Page 1 — ABB GENERAL PURPOSE DRIVES ACS580-01 drives Hardware manual...
Page 3 ACS580-01 drives Hardware manual Table of contents 1. Safety instructions 4. Mechanical installation 6. Electrical installation – Global (IEC) 7. Electrical installation – North America 10. Start-up 3AXD50000044794 Rev E Original instructions EFFECTIVE: 2023-08-31...
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 .......................... Cabinet installation (option +P944) ..............Examining the installation site ................Installation alternatives ..................Necessary tools ......................Moving the drive ....................... Unpacking and examining delivery, frames R1 and R2 ........Frames R1 and R2 cable box (IP21, UL Type 1) ..........
Page 7: Table Of Contents
Availability of d u /d t filter and common mode filter by drive type ......................Additional requirements for explosion-safe (EX) motors .... Additional requirements for ABB motors of types other than M2_, M3_, M4_, HX_ and AM_ ............... Additional requirements for braking applications ......
Page 8 8 Table of contents General guidelines – North America .............. Continuous motor cable shield/conduit and metal enclosure for equipment on the motor cable ............... Separate control cable ducts ................Implementing short-circuit and thermal overload protection ......Protecting the drive and the input power cable in short-circuits ... Protecting the motor and motor cable in short-circuits ......
Page 9 Table of contents 9 Guidelines for installing the drive to a TT system ........Identifying the grounding system of the electrical power network ..Disconnecting internal EMC filter or ground-to-phase varistor - frames R1…R3 ........................Disconnecting internal EMC filter or ground-to-phase varistor - frames R4…R9 .........................
Page 10 10 Table of contents Required tools ......................Grounding the motor cable shield at the motor end ........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 ..............
Page 11 Table of contents 11 Reinstalling side plates and covers, frames R6…R9 ........IP21 (UL Type 1) ..................IP55 (UL Type 12) ................... Installing UL Type 12 hood ..................Installing IP66 (UL Type 4X) sun shield ..............Connecting a PC ....................... Connecting a remote panel, or chaining one panel to several drives ....
Page 12 12 Table of contents Cleaning the heatsink, IP 66 (UL Type 4X) ............Fans ..........................Replacing the main cooling fan, IP21, IP55 and IP66 (UL Type 1, UL Type 12 and UL Type 4X) frames R1…R4 ..........R1…R3 ..................... R 4 ......................Replacing the main cooling fan, IP21 and IP55 (UL Type 1 and UL Type 12) frames R5…R8 ....................
Page 13 Table of contents 13 Fuses (IEC) ......................... gG fuses ......................uR and aR fuses ....................Calculating the short-circuit current of the installation ......Calculation example ................Circuit breakers (IEC) ....................Fuses (UL) ........................Circuit breakers (UL) ....................Dimensions, weights and free space requirements .......... Dimensions with flange ...................
Page 14 14 Table of contents Package materials for large wall-mounted drives and converter modules ....................... Package materials for options, accessories and spare parts ....Materials of manuals ..................Disposal ........................Applicable standards ....................Markings ........................CE marking ......................... Compliance with the European Low Voltage Directive ......Compliance with the European EMC Directive ...........
Page 15 Table of contents 15 Frame R3, IP66 (UL Type 4X) +B066 ..............Frame R3, IP66 (UL Type 4X) +B063 ..............Frame R3, IP66 (UL Type 4X) +C193 ..............Frame R4, IP21 (UL Type 1) ..................Frame R4, IP55 (UL Type 12) ................... Frame R4, IP55+E223 (UL Type 12) ................
Page 16 16 Table of contents Wiring .......................... Connection principle ..................Single ACS580-01 drive, internal power supply ......Single ACS580-01 drive, external power supply ......Wiring examples ....................Single ACS580-01 drive, internal power supply ......Single ACS580-01 drive, external power supply ......Multiple ACS580-01 drives, internal power supply ......
Page 17 Table of contents 17 Dimension drawings ..................CBAI-01 bipolar analog IO adapter module ............Contents of this chapter ................. Product overview ....................Layout ........................Mechanical installation ..................Necessary tools ..................Unpacking and examining the delivery ..........Installing the module ................Electrical installation ..................
Page 18 18 Table of contents Wiring ...................... Start-up ....................... Setting the parameters ............... Diagnostics .................... Technical data ....................Dimension drawing ................... CMOD-02 multifunction extension module (external 24 V AC/DC and isolated PTC interface) ......................Contents of this chapter ................. Product overview ....................Layout and example connections ..............
Page 19 Table of contents 19 Further information...
Page 21: Safety Instructions
Safety instructions 21 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 22: General Safety In Installation, Start-Up And Maintenance
22 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 23 Safety instructions 23 • 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 24: Electrical Safety In Installation, Start-Up And Maintenance
24 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 25: Additional Instructions And Notes
Safety instructions 25 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 26: Grounding
26 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 27: General Safety In Operation
Safety instructions 27 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 28: Safety In Operation
28 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 29: Introduction To The Manual
Introduction to the manual 29 Introduction to the manual Contents of this chapter This chapter describes the intended audience and contents of the manual. It contains a flowchart of steps in examining the delivery, installing and commissioning the drive. The flowchart refers to chapters/sections in this manual and other manuals.
Page 30: Quick Installation And Commissioning Flowchart
30 Introduction to the manual Quick installation and commissioning flowchart Task Identify the frame of your drive: R1…R9. Type designation key (page 54) Plan the installation: select the cables, etc. Guidelines for planning the electrical install- ation (page 95) Examine the ambient conditions, ratings and required cooling air flow.
Page 31: Terms And Abbreviations
Introduction to the manual 31 Task Connect the control cables. IEC: Connecting the control cables (page 159) North America: Connecting the control cables (page 202) Check the installation. Installation checklist (page 237) ACS580 standard control program firmware Commission the drive. manual (3AXD50000016097 [English]) Terms and abbreviations Term...
Page 32 32 Introduction to the manual Term Description DPMP-02, DPMP-03 Mounting platform for control panel (surface mounting) DPMP-EXT Optional mounting platform for door mounting of control panel Drive Frequency converter for controlling AC motors Embedded fieldbus Electromagnetic compatibility Fieldbus adapter FCAN Optional CANopen®...
Page 33: Related Documents
Introduction to the manual 33 Related documents You can find manuals on the Internet. See below for the relevant code/link. For more documentation, go to www.abb.com/drives/documents. ACS580-01 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 ACS580-01 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 T2/V T3/W R- UDC+...
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...
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...
Page 40 40 Operation principle and hardware description Mounting points (4 pieces) Input power connection (L1, L2, L3), motor connection (T1/U, T2/V, T3/W) Cover and brake connection (R-, R+) Cover screw PE connection (power line) Control panel Grounding connection (motor) Control panel connection Additional grounding connection Cold configuration connection for CCA- Cable entry...
Page 41 Operation principle and hardware description 41 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 connection (T1/U, T2/V, T3/W) Control panel and DC connection (UDC+, UDC-)
Page 42 42 Operation principle and hardware description R4 v2 IP21 / UL Type 1 New design of frame R4 types 062A-4, 073A-4 and 089A-4 are marked as R4 v2 PE 12...
Page 43 Operation principle and hardware description 43 Mounting points (4 pieces) EMC filter grounding screw (EMC). For disconnecting, see page (IEC) or Cover page (North America). Cover screw Input power connection (L1, L2, L3), motor connection (T1/U, T2/V, T3/W) Control panel and DC connection (UDC+, UDC-) Control panel connection PE connection (power line)
Page 44 44 Operation principle and hardware description Frame R5 R5 IP21 / UL Type 1 PE 13...
Page 45 Operation principle and hardware description 45 Mounting points (6 pieces: 2 at the top, Two EMC filter grounding screws, 11a: 2 at the bottom of the main part of the EMC (DC) and 11b: (EMC (AC). For dis- frame, 2 at the top of the cable box) connecting, see page (IEC) or page (North America).
Page 46 46 Operation principle and hardware description 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.
Page 47 Operation principle and hardware description 47 Mounting points (6 pieces: 2 at the top, Varistor grounding screw (VAR), under 2 at the bottom of the main part of the the control panel platform. For discon- frame, 2 at the top of the cable box) necting, see page (IEC) or page (North America).
Page 48: Overview Of Power And Control Connections
48 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, d u /d t and sine fil-...
Page 49: External Control Connection Terminals, Frames R1
Operation principle and hardware description 49 ￭ 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 50: External Control Connection Terminals, Frames R6
50 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 51: Control Panel
Operation principle and hardware description 51 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 install 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 52: Control Panel Door Mounting Kits
52 Operation principle and hardware description ￭ Control panel door mounting kits You can use a mounting platform to install 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 53: Locations Of The Labels On The Drive
Operation principle and hardware description 53 Description Typical drive losses when it operates at 90% of the motor nominal frequency and 100% of the drive nominal output current (calculated according to IEC61800-9-2). Nominal ratings in the supply voltage range, see Electrical ratings (page 266), Electrical...
