P Ld I Hd P Hd (Con- (Con- tinu- tinu- ous) ous) 3 phases U N = 400 V (380…415 V) 02A6-4 0.75...
Page 140: Definitions
140 Technical data Drive Nom- Max. Output ratings Frame Type inal cur- size Nominal use Light overload Heavy-duty use ACS560 rent I 1N I max I Ld P Ld I Hd P Hd (Con- (Con- tinu- tinu- ous) ous) 017A-4 22.7...
Page 141: Sizing
- 1000) m = 0.95. The minimum size required becomes then I = 18.18 A / 0.95 = 19.14 A. Referring to I in the ratings tables (starting from 139), drive type ACS560-01-025A-4 exceeds the I requirement of 19.24 A. ￭...
Page 142: Altitude Derating
142 Technical data Frame Temperature Action range 0…+40 °C Derating not required +32…+104 °F R3…R8 +40...+50 °C Derating required +104...+122 °F The output current is calculated by the current given in the rating tables multiplying तकनीकी डे ट ा by the derating factor (k, as shown in the following figure) Frames R0...R2 1.00 0.95...
Page 143: Switching Frequency Derating
Technical data 143 Check the network compatibility restrictions above 2000 m (6562 ft), see section Installation site altitude (page 160). Above 2000 m (6562 ft), the maximum permitted potential difference between the adjacent relays of the BREL-01 relay extension module (option +L511) decreases. At 4000 m (13123 ft), it is 30 V.
Page 144: Ur And Ar Fuse
￭ uR and aR fuse Drive type Input cur- uR and aR Minimum ACS560 rent I 2 t short cir- Rated Rated Bussmann cuit cur-...
Page 145: Gg Fuses
Technical data 145 ￭ gG fuses Drive type Input cur- gG (IEC 60269) Minimum ACS560 rent I 2 t short cir- Rated Rated ABBdesigna- cuit cur- current voltage tion type 60269 rent size A 2 s 3 phases U N = 400 V (380...480 V)
Page 146 146 Technical data Drive type Input cur- gG (IEC 60269) Minimum ACS560- rent I 2 t short cir- Rated cur- Rated ABBdesig- IEC 60269 cuit cur- rent I N voltage nation size rent type A 2 s 04A0-4 170M2695 05A6-4...
Page 147: Circuit Breakers
Technical data 147 Circuit breakers The table below lists MCB circuit breakers that can be used with the drive. Drive MCBs type ABB type Max. Tmax Tmax rat- Electron- SACE ordering ACS560- short-cir- frame XT ic release code for breaker...
Page 148: Dimensions, Weights And Free Space Requirements
148 Technical data Dimensions, weights and free space requirements Frame Dimensions and weight IP20 Weight 14.9 28.3 42.4 Standard frames...
Page 149: Thermal Losses, Cooling Data And Noise
Technical data 149 Symbols IP20 Height of front side Height of back side (without cable connecting box) Width Depth Frame size Free space Vertical installation Vertical installation Independent Side by side Above Below Above Below Interval See the figures in section Checking the installation site (page 53).
Page 150: Terminal And Lead-Through Data For The Power Cables
150 Technical data Drive Air flow Noise Frame Thermal losses type size Main cir- Control Control Main circuit ACS560- cuit nom- circuit circuit and control inal I 1N , Min. load Max. load circuit Max. load m 3 /h dB(A) 3 phases U N = 400V (380…480V)
Page 151: Terminal And Lead-Through Data For The Control Cables
Technical data 151 Drive U1. V1. W1 / U2. V2. W2 / R+. R- / DC+. DC- terminal PE terminals F r a m e t y p e A C S 5 6 0 size min. ( single Max.( (single core torque torque core and / mul-...
Page 152 152 Technical data Drive type ACS560 - Control Terminal F r a m e size +24V. DCOM.DGND DI. AI/O. AGND. RO. STO mm 2 mm 2 T (N·m) T (N·m) 3 phases U N = 400V (380…480V) 02A6-4...09A4-4 0.14...1.5 0.5...0.6 0.14...1.5...
Page 153: Electrical Power Network Specification
Technical data 153 Electrical power network specification Voltage ( U 1 ) Input voltage range 3~ 380…480 V AC. This is indicated in the type designation label as typical input voltage levels 3~ 400/480 V AC. Network type Public low voltage networks. TN (grounded), IT (ungrounded) and corner-grounded TN systems.
Page 154: Emc Compatibility And Motor Cable Length
A sine filter (optional) at the drive output can also cause a decrease in voltage. For more information, consult your local ABB Service representative (http://new.abb.com/channel-partners/search). *)Conducted and radiated emissions of these motor cable lengths do not comply with EMC requirements.
Page 155: Brake Resistor Connection Data For Frames R0
Technical data 155 Frame size Maximum motor cable length, 4 kHz 1) See the terms in section Definitions (page 168). Applicable for frames R4...R8. Frames R0...R2 require external EMC filter to meet the category 2 standards. Note 1: Radiated emissions are according to C3 with an internal EMC filter. Note 2: The internal EMC filter must be connected.
Page 156 156 Technical data Digital inputs DI1…DI6 Input type: NPN/PNP (Term. 13…18) DI1…DI4 and DI6 (Terminal 13…16 and 18) 12/24V DC logic levels: "0" < 4V. "1" > 8V R in : 2.68 kOhm Hardware filtering: 0.04 ms, digital filtering: 2ms sampling DI5 (Terminal 17) Can be used as a digital or frequency input.
Page 157 Technical data 157 Grounding of frames R0…R2 X2 & X3 Slot 1 +24V DGND DCOM RO1C RO1A RO1B OUT1 SGND Ground...
Page 158 158 Technical data Grounding of frames R3…R5 Slot 1 Slot 1 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 Ground *) Installed with jumpers at the factory.
Page 159: Energy Efficiency Data (Ecodesign)
RO3C RO3A RO3B DGND OUT1 OUT2 SGND 24VAC/DC+in 24VAC/DC-in Ground Installed with jumpers at the factory. *) Installed with jumpers at the factory. Energy efficiency data (ecodesign) Energy efficiency data according to IEC-61800-9-2 is available from the ecodesign tool (https://ecodesign.drivesmotors.abb.com).
Page 160: Auxiliary Circuit Power Consumption
160 Technical data Auxiliary circuit power consumption Maximum external power supply: Frames R0…R5: 25 W, 1.04 A at 24 V AC/DC (For R0...R2 with optional module BAPO-01 and for R3...R5 with optional module CMOD-01) Frames R6…R8: 36 W, 1.50 A at 24 V AC/DC (as standard, termin- als 40…41) Degree of protection Ambient conditions...
Page 161 Technical data 161 Air temperature -15 to +50 °C (5 -40 to +70 °C (-40 -40 to +70 °C (-40 to 122°C) for R0- to +158 °F) to +158 °F) R2 frames and -15 to 40 °C (5 to 104°F) for R3-R8 frames.
Page 162: Materials
IEC 62635 guidelines. To aid recycling, plastic parts are marked with an appropriate identification code. Contact your local ABB distributor for further information on environmental aspects and recycling instructions for profession- al recyclers. End of life treatment must follow international and local regulations.
Page 163: Ce Marking
Technical data 163 CE marking A CE mark is attached to the drive to verify that the drive follows the provisions of the European Low Voltage, EMC RoHirectives.The CE marking also verifies that the drive, in regard to its safety functions (such as Safe torque off), conforms with the Machinery Directive as a safety component.
Page 164: Compliance With The European Low Voltage Directive
164 Technical data ￭ Compliance with the European Low Voltage Directive...
Page 165: Compliance With The European Emc Directive
Technical data 165 The compliance with the European Low Voltage Directive has been verified according to standard EN 61800-5-1:2007. The declaration of conformity (3AXD10000549832) is available on the Internet. See section Document library on the Internet on the inside of the back cover. ￭...
Page 166: Compliance With The European Machinery Directive 2006/42/Ec 2Nd Edition - June 2010
￭ Compliance with the European Machinery Directive 2006/42/EC 2nd Edition – June 2010 EU Declaration of Conformity Machinery Directive 2006/42/EC Manufacturer: ABB India Limited Address: Plot No 5 &6 , 2 Phase , Peenya Industrial Area ,Bangalore,560058, India Phone: +91 80 22949359...