Page 54: Type Designation Key
54 Operation principle and hardware description Note: P n is not shown in UL (NEC) drive labels Type designation key The type designation contains information on the specifications and configuration of the drive. You find the type designation on the type designation label attached to the drive.
Page 55: Option Codes
Operation principle and hardware description 55 Code Description Size xxxx See the rating tables Voltage rating 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) B063...
Page 56 56 Operation principle and hardware description Code Description 0J400 No control panel J400 ACS-AP-S control panel (included as standard) J404 ACS-BP-S basic control panel J424 Blank control panel cover (no control panel) J425 ACS-AP-I control panel ACH-AP-S control panel with Bluetooth interface J429 ACS-AP-W control panel with Bluetooth interface J461...
Page 57: Manual Kit Ordering Codes
Operation principle and hardware description 57 Code Description P931 Extended warranty 36 months from delivery P932 Extended warranty 60 months from delivery Version for cabinet mounting P940 Drive module without front cover or cable box. With option +B063 or +B066 only. Version for cabinet mounting (drive module with front covers but without cable P944 box) for frames R5…R9.
Page 59: Mechanical Installation
Mechanical installation 59 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.
Page 60: Cabinet Installation (Option +P944)
60 Mechanical installation Cabinet installation (option +P944) See also ACS580…, ACH580… and ACQ580…+P940 and +P944 drive modules supplement (3AXD50000210305 [English]). For generic guidelines for planning the installation of the drive modules into a user-defined cabinet, see Drive modules cabinet design and construction instructions (3AUA0000107668 [English]).
Page 61: Installation Alternatives
Mechanical installation 61 Installation alternatives 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 62 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 could vary from this recommendation.
Page 63 Free space between the drives. 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 64 64 Mechanical installation Frame size Vertical installation side by side - Free space, IP66 (UL Type 4X) Above (a) Below (b) Beside (c) • 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.
Page 65 Mechanical installation 65 Frame Side up (c) Side down (d) Side up (c) Side down (d) size 1.18 7.87 1.18 7.87 1.18 7.87 1.18 7.87 1.18 7.87 1.18 7.87 1.18 7.87 1.18 7.87 1.18 7.87 1.18 7.87 Free space below is always measured from the drive frame, not from the cable box.
Page 66: Necessary Tools
66 Mechanical installation Necessary tools To move a heavy drive, you need a crane, fork-lift or pallet truck (check load capacity!). To lift a heavy drive, you need a hoist. To install the drive mechanically, you need the following tools: •...
Page 67: Unpacking And Examining Delivery, Frames R1 And R2
Mechanical installation 67 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 68 68 Mechanical installation To unpack: • Open the cardboard box (8) • 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) •...
Page 69: Frames R1 And R2 Cable Box (Ip21, Ul Type 1)
Mechanical installation 69 ￭ 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 70: Unpacking And Examining Delivery, Frame R3
70 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. See section Type designation label (page 52).
Page 71 Mechanical installation 71 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 72: Unpacking And Examining Delivery, Frames R1
72 Mechanical installation Unpacking and examining delivery, frames R1…R3, IP66 (UL Type 4X) 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 73 Mechanical installation 73 Cardboard box bottom Cardboard box lid Cardboard tray Bottom cushion (2 pcs) Top cushion (2 pcs) Straps (2 pcs) Drive To unpack: • Cut the straps (6) • Lift the box lid (2) • Remove the top cushions (5) •...
Page 74: Unpacking And Examining Delivery, Frames R4
74 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. See section Type designation label (page 52).
Page 75 Mechanical installation 75 Drive Top cushion Cardboard box. Mounting template in Bottom cushion the cardboard box. Bottom cushion Option support: Top cushion • Europe: Quick installation and start- up guide kit (6 languages) Note: Hood included with option +B056 • North America: Quick installation and (IP55/UL Type 12) in North America start-up guide •...
Page 76: Unpacking And Examining Delivery, Frame R5 And R6
76 Mechanical installation Unpacking and examining delivery, frame R5 and R6 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 77: Frame R5 Cable Box (Ip21, Ul Type 1)
Mechanical installation 77 To unpack: • Cut the straps (9). • Remove the cardboard box (6) and option box (3). • Remove the cover protecting film (5). • Remove the fixing brackets (2). • Lift the drive. ￭ Frame R5 cable box (IP21, UL Type 1) This illustration shows the contents of the cable box package.
Page 78: Frame R6 Cable Box (Ip21, Ul Type 1)
78 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 79: Unpacking And Examining Delivery, Frame R7
Mechanical installation 79 Unpacking and examining delivery, frame R7 Drive with factory installed options Cable box (not with option +B056, +C135 or +P944). Note: The cable box is mounted to the IP55 drive module frame at the factory. Packing brackets, 2 pcs In the option tray: •...
Page 80 80 Mechanical installation To unpack: • Cut the straps (9). • Remove the cardboard box (5) and option tray (4). • Remove the VCI bag (8). • Attach lifting hooks to the lifting eyes of the drive (see the figure in section Safety (page 59)).
Page 81: Frame R7 Cable Box (Ip21, Ul Type 1)
Mechanical installation 81 ￭ 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 82: Unpacking And Examining Delivery, Frames R8 And R9
82 Mechanical installation Unpacking and examining delivery, frames R8 and 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 83 Mechanical installation 83 Cable box. Power and control cable • North America: Quick installation and grounding shelves in a plastic bag, as- start-up guide sembly drawing. • Multilingual residual voltage warning stickers Note: The cable box is mounted to the Control panel selected in the order (in IP55 drive module frame at the factory.
Page 84: Frame R8 Cable Box (Ip21, Ul Type 1)
84 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 85: Frame R9 Cable Box (Ip21, Ul Type 1)
Mechanical installation 85 ￭ 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 86: Installing The Drive
86 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. Mark the hole locations using the mounting template included in the package. Do not leave the mounting template under the drive.
Page 87: Installing The Cable Box, Frames R1
Mechanical installation 87 IP66 (UL Type 4X) 6.89 6.89 9.61 19.57 22.87 24.49 Weight 11.8 14.5 26.4 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.
Page 88: Installing The Drive Vertically, Frame R5
88 Mechanical installation 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). 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 212).
Page 89: Ip21 (Ul Type 1)
Mechanical installation 89 R5 IP21 (UL Type 1) R5 IP55 (UL Type 12) ×2 24.09 24.09 22.87 22.87 6.30 6.30 d > 7.87 7.87 ×2 e > 3.94 3.94 ×2 28.3 62.4 29.0 64.0 R5: M6 (¼ in) ×2 ×6 ×2 IP21 (UL Type 1) 4.
Page 90: Ip21 (Ul Type 1), Ip55 (Ul Type 12)
90 Mechanical installation 8. Put the tabs at the top of the front cover in their counterparts on the housing and then press at the bottom (8a) and tighten the retaining screws (8b). 3×M5 (#10) IP21 (UL Type 1), IP55 (UL Type 12) 9.
Page 91: Installing The Drive Vertically, Frames R6
Mechanical installation 91 ￭ 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. Mark the hole locations for the six mounting holes using the mounting template included in the package.
Page 92: Ip21 (Ul Type 1)
92 Mechanical installation 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 93: Ip55 (Ul Type 12)
Mechanical installation 93 IP55 (UL Type 12) 9. 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). 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 212).
Page 94: Strut Channel Installation (Us Only)
94 Mechanical installation For more information on flange mounting, see Flange mounting kit installation supplement (3AXD50000019100 [English]). Strut channel installation (US only) Contents of the mounting kit: • Upper mounting clip labeled “Top” • Lower mounting clip labeled “Bottom” ￭ Installation instructions Install clips when mounting frame sizes R1…R3 to strut channel.
Page 95: 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 96: Selecting The Main Contactor
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 97: Requirements Tables
Guidelines for planning the electrical installation 97 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 98: Requirements For Abb Motors, P
Nominal AC line Requirement for voltage Motor insu- ABB d u /d t and common mode filters, in- lation sys- sulated N-end motor bearings P n < 100 kW and frame size < IEC 315 P n < 134 hp and frame size < NEMA 500 Random-wound U n ≤...
Page 99: Requirements For Abb Motors, P
Motor type Nominal AC line Requirement for voltage Motor insu- ABB d u /d t and common mode filters, in- lation sys- sulated N-end motor bearings 100 kW ≤ P n < 350 P n ≥ 350 kW frame size ≥...
Page 100: Requirements For Non-Abb Motors, P N < 100 Kw (134 Hp)
Nominal AC line Requirement for voltage Motor insu- ABB d u /d t and common mode filters, in- lation sys- sulated N-end motor bearings P n < 100 kW and frame size < IEC 315 P n < 134 hp and frame size < NEMA 500 Random-wound U n ≤...