Page 167 AR Madhusudhan Laxmikantha shenoy Vice President, MODP Manager , Prodcut Engineering ABB India Limited ABB India Limited 3AXD10000549832 Rev. 3 IMS template code: 3AFE011906, Rev. C 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...
Page 168: Compliance With The En 61800-3:2004 + A1:2012
168 Technical data Compliance with the EN 61800-3:2004 + A1:2012 ￭ Definitions EMC stands for Electromagnetic Compatibility. It is the ability of electrical/electronic equipment to operate without problems within an electromagnetic environment. Likewise, the equipment must not disturb or interfere with any other product or system within its locality. First environment includes establishments connected to a low-voltage network which supplies buildings used for domestic purposes.
Page 169: Category C3
Technical data 169 2. The motor and control cables are selected as specified in this manual. 3. The drive is installed according to the instructions given in this manual. 4. For the maximum motor cable length with 4 kHz switching frequency, see section Maximum recommended motor cable length (page 154).
Page 170 170 Technical data Medium voltage network Supply transformer Neighbouring network Static screen Point of measurement Low voltage Low voltage Equipment Drive (victim) Equipment Equipment 2. An EMC plan for preventing disturbances is drawn up for the installation. A template is available from the local representative. 3.
Page 171: Dimension Drawings
Dimension drawings 171 Dimension drawings Contents of this chapter This chapter shows the dimension drawings of the ACS560. The dimensions are given in millimeters and [inches]. Frame R0, IP20...
Page 172: Frame R1, Ip20
172 Dimension drawings Frame R1, IP20...
Page 173: Frame R2, Ip20
Dimension drawings 173 Frame R2, IP20...
Page 174: Frame R3, Ip20
174 Dimension drawings Frame R3, IP20...
Page 175: Frame R4, Ip20
Dimension drawings 175 Frame R4, IP20...
Page 176: Frame R5, Ip20
176 Dimension drawings Frame R5, IP20...
Page 177: Frame R6, Ip20
Dimension drawings 177 Frame R6, IP20...
Page 178: Frame R7, Ip20
178 Dimension drawings Frame R7, IP20...
Page 179: Frame R8, Ip20
Dimension drawings 179 Frame R8, IP20...
Page 181: Resistor Braking
Resistor braking 181 Resistor braking Contents of this chapter The chapter describes how to select the brake resistor and cables, protect the system, connect the brake resistor and enable resistor braking. 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 182 182 Resistor braking 2. Calculate resistance R with Equation 1. रे ि ज़ टर (अवरोधक) ब्रे ि कं ग 3. Calculate energy E with Equation 2. रे ि ज़ टर ब्रे ि क ं ग, फ्र े म R0…R3 Rpulse ब्रे...
Page 183 Resistor braking 183 Type R min R max P BRcont P BRmax Refer- Braking time 1) ACS560 ence resistor types Dano- therm 3-phase UN = 380 or 480V 02A6-4 0.55 0.75 0.83 1.10 360 C T 03A3-4 0.75 1.00 1.13 1.50...
Page 184 = 800 Nm n start = 1000 rpm n stop then stop time, Example for selecting a brake resistor the selected drive = ACS560-01-04A0-4 motor power = 1.5kW (P Rmax ) stop time (t on ) = 30s running time (T)
Page 185: Selecting And Routing The Brake Resistor Cables
The maximum length of the resistor cable(s) is 10 m (33 ft). EMC compliance of the complete installation Note: ABB has not verified that the EMC requirements are fulfilled with external user-defined brake resistors and cabling. The EMC compliance of the complete installation must be considered by the customer.
Page 186: Protecting The System In Brake Circuit Fault Situations
186 Resistor braking Arrange the cooling of the resistor in a way that: • no danger of overheating is caused to the resistor or nearby materials • the temperature of the room the resistor is located in does not exceed the allowed maximum.
Page 187: Mechanical Installation
Resistor braking 187 L1 L2 L3 Θ ACS560 ACS560 L1 L2 L3 +24V ￭ Mechanical installation All brake resistors must be installed outside the drive. Follow the resistor manufacturer’s instructions. ￭ Electrical installation Checking the insulation of the assembly Follow the instructions given in section Resistor braking, frames R0…R3 (page...