Page 101: Requirements For Non-Abb Motors, P
Motor type Nominal AC line Requirement for voltage Motor insu- ABB d u /d t and common mode filters, in- lation sys- sulated N-end motor bearings 100 kW ≤ P n < 350 P n ≥ 350 kW frame size ≥...
Page 102: Abbreviations
If you use an explosion-safe (EX) motor, obey 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 103: Additional Requirements For 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 104: Additional Data For Calculating The Rise Time And The Peak Line-To-Line Voltage
104 Guidelines for planning the electrical installation Nominal AC supply Requirement for voltage ABB d u /d t and common mode filters, insu- Motor insulation sys- lated N-end motor bearings P n < 100 kW or frame 100 kW < P n < 350 kW size <...
Page 105: Additional Note For Sine Filters
Guidelines for planning the electrical installation 105 Û du/dt -------------(1/ µs) Û -- - - -- - - - - - (1/ µs) l (m) l (m) Drive with d u /d t filter Drive without d u /d t filter Motor cable length Nominal AC line voltage Û...
Page 106: Selecting The Power Cables
106 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 current provided by the supply network.
Page 107: Power Cable Types
Guidelines for planning the electrical installation 107 ￭ Power cable types Preferred power cable types This section presents the preferred cable types. Make sure that the selected cable type also complies with local/state/country electrical codes. Cable type Use as input power cabling Use as motor cabling and as brake resistor cabling Symmetrical shielded (or ar-...
Page 108: Alternate Power Cable Types
108 Guidelines for planning the electrical installation Alternate power cable types Cable type Use as input power cabling Use as motor cabling and as brake resistor cabling Yes with phase conductor Yes with phase conductor smaller than 10 mm 2 (8 AWG) smaller than 10 mm 2 (8 AWG) Cu, or motors up to 30 kW (40 hp).
Page 109: Not Allowed Power Cable Types
￭ Additional guidelines – North America ABB recommends the use of metallic conduit for power wiring. ABB also recommends the use of symmetrical shielded VFD cable between drive and motor(s). This table shows examples of methods for wiring the drive. Refer to NFPA 70 (NEC) along with state and local codes for the appropriate methods for your application.
Page 110: Metal Conduit
110 Guidelines for planning the electrical installation Wiring method Notes Free air Prefer symmetrical shielded VFD cable. Enclosures, air handlers, etc. Allowed internally in enclosures when in ac- cordance with UL. 1) Metallic conduit may be used as an additional ground path, provided this path is a solid path capable of handling ground currents.
Page 111: Grounding Requirements
Guidelines for planning the electrical installation 111 Insulation jacket Helix of copper tape or copper wire Copper wire shield Inner insulation Cable core Grounding requirements This section gives general requirements for grounding the drive. When you plan the grounding of the drive, obey all the applicable national and local regulations. The conductivity of the protective earth conductor(s) must be sufficient.
Page 112: Additional Grounding Requirements - Iec
112 Guidelines for planning the electrical installation conductor must be determined 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 )
Page 113: 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 114: 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 115: General Guidelines - North America
Guidelines for planning the electrical installation 115 • Do not run extra cables through the drive. • Make sure that the cable trays have good electrical bonding to each other and to the grounding electrodes. Aluminum tray systems can be used to improve local equalizing of potential.
Page 116: Continuous Motor Cable Shield/Conduit And Metal Enclosure For Equipment On The Motor Cable
116 Guidelines for planning the electrical installation Input power cabling Motor cabling Conduit ￭ Continuous motor cable shield/conduit and metal 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 117: Separate Control Cable Ducts
Guidelines for planning the electrical installation 117 ￭ 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 118: Protecting The Motor And Motor Cable In Short-Circuits
118 Guidelines for planning the electrical installation WARNING! Due to the inherent operating principle and construction of circuit breakers, independent of the manufacturer, hot ionized gases can escape from the breaker enclosure in case of a short-circuit. To ensure safe use, pay special attention to the installation and placement of the breakers.
Page 119: Protecting The Motor Against Overload Without Thermal Model Or Temperature Sensors
Guidelines for planning the electrical installation 119 a motor thermal protection function that protects the motor and switches off the current when necessary. Depending on a drive parameter value, the function either monitors a calculated temperature value (based on a motor thermal model) or an actual temperature indication given by motor temperature sensors.
Page 120: Implementing The Emergency Stop Function
120 Guidelines for planning the electrical installation Implementing the emergency stop function For safety reasons, install the emergency stop devices at each operator control station and at other operating stations where the emergency stop may be needed. Implement the emergency stop according to relevant standards. Note: You can use the Safe torque off function of the drive to implement the Emergency stop function.
Page 121: Implementing An Atex-Certified Motor Thermal Protection
Guidelines for planning the electrical installation 121 Give a stop command to the drive. 2. Wait until the drive decelerates the motor to zero speed. 3. Open the contactor. If you have the vector control mode and motor coast stop selected, or scalar control mode selected, open the contactor as follows: Give a stop command to the drive.
Page 122: Using A Safety Switch Between The Drive And The Motor
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 123: Example Bypass Connection
Guidelines for planning the electrical installation 123 ￭ Example bypass connection An example bypass connection is shown below. Drive main switch Bypass circuit breaker Drive main contactor Bypass contactor Drive output contactor Drive main contactor on/off control Motor power supply selection (drive or direct-on-line) Start when motor is connected direct-on-line Stop when motor is connected direct-on-line...
Page 124: Switching The Motor Power Supply From Drive To Direct-On-Line
124 Guidelines for planning the electrical installation Switching the motor power supply from drive to direct-on-line Stop the drive and the motor with the drive control panel stop key (drive in the local control mode) or the external stop signal (drive in the remote control mode).
Page 125: Limiting Relay Output Maximum Voltages At High Installation Altitudes
Guidelines for planning the electrical installation 125 230 V AC 230 V AC + 24 V DC Relay output Varistor RC filter Diode Limiting relay output maximum voltages at high installation altitudes Isolation areas (page 230) for frames R1…R5 and Isolation areas (page 234) frames R6…R9.
Page 126: Connecting A Motor Temperature Sensor To The Drive Through An Option Module
126 Guidelines for planning the electrical installation 2. If there is basic insulation between the sensor and the live parts of the motor, or if the insulation type is not known: You can connect the sensor to the drive via an option module. The sensor and the module must form a double or reinforced insulation between the motor live parts and the drive control unit.
Page 127 Guidelines for planning the electrical installation 127 • CMOD-02 multifunction extension module (external 24 V AC/DC and isolated PTC interface) (page 454) • CPTC-02 ATEX-certified thermistor protection module, Ex II (2) GD (option +L537+Q971) user's manual (3AXD50000030058 [English]).
Page 129: Electrical Installation - Global (Iec)
Electrical installation – Global (IEC) 129 Electrical installation – Global (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 •...
Page 130: Grounding The Motor Cable Shield At The Motor End
130 Electrical installation – Global (IEC) • 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° at the cable entry of the motor terminal box.
Page 131: 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 132: Grounding System Compatibility Check
132 Electrical installation – Global (IEC) 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 (page 132) below. ￭ EMC filter A drive with EMC filter connected can be installed to a symmetrically grounded TN-S system.
Page 133 Electrical installation – Global (IEC) 133 Frame Symmetrically groun- Corner-grounded (B1) and IT systems (ungrounded or size ded TN systems (TN- midpoint-grounded delta high-resistance grounded S systems) ie. center- systems (B2) [>30 ohms]) (C) grounded wye (A) ≤ 600 V R1…R3 Do not disconnect Disconnect EMC screw.
Page 134: Guidelines For Installing The Drive To A Tt System
Two EMC screws R6…R9 Two EMC screws Drive Note: • 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. •...
Page 135: Identifying The Grounding System Of The Electrical Power Network
Electrical installation – Global (IEC) 135 ￭ 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 136: Disconnecting Internal Emc Filter Or Ground-To-Phase Varistor - Frames R4
136 Electrical installation – Global (IEC) 2. Open the front cover, if not already opened, see page 140. 3. To disconnect the internal EMC filter, remove the EMC screw (3a) and place it in the storage place (3b). 4. To disconnect the ground-to-phase varistor, remove the varistor screw (4a) and place it in the storage place (4b) Screw EMC (DC)
Page 137 Electrical installation – Global (IEC) 137 Switch off the power from the drive. 2. Open the cover, if not already opened. Frame R4: see page 140, frame R5: see page 148, frames R6…R9: see page 92. 3. To disconnect the internal EMC filter, remove the EMC screw(s). 4.
Page 138 138 Electrical installation – Global (IEC) R4 v2 R6…R9 Screw EMC (DC) EMC (AC)
Page 139: Connecting The Power Cables
(if used). It is also recommended for the input power cable. If necessary, install an external filter (d u /d t , common mode, or sine filter). Filters are available from ABB. For IP66 (UL Type 4X) drive with optional disconnect, wire to terminals 2T1, 4T2 and...
Page 140: Connection Procedure, Frames R1
140 Electrical installation – Global (IEC) Note: Frames R1…R3 have a built-in brake chopper. If necessary, you can connect a brake resistor to terminals R-and UDC+/R+. The brake resistor is not included in the drive delivery. In frames R4…R9, you can connect an external brake chopper to terminals UDC+ and UDC- .
Page 141: Motor Cable
Electrical installation – Global (IEC) 141 2. Attach the residual voltage warning sticker in the local language. R3…R4 3. Remove the rubber grommets for the motor and input power cables, as well as brake resistor cable, if used. Remove the grommets for the control cables when you are connecting them. Note: The drive is shipped with grommet cones pointing up.
Page 142 142 Electrical installation – Global (IEC) 5a 5b 6. Slide the cable through the hole in the cable entry and attach the grommet to the hole. IP66 (UL Type 4X) drives: Tighten the cable gland nut on the outside. WARNING! If you install IP66 (UL Type 4X) drive indoors or outdoors in a wet, dirty, dusty, corrosive or similar environment, all cables, conduits and fittings must be approved for use in this type of environment.
Page 143 Electrical installation – Global (IEC) 143 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 (7a). IP66 (UL Type 4X): for best EMC performance, do not ground the shield. The motor cable shield should only be grounded at the motor end, not at the drive end.
Page 144: Input Power Cable
144 Electrical installation – Global (IEC) 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. IP66 (UL Type 4X) drives: Attach the cable gland to the hole and tighten nut on the inside.
Page 145 Electrical installation – Global (IEC) 145 R1…R2 INPUT BRAKE RES MOTOR T1/U T2/V T3/W UDC+ INPUT BRAKE RES MOTOR UDC+ 11b 11c R1…R2 IP66 (UL Type 4X) R3 IP66 (UL Type 4X) BRAKE RES MOTOR INPUT BRAKE MOTOR INPUT L1 L2 L3 R- T1/U T2/V T3/W UDC+ T1/U...
Page 146: Grounding Shelf
146 Electrical installation – Global (IEC) R4 v2 T1/U T2/V T3/W T1/U T2/V T3/W UDC+ UDC+ Frame size N·m lbf·ft N·m lbf·ft N·m lbf·ft N·m lbf·ft L1, L2, L3 Grounding shelf 12. Frames R1…R2, R4: Install the grounding shelf (included with the mounting screws in a plastic bag in the delivery).
Page 147 Electrical installation – Global (IEC) 147 14. Connect the cable as the motor cable in step 7. Ground the shield 360 degrees (14a). Connect the twisted shield to the grounding terminal (14b) and the conductors to the R+ and R- terminals (14c) and tighten to the torque given in the table.
Page 148: Finalization
148 Electrical installation – Global (IEC) 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 164).
Page 149 Electrical installation – Global (IEC) 149 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 Grounding system compatibility check (page 132) if you have to disconnect the EMC filter and ground-to-phase varistor.
Page 150 150 Electrical installation – Global (IEC) 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 151 Electrical installation – Global (IEC) 151 Frame size T1/U, T2/V, T3/W N·m lbf·ft N·m lbf·ft N·m lbf·ft 11.1 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 152 152 Electrical installation – Global (IEC) 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 11.1 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 153: Connection Procedure, Frames R6
Electrical installation – Global (IEC) 153 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 154: Motor Cable
154 Electrical installation – Global (IEC) 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 155: 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 156: Detaching And Reinstalling The Connectors
156 Electrical installation – Global (IEC) M5×25/35 Frame size L1, L2, L3, T1/U, T2/V, T3/W N·m lbf·ft 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 157 Electrical installation – Global (IEC) 157 • Put the connector back onto the terminal post. Start the combi screw, and turn it at least two rotations by hand. WARNING! Before using tools, make sure that the nut/screw is not cross-threading. Cross-threading will damage the drive and cause danger.
Page 158: Dc Connection
158 Electrical installation – Global (IEC) 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. DC connection The UDC+ and UDC- terminals (as standard in frames R4…R9) are for using external brake chopper units.
Page 159: Connecting The Control Cables
Electrical installation – Global (IEC) 159 Connecting the control cables ￭ Connection diagram Default I/O connection diagram (page 218) for the default I/O connections of the drive. ￭ Control cable connection procedure R1…R9 WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur.
Page 160 160 Electrical installation – Global (IEC) 8. Ground the outer shield of the cable 360 degrees under the grounding clamp. Keep the cable unstripped as close to the terminals of the control unit as possible. Frames R5…R9: Secure the cables mechanically at the clamps below the control unit.
Page 161 Electrical installation – Global (IEC) 161 R1…R2 INPUT BRAKE RES MOTOR INPUT BRAKE RES UDC+ MOTOR 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 162 162 Electrical installation – Global (IEC) R1…R3 IP66 (UL Type 4X) MOTOR BRAKE RES INPUT BRAKE RES MOTOR L1 L2 L3 R- T1/U T2/V T3/W T2/V T3/W UDC+ T1/U T2/V T3/W UDC+ R1…R3 IP66: 0.5…0.6 N·m (0.4 lbf·ft) R4: 0.5…0.6 N·m (0.4 lbf·ft)
Page 163 Electrical installation – Global (IEC) 163 0.5...0.6 N·m (0.4 lbf·ft)
Page 164: Installing Option Modules
164 Electrical installation – Global (IEC) 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. Stop the drive and do the steps in section Electrical safety precautions (page 24)
Page 165: Option Slot 2 (I/O Extension Modules)
Electrical installation – Global (IEC) 165 ￭ Option slot 2 (I/O extension modules) 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 166: Option Slot 1 (Fieldbus Adapter Modules)
166 Electrical installation – Global (IEC) ￭ Option slot 1 (fieldbus adapter modules) 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. This is necessary for fulfilling the EMC requirements and for correct operation of the module.
Page 167: Reinstalling Grommets
Electrical installation – Global (IEC) 167 Reinstalling grommets UL Type 12: To maintain UL Type 12, reinstall grommets (top of the grommets downwards) to all cable entry holes without conduits. IP66 (UL Type 4X): Plug unused holes with a hole plug with IP66 (UL Type 4X) or better protection rating and tighten securely.
Page 168: Reinstalling Covers
168 Electrical installation – Global (IEC) Reinstalling covers ￭ Reinstalling cover, frames R1…R4 Reinstall the cover: Put the tabs on the cover top in their counterparts on the housing (1a) and the press the cover (1b). IP66 (UL Type 4X): Reinstall the cover. 2.
Page 169: Reinstalling Covers, Frame R5
Electrical installation – Global (IEC) 169 ￭ Reinstalling covers, frame R5 IP21 (UL Type 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 170: Reinstalling Side Plates And Covers, Frames R6
170 Electrical installation – Global (IEC) ￭ Reinstalling side plates and covers, frames R6…R9 IP21 (UL Type 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 171: Installing Ip66 (Ul Type 4X) Sun Shield
Electrical installation – Global (IEC) 171 IP21 (UL Type 1) IP55 (UL Type 12) Installing IP66 (UL Type 4X) sun shield Refer to ACH580-01, ACQ580-01, ACS580-01 4X IP66 drives, sun shield quick installation guide (3AXD50001019006 [English]), included in the sun shield package. Connecting a PC WARNING! Do not connect the PC directly to the control panel connector of the control...
Page 172: Connecting A Remote Panel, Or Chaining One Panel To Several Drives
172 Electrical installation – Global (IEC) USB connected Stop Start Loc/Rem Stop Loc/Rem Start Note: For IP66 (UL Type 4X) drive, the USB connection on the panel cannot be accessed while the cover is in place. Use the Bluetooth functionality to troubleshoot the drive using the DriveTune app from your phone.
Page 173: Electrical Installation - North America
Electrical installation – North America 173 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 174: Required Tools
174 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°...
Page 175: 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 176: Grounding System Compatibility Check
176 Electrical installation – North America 1000 V DC, > 1 Mohm 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 (VAR) below.
Page 177: When To Connect Emc Filter Or Disconnect Ground-To-Phase Varistor: Tn-S, It, Corner-Grounded Delta And Midpoint-Grounded Delta Systems
Electrical installation – North America 177 ￭ When to connect EMC filter or disconnect ground-to-phase varistor: TN-S, IT, corner-grounded delta and midpoint-grounded delta systems Requirements for disconnecting EMC filter and varistor and additional requirements for different electrical power systems are given below. Note: Configure the EMC filter based on the electrical system of the installation site.
Page 178: Guidelines For Installing The Drive To A Tt System
178 Electrical installation – North America 2) Metal screw must not be used. 3) Frames R4 and R5 are evaluated for use on corner-grounded delta networks by UL standards. (R4 and R5 frames are not to be used on IEC installations of corner grounded networks.) Note: The VAR screw on R1…R3 also connects the EMC (AC) circuit internally within the drive.