Page 188: Resistor Braking, Frames R4
188 Resistor braking Disable the overvoltage control of the drive with parameter 30.30 Overvoltage control. 2. Set the source of parameter 31.01 External event 1 source to point to the digital input where the thermal switch of the brake resistor is wired. 3.
Page 189 R m i n R m a x P BRcont P BRmax Reference resistor Braking time 1) type types ACS560 o h m o h m Danotherm 3-phase UN = 380 or 480V Refer to brak- ing resistor 062A-4 ACS-BRK-D 18.1...
Page 191: The Safe Torque Off Function
The Safe torque off function 191 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 (such as an emergency stop circuit) that stop the drive in case of danger.
Page 192: Compliance With The European Machinery Directive And The Uk Supply Of Machinery (Safety) Regulations
192 The Safe torque off function Standard Name IEC 61000-6-7:2014 Electromagnetic compatibility (EMC) – Part 6-7: Generic standards – Immunity requirements for equipment intended to perform functions in a safety-related system (functional safety) in industrial locations IEC 61326-3-1:2017 Electrical equipment for measurement, control and laborat- ory use –...
Page 193: Wiring
The Safe torque off function 193 Wiring For the electrical specifications of the STO connection, see the technical data of the control unit. ￭ Connection principle (R0…R2) Connection with internal power supply + 24 V DC OUT1 SGND UDC+ UDC- Drive Control unit Control logic...
Page 194: Connection With External Power Supply
194 The Safe torque off function Connection with external power supply 24 V DC OUT1 + 24 V DC SGND UDC+ UDC- Drive Control unit Control logic To motor Activation switch ￭ Wiring examples (R0…R2) Wiring with internal power supply OUT1 SGND Drive...
Page 195: Wiring With External Power Supply
The Safe torque off function 195 Wiring with external power supply 24 V DC OUT1 SGND ÍN2 Drive Safety PLC Safety relay ￭ Connection principle (R3…R8) Connection with internal power supply OUT1 + 24 V DC OUT2 + 24 V DC SGND UDC+ UDC-...
Page 196: Connection With External Power Supply
196 The Safe torque off function Activation switch Connection with 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 (R3…R8) Wiring with internal power supply OUT1 OUT2...
Page 197: Wiring With External Power Supply
The contacts of the switch or relay must open/close within 200 ms of each other. ￭ Cable types and lengths • ABB recommends double-shielded twisted-pair cable. • Maximum cable lengths: • 300 m (1000 ft) between activation switch [K] and drive control unit •...
Page 198: Grounding Of Protective Shields
198 The Safe torque off function Note: The voltage at the STO input terminals of the drive must be at least 13 V DC to be interpreted as “1”. The pulse tolerance of the input channels is 1 ms. ￭ Grounding of protective shields •...
Page 199: Operation Principle
The Safe torque off function 199 Operation principle 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 200: Start-Up Including Validation Test
200 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 at initial start-up of the safety function 2.
Page 201 The Safe torque off function 201 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 202: Use
202 The Safe torque off function 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 203 The Safe torque off function 203 causes danger 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 204: 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 200). Use only spare parts approved by ABB. Record all maintenance and proof test activities in the machine logbook. ￭ Competence...
Page 205: 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 206: Safety Data
206 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 applies only if both STO channels are used.
Page 207 The Safe torque off function 207...
Page 208: Terms And Abbreviations
208 The Safe torque off function • The following temperature profile is used in safety value calculations: • 670 on/off cycles per year with Δ T = 71.66 °C • 1340 on/off cycles per year with Δ T = 61.66 °C •...
Page 209 The Safe torque off function 209 Term or Reference Description abbreviation MTTF D EN ISO 13849-1 Mean time to dangerous failure: (Total number of life units) / (Number of dangerous, undetected failures) during a particular measurement interval under stated conditions PFD avg IEC 61508 Average probability of dangerous failure on demand,...
Page 210: Tüv Certificate
210 The Safe torque off function ￭ TÜV certificate The TÜV certificate is available on the Internet at www.abb.com/drives/documents. ￭ Declarations of conformity EU Declaration of Conformity Machinery Directive 2006/42/EC Manufacturer: ABB India Limited Address: Plot No 5 &6 , 2...