Page 179: Identifying The Grounding System Of The Electrical Power Network
Electrical installation – North America 179 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 180: Disconnecting Internal Emc Filter Or Ground-To-Phase Varistor - Frames R1
180 Electrical installation – North America The table below shows the line-to-ground voltages in relation to the line-to-line voltage for each grounding system. U L-L U L1-G U L2-G U L3-G Electrical power system type 0.58·X 0.58·X 0.58·X TN-S system (symmetrically grounded) Corner-grounded delta system (nonsym- 1.0·X 1.0·X...
Page 181: Disconnecting Internal Emc Filter Or Ground-To-Phase Varistor - Frames R4
Electrical installation – North America 181 Screw Default material EMC (DC) Plastic Metal ￭ Disconnecting internal EMC filter or ground-to-phase varistor - frames R4…R9 Extra screws to configure the drive for different networks are provided in the drive shipment, see the table in page 178. To disconnect the internal EMC filter or ground-to-phase varistor: Do the steps in section Electrical safety precautions (page 24)
Page 182 182 Electrical installation – North America 2. Open the cover, if not already opened. Frame R4: see page 186, frame R5: see page 194, frames R6…R9: see page 198. 3. To disconnect the internal EMC filters: The DC EMC filter is disconnected by default with no screw or with a plastic screw (3A).
Page 183 Electrical installation – North America 183 R4 v2 R6…R9 Screw EMC (DC) EMC (AC)
Page 184: Connecting The Power Cables
184 Electrical installation – North America Connecting the power cables ￭ Connection diagram UDC+ UDC- T1/U T2/V T3/W Note: UL (NEC) installation can include separate insulated conductors inside a conduit, shielded VFD cable in conduit, or shielded VFD cable without conduit. The normal dashed symbol (3) in this diagram represents the shield of shielded VFD cable.
Page 185 All openings in the drive enclosure must be closed with UL listed devices having the same UL Type rating as the drive UL Type. ABB does not recommend an asymmetrically constructed motor cable or a conduit for motor cabling for motors above 30 kW (40 hp) (see General guidelines (page 106)).
Page 186: Connection Procedure, Frames R1
186 Electrical installation – North America ￭ Connection procedure, frames R1…R4 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). IP66 (UL Type 4X): Loosen the retaining screws with a T20 Torx screwdriver (1a) and take the cover off (1b).
Page 187: Motor Cabling
Electrical installation – North America 187 • Cut a sufficient hole in the rubber grommet. Slide the grommet onto the cable (4a). Prepare the power cables (conduit): • Attach the cable conduit fittings (not included) to the cable entry holes in place of the removed grommets or knockouts (4b).
Page 188 188 Electrical installation – North America 6. Slide the cable through the hole in the cable entry and attach the grommet to the hole. IP66 (UL Type 4X) drives: Tighten the cable gland nut on the outside. 7. Connect the motor cable: •...
Page 189 Electrical installation – North America 189 R1…R2 INPUT BRAKE RES MOTOR T1/U T2/V T3/W UDC+ INPUT BRAKE RES MOTOR UDC+ R4 v2 T1/U T2/V T3/W T1/U T2/V T3/W UDC+ UDC+ Frame size R4 v2 N·m lbf·ft N·m lbf·ft N·m lbf·ft N·m lbf·ft N·m...
Page 190: Input Power Cabling
190 Electrical installation – North America Input power cabling 8. Strip the ends of the conductors. Conduit 9. Slide the conductors through the conduit. 10. Connect the conductors: • Connect the grounding conductor to the grounding terminal. (10a) • Connect the phase conductors to the L1, L2 and L3 terminals. Tighten the screws to the torque given in the table.
Page 191 Electrical installation – North America 191 R1…R2 IP66 (UL Type 4X) R3 IP66 (UL Type 4X) INPUT BRAKE RES MOTOR BRAKE MOTOR INPUT L1 L2 L3 R- T1/U T2/V T3/W UDC+ T1/U T2/V T3/W UDC+ R1…R2 IP66 (UL Type 4X) with disconnect R3 IP66 (UL Type 4X) with disconnect BRAKE RES MOTOR...
Page 192: Brake Resistor Cabling (If Used)
192 Electrical installation – North America R4 v2 T1/U T2/V T3/W T1/U T2/V T3/W UDC+ UDC+ Frame size R4 v2 N·m lbf·ft 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 193: Finalization
Electrical installation – North America 193 R1…R2 BRAKE RES INPUT MOTOR UDC+ INPUT MOTOR BRAKE RES T1/U T2/V T3/W UDC+ R1…R2 IP66 (UL Type 4X) R3 IP66 (UL Type 4X) MOTOR INPUT BRAKE RES MOTOR BRAKE RES L1 L2 L3 R- T1/U T2/V T3/W UDC+ INPUT...
Page 194: Connection Procedure, Frame R5
194 Electrical installation – North America 13. Secure the conduits outside the unit mechanically. ￭ Connection procedure, frame R5 IP21 (UL Type 1) Remove the module cover: Loosen the retaining screws with a T20 Torx screwdriver (1a) and lift the cover from the bottom outwards (1b) and then up (1c).
Page 195 Electrical installation – North America 195 4. Remove the rubber grommets, if present, for the motor and input power cabling. Remove the grommets for the control cabling when you are connecting them. 5. Prepare the power cables as in Connection procedure, frames R1…R4 (page 186), step 4 Note: If the drive is shipped with grommet cones pointing up they must be...
Page 196 196 Electrical installation – North America • Ground the shield 360 degrees by tightening the clamp of the power cable grounding shelf onto the stripped part of the cable (8a). • Connect the twisted shield of the cable to the grounding terminal (8b). •...
Page 197 Electrical installation – North America 197 Frame size L1, L2, L3 N·m lbf·ft N·m lbf·ft 11.1 13. Reinstall the shroud on the power terminals by putting the tabs at the top of the shroud in their counterparts on the drive frame (13a) and then pressing the shroud in place (13b).
Page 198: Connection Procedure, Frames R6
198 Electrical installation – North America ￭ Connection procedure, frames R6…R9 WARNING! If you install the drive on any other system than symmetrically grounded TN-S system, see see Grounding system compatibility check (page 176) if you have to disconnect the EMC filter and ground-to-phase varistor. Attach the residual voltage warning sticker in the local language next to the control unit.
Page 199: Motor Cabling
Electrical installation – North America 199 Remove the grommets for the control cabling when you are connecting them. 7. Prepare the power cables as in Connection procedure, frames R1…R4 (page 186), step 4 Note: If the drive is shipped with grommet cones pointing up they must be removed and inserted back pointing down.
Page 200: 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 201 Electrical installation – North America 201 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 202: Dc Connection
202 Electrical installation – North America 15. Reinstall the shroud on the power terminals. 16. Secure the conduits outside the unit mechanically. DC connection The UDC+ and UDC- terminals (as standard in frames R4…R9) are for using external brake chopper units. Connecting the control cables ￭...
Page 203 Electrical installation – North America 203 3. Remove the rubber grommets from the cable entry for the cables to be connected. Attach cable conduits to the empty cable entry holes. Slide the cables through the cable conduits. 4. Frames R5…R9: Secure the cables mechanically at the clamps below the control unit.
Page 204 204 Electrical installation – North America R1…R2 INPUT BRAKE RES MOTOR UDC+ INPUT MOTOR BRAKE RES UDC+ R1…R2: 0.4 lbf·ft R3: 0.4 lbf·ft...
Page 205 Electrical installation – North America 205 R1...R3 IP66 (UL Type 4X) BRAKE RES MOTOR INPUT BRAKE RES MOTOR L1 L2 L3 T2/V T3/W R- T1/U T2/V T3/W UDC+ T1/U T2/V T3/W UDC+ R4: 0.4 lbf·ft R1…R3: 0.4 lbf·ft...
Page 206 206 Electrical installation – North America T1/U T2/V T2/W R5: 0.4 lbf·ft...
Page 207 Electrical installation – North America 207 R6…R9 R6…R9: 0.4 lbf·ft...
Page 208: Installing Option Modules
208 Electrical installation – North America Installing option modules See section Installing option modules (page 164). Reinstalling grommets UL Type 12: To maintain UL Type 12, reinstall grommets (top of the grommets downwards) to all cable entry holes without conduits. IP66 (UL Type 4X): Plug unused holes with a hole plug with IP66 (UL Type 4X) or better protection rating and tighten securely.
Page 209: Reinstalling Covers
Electrical installation – North America 209 Reinstalling covers ￭ Reinstalling cover, frames R1…R4 Reinstall the cover: Put the tabs on the cover top in their counterparts on the housing (1a) and the press the cover (1b). IP66 (UL Type 4X): Reinstall the cover. 2.
Page 210: Reinstalling Covers, Frame R5
210 Electrical installation – North America ￭ Reinstalling covers, frame R5 IP21 (UL Type 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 211: Reinstalling Side Plates And Covers, Frames R6
Electrical installation – North America 211 ￭ Reinstalling side plates and covers, frames R6…R9 IP21 (UL Type 1) Reinstall the side plates of the cable box (1a). Tighten the retaining screws with a T20 Torx screwdriver (1b). 2. Slide the cover of the cable box on the module from below until the cover snaps into place.
Page 212: Installing Ul Type 12 Hood
212 Electrical installation – North America IP21 (UL Type 1) IP55 (UL Type 12) Installing UL Type 12 hood UL Type 12 hood for ACS580-01, ACH580-01 and ACQ580-01, and for ACH580-31 and ACQ580-31 frames R6 and R8 (3AXD50000225972 [English]) which is included in the hood package.
Page 213: Connecting A Remote Panel, Or Chaining One Panel To Several Drives
Electrical installation – North America 213 USB connected Stop Start Loc/Rem Stop Loc/Rem Start Note: For IP66 (UL Type 4X) drive, the USB connection on the panel cannot be accessed while the cover is in place. Use the Bluetooth functionality to troubleshoot the drive using the DriveTune app from your phone.
Page 215: Control Unit
Control unit 215 Control unit Contents of this chapter This chapter contains the default I/O connection diagram, descriptions of the terminals and technical data for the drive control unit (CCU-23 and CCU-24).
Page 216: Layout
216 Control unit Layout The layout of the external control connection terminals on the drive module control unit is shown below. R1…R5 SLOT 1 Option slot 1 (fieldbus adapter modules) ANALOG IN/OUT 1…3 Analog input 1 4…6 Analog input 2 1…3 7…9 Analog outputs...
Page 217 Control unit 217 R6…R9 SLOT 1 SLOT 1 Option slot 1 (fieldbus adapter modules) ANALOG IN/OUT 1…3 Analog input 1 4…6 Analog input 2 1…3 7…9 Analog outputs 4…6 10…12 Auxiliary voltage output, digital input common 7…9 DIGITAL IN 10…12 13…18 Digital inputs 13…15...
Page 218: Default I/O Connection Diagram
218 Control unit Default I/O connection diagram The default I/O connections of the ABB Standard macro are shown below. R1…R5 Connection Term Description X1 Reference voltage and analog inputs and outputs Signal cable shield (screen) Output frequency reference: 0…10 V 1) 3) 1...10 kohm...
Page 219 Control unit 219 Connection Term Description RO1C Ready run 250 V AC / 30 V DC RO1A Ready run status RO1B RO2C Running Run status 250 V AC / 30 V DC RO2A RO2B Fault status RO3C Fault (-1) 250 V AC / 30 V DC RO3A RO3B X5 EIA-485 Modbus RTU...
Page 220 220 Control unit R6…R9 Connection Term Description X1 Reference voltage and analog inputs and outputs Signal cable shield (screen) Output frequency reference: 0…10 V 1) 3) 1...10 kohm AGND Analog input circuit common +10V Reference voltage 10 V DC Not configured Max.
Page 221 Control unit 221 Connection Term Description RO1C Ready run 250 V AC / 30 V DC RO1A Ready run status RO1B RO2C Running Run status 250 V AC / 30 V DC RO2A RO2B Fault status RO3C Fault (-1) 250 V AC / 30 V DC RO3A RO3B X5 EIA-485 Modbus RTU...
Page 222 222 Control unit Notes: Current [0(4)…20 mA, R in = 100 ohm] or voltage [0(2)…10 V, R in >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 installed on the board.
Page 223: Additional Information On The Control Connections
Control unit 223 WARNING! Connect an external AC power supply (24 V AC) only to control unit connectors 40 and 41. If you connect it to connector AGND, DGND or SGND, damage to the power supply or control unit can occur. Additional information on the control connections ￭...
Page 224: Connecting Motor Temperature Sensors To The Drive
224 Control unit Connection examples are shown below. With signal ground reference terminal Without signal ground reference terminal 100 ohm Automation controller Drive Termination switch. The devices at the ends of the fieldbus must have termination on. All other devices must have termination off. Biasing switch.
Page 225: Npn Configuration For Digital Inputs (X2 & X3)
Control unit 225 Internal +24 V power supply External +24 V power supply PNP connection (source) PNP connection (source) X2 & X3 X2 & X3 +24V +24V 0 V DC DGND DGND +24 V DC DCOM DCOM WARNING! Do not connect the +24 V AC cable to the control unit ground when the control unit is powered from an external 24 V AC supply.
Page 226: Connection Examples Of Two-Wire And Three-Wire Sensors To Analog Input (Ai2)
226 Control unit 8 AO2 8 AO2 1 kohm 1 kohm 500 ohm 9 AGND 9 AGND ￭ Connection examples of two-wire and three-wire sensors to analog input (AI2) Note: The maximum capability of the auxiliary voltage output (24 V DC [250 mA]) must not be exceeded.
Page 227 Control unit 227 Note: Only 24 V DC can be used for STO. Only PNP input configuration can be used.
Page 228: Technical Data
228 Control unit Technical data R1…R5 External power supply Maximum power: 25 W, 1.04 A at 24 V AC/DC ±10% as standard through option module Terminal size: 0.2 … 2.5 mm 2 (24 … 14 AWG) CMOD-01 or CMOD-02 +24 V DC output Total load capacity of this outputs is 6.0 W (250 mA / 24 V) minus the power taken by the option modules installed on (Term.
Page 229 Control unit 229 Analog inputs AI1 and AI2 Current/voltage input mode selected with a parameter, see (Term. 2 and 5) Connecting motor temperature sensors to the drive (page 224). Current input: 0(4)…20 mA, R in : 100 ohm Voltage input: 0(2)…10 V, R in : > 200 kohm Terminal size: 0.14 …...
Page 230 230 Control unit Isolation areas AI/AO 24 V SLOT1 SLOT2 Panel port Fieldbus extension I/O extension Reinforced insulation (IEC/EN 61800-5-1:2007, UL 61800-5-1 First edition) Functional insulation (IEC/EN 61800-5-1:2007, UL 61800-5-1 First edition) Below altitudes 4000 m (13123 ft): 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...
Page 231 Control unit 231 Ground isolation diagram 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 *) Jumper installed at factory...
Page 232 232 Control unit R6…R9 External power supply Maximum power: 36 W, 1.50 A at 24 V AC/DC ±10% as standard Terminal size: 0.14 … 2.5 mm 2 (26 … 14 AWG) Term. 40, 41 +24 V DC oaroutput Total load capacity of this outputs is 6.0 W (250 mA / 24 V) minus the power taken by the option modules installed on (Term.
Page 233 Control unit 233 Analog inputs AI1 and AI2 Current/voltage input mode selected with a parameter, see (Term. 2 and 5) Connecting motor temperature sensors to the drive (page 224). Current input: 0(4)…20 mA, R in : 100 ohm Voltage input: 0(2)…10 V, R in : > 200 kohm Terminal size: 0.14 …...
Page 234 234 Control unit Isolation areas SLOT 1 1…3 4…6 7…8 10…12 24 V 13…15 16…18 34…38 EIA/R5-485 40, 41 Ext. 24 V SLOT 2 19…21 22…24 25…27 Panel port Power unit connection at the bottom of the con- trol unit Reinforced insulation (IEC/EN 61800-5-1:2007, UL 61800-5-1 First edition) Functional insulation (IEC/EN 61800-5-1:2007, UL...
Page 235 Control unit 235 Note: There is reinforced insulation on the power unit. Ground isolation diagram 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...
Page 237: Installation Checklist
Installation checklist 237 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 238 238 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 239 Installation checklist 239 Make sure that … The control cables are connected to the correct terminals, and the terminals are tightened to the correct torque. If a drive bypass connection will be used: The direct-on-line contactor of the motor and the drive output contactor are either mechanically and/or electrically interlocked, that is, they cannot be closed at the same time.
Page 241: Start-Up
Start-up 241 Start-up Contents of this chapter This chapter describes the start-up procedure of the drive. Reforming the capacitors The capacitors must be reformed if the drive has not been powered (either in storage or unused) for a year or more. The manufacturing date is on the type designation label.
Page 243: Maintenance
Contents of this chapter This chapter contains maintenance instructions. Maintenance intervals The tables below show the maintenance tasks which can be done by the end user. For ABB Service offering, refer to www.abb.com/drivesservices or consult your local ABB Service representative (www.abb.com/searchchannels).
Page 244 244 Maintenance Recommended annual actions by the user Action Description Capacitor reforming for spare modules and spare capacitors, see Capa- citors (page 261) Tightness of terminals Dustiness, corrosion or temperature Heatsink cleaning IP66 (UL Type 4X) frames R1…R3: Drive cover and gasket assembly Component Years from start-up Cooling...