Page 211 Name and address: Jussi Vesti, Hiomotie 13, 00380 Helsinki, Finland Bangalore, 27 May 2020 Signed for and on behalf of: AR Madhusudhan Laxmikantha shenoy Vice President, MODP Manager , Prodcut Engineering ABB India Limited ABB India Limited 3AXD10000549832 Rev. 3 IMS template code: 3AFE011906, Rev. C...
Page 213: Optional Panel Bus Adapters And Extension Modules
Optional panel bus adapters and extension modules 213 Optional panel bus adapters and extension modules Contents of this chapter This chapter describes: • how to install and start up the optional BIO-01 I/O extension module, CMOD-01 power extension module, BREL-01 I/O extension module and BAPO-01 power extension module •...
Page 214: Layout
Electrical installation See chapter Electrical installation (page 83). If you configure the inputs, set up the wiring accordingly. The BIO-01 module has removable spring clamp terminals. Use ferrules on the multistranded cables before assembly. Sample wiring with the ABB standard macro...
Page 215: Start-Up
The BIO-01 module is automatically identified by the drive firmware. To configure the inputs refer to the ACS480 firmware manual (3AXD50000047399 [English]) After connecting the device, restart the drive for auto detection of the BIO-01 module. To configure the inputs manually, refer to the ACS560 firmware manual (3AXD50000044997[English]. ￭ Technical data...
Page 216: Dimensions
216 Optional panel bus adapters and extension modules Dimensions...
Page 217: Cmod-01 Multifunction Extension Module (External 24 Vac/Dc)
Optional panel bus adapters and extension modules 217 CMOD-01 multifunction extension module (external 24 V AC/DC) Note: In ACS560 drives, use CMOD-01 module as an interface for providing external 24 V AC/DC power supply and not as an I/O extension module. ￭...
Page 218: Mechanical Installation
218 Optional panel bus adapters and extension modules Grounding screw Diagnostic LED Hole for mounting screw 2-pin terminal block for external power 3-pin terminal blocks for relay out- supply puts RO4C 24V AC/DC + in RO4A 24 V DC 24 V AC/DC RO4B 24V AC/DC - in 24 V AC/DC + in...
Page 219: Electrical Installation
Optional panel bus adapters and extension modules 219 2. Make sure that there are no signs of damage. Installing the module See section Installing option modules . Electrical installation WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur.
Page 220: Technical Data
220 Optional panel bus adapters and extension modules Diagnostics Faults and warning messages Warning A7AB Extension I/O configuration failure. LEDs The extension module has one diagnostic LED. Color Description Green The extension module is powered up. Technical data Installation Into an option slot on the drive control unit Degree of protection IP20 / UL Type 1 Ambient conditions...
Page 221: Dimension Drawing
Optional panel bus adapters and extension modules 221 Isolation areas CMOD-01 24 V 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 222: Bapo-01 Auxiliary Power Extension Module
222 Optional panel bus adapters and extension modules BAPO-01 auxiliary power extension module ￭ Hardware description The BAPO-01 auxiliary power extension module (option +L534) lets you use an external 24 V DC power supply with the drive. An external power supply is used to keep the drive control board energized during a power outage.
Page 223: Layout
Optional panel bus adapters and extension modules 223 Layout BAPO-01 module Locking screw hole Internal X100 connector Internal X102 connector Grounding rail ￭ Mechanical installation See the electrical installation instructions of the drive. ￭ Electrical installation Connect the external power supply to the +24 V and DGND terminals on the drive. See the electrical installation instructions of the drive.
Page 224: Start-Up
224 Optional panel bus adapters and extension modules Do not chain an external 24 V DC power supply to several drives. Each drive must be powered by a single 24 V DC power supply, or a separate 24 V DC output of one auxiliary power source.
Page 225: Rdum-01 Blank Control Panel
Optional panel bus adapters and extension modules 225 Dimensions: 26 [1.024] 11.3 [0.444] 86.1 [3.391] 16 [0.63] 2.5 [0.098] 52.5 [2.067 42.2 [1.662] 13.3 [0.524] 68.5 [2.697] RDUM-01 blank control panel ￭ Hardware description Product overview RDUM -01 is a blank control panel cover that can be used to connect drive to a remote basic or assistant control panel mounted on a cabinet door.