Page 245 • 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 246: Cleaning The Exterior Of The Drive, Ip21 And Ip55
246 Maintenance Cleaning the exterior of the drive, IP21 and IP55 (UL Type 1 and UL Type 12) 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 247: Cleaning The Exterior Of The Drive, Ip66 (Ul Type 4X)
Maintenance 247 Cleaning the exterior of the drive, IP66 (UL Type 4X) IP66 (UL Type 4X) drives have a degree of protection against dust, dirt, precipitation, salt spray, splashing water and hose-directed spray. In addition, the drive has been tested to not be damaged by occasional exposure to common cleaners and disinfectants, algaecides and microbicides at concentrations recommended by the manufacturer for general use.
Page 248: Cleaning The Heatsink, Ip21, Ip55 (Ul Type 1, 12)
248 Maintenance Cleaning the heatsink, IP21, IP55 (UL Type 1, 12) 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.
Page 249: Cleaning The Heatsink, Ip 66 (Ul Type 4X)
Maintenance 249 Cleaning the heatsink, IP 66 (UL Type 4X) 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 Type 4X IP66 heatsinks as follows. Do not use this procedure for IP21 andIP 55 (UL Type 1 and 12) drives.
Page 250: Fans
250 Maintenance Fans Maintenance intervals (page 243) 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 251: Replacing The Main Cooling Fan, Ip21, Ip55 And Ip66 (Ul Type 1, Ul Type 12 And Ul Type 4X) Frames R1
Maintenance 251 ￭ Replacing the main cooling fan, IP21, IP55 and IP66 (UL Type 1, UL Type 12 and UL Type 4X) 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. Stop the drive and disconnect it from the power line.
Page 252 252 Maintenance 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 253: Replacing The Main Cooling Fan, Ip21 And Ip55 (Ul Type 1 And Ul Type 12) Frames R5
Maintenance 253 ￭ 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. Stop the drive and disconnect it from the power line.
Page 254: Replacing The Main Cooling Fans, Ip21 And Ip55 (Ul Type 1 And Ul Type 12) Frame R9
254 Maintenance ￭ 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. Stop the drive and disconnect it from the power line.
Page 255: Replacing The Auxiliary Cooling Fan, Ip21 And Ip55 (Ul Type 1 And Ul Type 12) Frames R6
Maintenance 255 ￭ 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. Stop the drive and disconnect it from the power line.
Page 256: Replacing The Auxiliary Cooling Fan, Ip55 (Ul Type 12) Frames R1
256 Maintenance ￭ 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. 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 257: Replacing The Auxiliary Cooling Fan, Ip55 And Ip66 (Ul Type 12 And Ul Type 4X) Frame R3
Maintenance 257 ￭ Replacing the auxiliary cooling fan, IP55 and IP66 (UL Type 12 and UL Type 4X) frame R3 WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. Stop the drive and disconnect it from the power line.
Page 258 258 Maintenance...
Page 259: Replacing The Auxiliary Cooling Fan, Ip55 (Ul Type 12) Frame R4; Ip21 And Ip55 (Ul Type 1 And Ul Type 12) Frame R5
Maintenance 259 ￭ 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 260: Replacing The Second Auxiliary Cooling Fan, Ip55 (Ul Type 12) Frames R8
260 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. 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 261: 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. ￭ Reforming the capacitors The capacitors must be reformed if the drive has not been powered (either in storage or unused) for a year or more.
Page 262: Leds
262 Maintenance LEDs ￭ Drive LEDs 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. The table below describes the drive LED indications. Drive LEDs POWER and FAULT, on the front of the drive, under the control panel / panel cover If a control panel is attached to the drive, switch to remote control (otherwise a fault...
Page 263: Control Panel Leds
Maintenance 263 ￭ Control panel LEDs The assistant 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 264: 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 265: Technical Data
Technical data 265 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.
Page 266: Electrical Ratings
266 Technical data Electrical ratings ￭ ACS580- Frame Input Max. Output ratings 01-… rating current Nominal use Light-duty use Heavy-duty use I max I Ld P Ld I Hd P Hd 3-phase U n = 230 V 04A7-2 0.75 0.75 0.55 06A7-2 0.75...
Page 267 Technical data 267 ACS580- Frame Input rating Output ratings 01-… A 1) 1-phase U n = 230 V 04A7-2 0.37 06A7-2 0.55 07A6-2 0.75 012A-2 018A-2 11.8 025A-2 17.3 032A-2 30.4 15.2 047A-2 060A-2 089A-2 115A-2 144A-2 18.5 171A-2 213A-2 276A-2 Continuous current, no overloadability See definitions and notes in section...
Page 268 268 Technical data ACS580- Frame Input Max. Output ratings 01-… rating current Nominal use Light-duty use Heavy-duty use I max I Ld P Ld I Hd P Hd 3-phase U n = 400 V (380…415 V) 02A7-4 0.75 0.75 03A4-4 04A1-4 05A7-4 07A3-4...
Page 269 Technical data 269 ACS580- Frame Input Max. Output ratings 01-… rating current Nominal use Heavy-duty use I max I Ld P Ld I Hd P Hd 3-phase U n = 480 V 02A7-4 0.75 0.55 0.75 03A4-4 0.75 04A1-4 05A7-4 07A3-4 09A5-4 12A7-4...
Page 270: Definitions
270 Technical data See definitions and notes in section Definitions (page 270) Definitions Nominal output voltage of the drive. For input voltage range [ U 1 , see section Electrical power network specification (page 342). 50 Hz for IEC ratings and 60 Hz for UL (NEC) ratings.
Page 271 Technical data 271 ACS580- Frame size Input Output ratings 01-… rating Max. Light-duty use Heavy-duty use current I max I Ld P Ld I Hd P Hd 10A6-2 10.6 14.3 10.6 017A-2 16.7 22.6 16.7 10.6 024A-2 24.2 32.7 24.2 16.7 031A-2 30.8...
Page 272 272 Technical data ACS580- Frame size Input rating Output ratings 01-… A 1) 031A-2 30.4 15.2 046A-2 059A-2 075A-2 R4 v2 075A-2 088A-2 090A-2 R4 v2 114A-2 143A-2 169A-2 211A-2 273A-2 343A-2 396A-2 ACS580- Frame size Input Output ratings 01-… rating Max.
Page 273 Technical data 273 ACS580- Frame size Input Output ratings 01-… rating Max. Light-duty use Heavy-duty use current I max I Ld P Ld I Hd P Hd 027A-4 27.0 41.4 27.0 20.0 21.0 15.0 034A-4 34.0 48.6 34.0 25.0 27.0 20.0 044A-4 44.0...
Page 274: Definitions
274 Technical data ACS580- Frame size Input Max. Output ratings 01-… rating current Light-duty use Heavy-duty use I max I Ld P Ld I Hd P Hd 09A0-6 12.2 011A-6 11.0 16.2 11.0 017A-6 17.0 23.0 17.0 11.0 022A-6 22.0 30.6 22.0 17.0...
Page 275: Ul Listed Multiple Ratings
P Hd Typical motor power in heavy-duty use (50% overload). UL listed multiple ratings Refer to the manual supplement Multiple ratings for ABB ACS380-04, ACS580-01, ACQ580-01 and ACS880-01 drives (3AXD50000916184 [English]). ￭ Conversion tables for IEC and North American type codes...
Page 276: Sizing
276 Technical data IEC type North American type Frame size ACS580-01-… ACS580-01-… 3-phase U n = 480 V 02A7-4 02A1-4 03A4-4 03A0-4 04A1-4 03A5-4 05A7-4 04A8-4 07A3-4 06A0-4 09A5-4 07A6-4 12A7-4 012A-4 018A-4 014A-4 026A-4 023A-4 033A-4 027A-4 039A-4 034A-4 046A-4 044A-4 062A-4...
Page 277: Deratings
Note: The ratings apply at ambient temperature of 40 °C (104 °F) for I for UL (NEC)). Above theses temperatures derating is required. Note: The DriveSize dimensioning PC tool available from ABB (http://new.abb.com/drives/software-tools/drivesize) is recommended for selecting the drive, motor and gear combination.
Page 278 278 Technical data Switching frequency derating by derating factor (page 283): No derating needed for 4 kHz. Altitude derating (page 282): The derating factor for 4921 ft (1500 m) is 1 - 1/10 000 m · (1500 - 1000) m = 0.95.
Page 279: Surrounding Air Temperature Derating, Ip21 (Ul Type 1)
Technical data 279 No derating needed for 35 °C ambient temperature. Referring to I in the ratings tables (starting from page 272), drive type ACS580-01-026A-4 exceeds the I requirement of 19.43 A. 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).