Page 226: Layout
226 Optional panel bus adapters and extension modules Layout Item Description LEDs mirrored from the drive control unit Connector X100 to the drive control unit Connector X101 for connecting a control panel or a PC Cable hole locations. Used when the cabling connected to the module is routed outside the drive.
Page 227: Installing Assistant Or Basic Control Panel On The Cabinet Door
DPMP-01 flush mounting panel on the cabinet door and then install the basic or assistant control panel. You can order DPMP-02 and DPMP-01 from ABB. CDPI-02 panel bus adapters The CDPI-02 panel bus adapters can be used to connect a remote ACx-AP-x control panel to the drive, or to chain the control panel or a PC to several drives on a panel bus.
Page 228: Hardware Description
228 Optional panel bus adapters and extension modules ￭ Hardware description Product overview BREL-01 relay output extension module (option +L511) adds four relay outputs to the drive. Note: This is applicable only for R0...R2 frames. Layout 1. BREL-01 module 2. Locking screw hole 3.
Page 229: Electrical Installation
Optional panel bus adapters and extension modules 229 ￭ Electrical installation Use 0.5 … 2.5 mm (20 … 14 AWG) cable with a sufficient voltage rating. If you connect an inductive load (relay or contactor coil, motor) protect the relay contacts with a varistor, RC filter (AC) or diode (DC).
Page 230 230 Optional panel bus adapters and extension modules Name/Value Description Def / FbEq16/32 15.01 Extension Activates (and specifies the type of) I/O extension None module type module. BREL External relay option BREL-01. 15.02 Detected I/O extension module detected on the drive. None extension module...
Page 231: Technical Data
Optional panel bus adapters and extension modules 231 Name/Value Description Def / FbEq16/32 0.0 … 3000.0 s Activation delay for RO4. 10 = 1 s 15.09 RO4 OFF delay Defines the deactivation delay for relay output RO4. 0.0 s 0.0 … 3000.0 s Deactivation delay for RO4.
Page 232 232 Optional panel bus adapters and extension modules Dimensions:...
Page 233: External Input Choke
External input choke 233 External input choke Contents of this chapter This chapter describes about external input chokes available for the R0...R2 (2.6A to 25A) frame sizes. In R0...R5 (33 A to 293 A) frame sizes, built-in DC swinging choke is provided by default. DC swinging choke reduces 20% more harmonics in partial loads due to its patented swinging choke technology and also helps in protecting the drive from input variations and reduces DC ripple content.
Page 234: External Input Choke Types
3AYN477110-CH K3A CHK-03 For 9.4 -126A drives 3AYN477110-CHK4A CHK-04 For 17A drives 3AYN477110-CHK5A CHK-05 For 25A drives For choke data sheet, contact your local ABB representative (www.abb.com/searchchannels). Mechanical dimensions N o . Mechanical Choke type parameters CHK-01 (mm) CHK-02 (mm)
Page 235 External input choke 235 N o . Mechanical Choke type parameters CHK-01 (mm) CHK-02 (mm) CHK-03 (mm) CHK-04 (mm) CHK-05 (mm) ≤166 ≤195 ≤208 ≤195 295±3 ≤113 ≤116 ≤131 ≤131 155±3 78 ±1 105±3 105±3 105±3 193±2 122 ±2 148±2 148±2 148±2 118±2...
Page 237: Contents Of This Chapter
Checking the compatibility of the motor drive. ￭ d u /d t filter types Drive type ACS560- d u /d t filter type 3 phases U N = 400 V (380…480 V) 02A6-4 NOCH0016-6X 03A3-4...
Page 238: Description, Installation And Technical Data Of The Foch Filters
238 d u /d t filters Drive type ACS560- d u /d t filter type 039A-4 NOCH0070-6X 046A-4 NOCH0070-6X 062A-4 NOCH0070-6X 073A-4 NOCH0070-6X 088A-4 NOCH0120-6X 106A-4 NOCH0120-6X 145A-4 NOCH0120-6X 169A-4 FOCH0260-7X 206A-4 FOCH0260-7X 246A-4 FOCH0260-7X 293A-4 FOCH0260-7X ￭ Description, installation and technical data of the FOCH filters See FOCH d u/ d t filters hardware manual (3AFE68577519 [English]).
Page 239: 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.

ABB ACS560 Hardware Manual

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