Page 280: Surrounding Air Temperature Derating, Ip55 (Ul Type 12)
280 Technical data -099A-6, -125A-6, -144A-6: In the temperature range +40…45 °C (+104…113 °F), the rated output current is not derated at all. In the temperature range +45…50 °C (+113…122 °F), the rated output current is derated by 1% for every added 1 °C (1.8 °F).
Page 281 Technical data 281 calculated by multiplying the current given in the rating table by the derating factor (k): 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;...
Page 282: 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 283: Switching Frequency Derating By Derating Factor
Technical data 283 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 284 284 Technical data Frame ACS580-01-… 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 0.74 047A-2…060A-2...
Page 285 Technical data 285 Frame ACS580-01-… 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 024A-2…031A-2 0.86 0.74 046A-2…059A-2 0.85 0.72 075A-2 0.86 0.74 R4 v2 075A-2…090A-2 0.65 0.47...
Page 286: Switching Frequency Derating With Actual Output Current Values
286 Technical data Frame ACS580-01-… 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 242A-6 0.83 0.66 0.50 271A-6 0.74 0.66 0.50 Switching frequency derating with actual output current values These tables show the output current values with different switching frequencies.
Page 287 Technical data 287 Frame ACS580- Nominal Nominal output current ( I 2 ) for the minimum switching size 01-… output frequencies at 40 °C (+104 °F) 1 kHz 2 kHz 4 kHz 8 kHz 12 kHz 16 kHz 3-phase U n = 400 V 02A7-4 03A4-4 04A1-4...
Page 288 288 Technical data UL (NEC) Nominal output current ( I 2 ) for the minimum switching Frame ACS580- Nominal size 01-… output frequencies 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...
Page 289 Technical data 289 Frame ACS580- Nominal Nominal output current ( I 2 ) for the minimum switching size 01-… output frequencies at 40 °C (+104 °F) 1 kHz 2 kHz 4 kHz 8 kHz 12 kHz 16 kHz 3-phase U 1 = 440…480 V, P n at U n = 480 V, 60 Hz 02A1-4 03A0-4 03A5-4...
Page 290: Output Frequency Derating
290 Technical data Frame ACS580- Nominal Nominal output current ( I 2 ) for the minimum switching size 01-… output frequencies at 40 °C (+104 °F) 1 kHz 2 kHz 4 kHz 8 kHz 12 kHz 16 kHz 3-phase U 1 = 500…600 V, P n at U n = 575 V, 60 Hz 02A7-6 03A9-6 06A1-6...
Page 291: Gg Fuses
0.5 seconds. Obey the local regulations. ACS580- Input gG (IEC 60269) Min. 01-… current short- I 2 t Nominal Voltage ABB type circuit current rating 60269 current size A 2 s 3-phase U n = 230 V 04A7-2 2500...
Page 292 292 Technical data ACS580- Input gG (IEC 60269) Min. 01-… current short- I 2 t Nominal Voltage ABB type circuit current rating 60269 current size A 2 s 276A-2 5500 110000 OFAF2H400 3-phase U n = 400 or 480 V...
Page 293: Ur And Ar Fuses
Technical data 293 ￭ uR and aR fuses ACS580- Input uR or aR (DIN 43620 blade style) Min. 01-… current short- I 2 t Nominal Voltage Bussmann IEC 60269 circuit current rating type size current A 2 s 3-phase U n = 230 V 04A7-2 170M1563 06A7-2...
Page 294 294 Technical data ACS580- Input uR or aR (DIN 43620 blade style) Min. 01-… current short- I 2 t Nominal Voltage Bussmann IEC 60269 circuit current rating type size current A 2 s 033A-4 32.0 1450 170M1565 039A-4 38.0 1450 170M1565 046A-4 45.0...
Page 295 Technical data 295 ACS580- Input uR or aR (DIN 43653 bolted tags) Min. 01-… current short- I 2 t Nominal Voltage Bussmann IEC 60269 circuit current rating type size current A 2 s 3-phase U n = 400 or 480 V 02A7-4 170M1311 03A4-4...
Page 296: Calculating The Short-Circuit Current Of The Installation
296 Technical data ￭ Calculating the short-circuit current of the installation Make sure that the short-circuit current of the installation is at least the value given in the fuse table. The short-circuit current of the installation can be calculated as follows: k2-ph 2 ·...
Page 297 Technical data 297 (430 V) · = 22.19 mohm · = 0.072 600 kVA m · 0.398 = 67.66 mohm = 170 m · 0.082 = 13.94 mohm = 170 410 V = 2.7 kA k2-ph 2 · (67.66 mohm) + (22.19 mohm + 13.94 mohm) The calculated short-circuit current 2.7 kA is higher than the minimum short-circuit current of the drive aR fuse type 170M3016 (1000 A).
Page 298: 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 299: Fuses (Ul)
1) Trip characteristic Z is recommended 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. For IP66 (UL Type 4X) drives that include the disconnect and fuse option, no branch circuit protection is required external to the drive.
Page 300 300 Technical data ACS580- Input current Maximum cur- Voltage rating Bussmann type 01-… rent class 3-phase U 1 = 200…240 V, P n at U n = 208/230 V, 60 Hz 04A6-2 JJS-15 06A6-2 JJS-15 07A5-2 JJS-15 10A6-2 10.6 JJS-15 017A-2 16.7 JJS-30...
Page 301 Technical data 301 ACS580- Input current Maximum cur- Voltage rating Bussmann type 01-… rent class 027A-4 27.0 JJS-40 034A-4 34.0 JJS-60 044A-4 44.0 JJS-60 052A-4 JJS-80 065A-4 JJS-100 077A-4 JJS-110 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...
Page 302 2. Fuses with a higher current rating than specified must not be used. 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.
Page 303: Circuit Breakers (Ul)
Circuit breakers are not required to be in the same enclosure as the drive. Notes below the tables must be followed when using these breakers. ACS580- Frame Input Enclosure Drive ABB circuit breaker 01-… size current maximum voltage minimum volume...
Page 304 304 Technical data ACS580- Frame Input Enclos- Drive ABB circuit breaker Maximum Maximum 01-… size cur- maxim- voltage volume peak rent umcur- minim- rent volume 65 kA @ 240 V 3-phase U = 440…480 V, P at U = 480 V, 60 Hz...
Page 305 Technical data 305 ACS580- Frame Input CB max- Enclos- Drive ABB circuit breaker Maximum Maximum 01-… size current imum voltage ure min- volume peak current imum volume 65 kA @ 240 V 3-phase U = 500…600 V, P at U...
Page 306 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 307: Dimensions, Weights And Free Space Requirements
I and I t are the same or less than the ABB specified circuit breaker. peak 13. For 480 V and 600 V drives: Do not use non-current limiting inverse time circuit breakers.
Page 308 308 Technical data Frame Dimensions and weights size IP21 UL Type 1 Weight Weight 42.4 21.57 21.63 28.62 23.20 9.92 14.53 93.5 23.62 23.67 34.65 25.25 11.18 14.57 119.1 26.77 26.66 37.99 28.39 11.81 15.47 152.1 26.77 26.77 37.60 29.19 14.96 16.46 213.9...
Page 309 Technical data 309 IP21 (UL Type 1), R1…R2, R5…R9 Symbols IP21 / UL Type 1 R5.…R9: Height back without cable/conduit box R5.…R9: Height front without cable/conduit box 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 310 310 Technical data IP55 (UL Type 12) , R3…R4 IP55 (UL Type 12) , R1…R2, R5…R9 1) IP55 / UL Type 12 without hood 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...
Page 311 Technical data 311 Symbols Hood height Hood width 1) See H3 and H4 location for R1…R2 in the figure on page Frame Dimensions and weights size IP66 UL Type 4X Weight Weight 11.8 20.55 8.19 9.79 11.05 14.5 23.86 8.19 10.22 11.48 26.4...
Page 312 312 Technical data Frame Dimensions and weights size IP66 with sun shield UL Type 4X with sun shield Weight Weight 15.1 24.35 11.98 16.00 17.7 27.66 11.98 16.00 34.3 29.27 15.60 16.40 IP66 (UL Type 4X), R1…R3 with sun shield Symbols Height back with cable/conduit box Width...
Page 313: Dimensions With Flange
Technical data 313 ￭ Dimensions with flange Frame Dimensions with flange option kit (+C135), IP21 (UL Type 1) & UL Type 12 size IP55 (UL Type 12) hood 18.15 8.12 5.22 4.28 4.95 21.69 8.12 5.13 4.51 4.95 24.13 11.42 4.65 4.58 7.53...
Page 314 314 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) Frame Dimensions with flange option kit (+C135), IP66 (UL Type 4X) size 25.32 10.71 5.41 3.88 0.35 28.55 10.71 5.42...
Page 315 Technical data 315 IP66 (UL Type 4X), R1…R3 with flange option Symbols kit (+C135) Height back with cable/conduit box Width Depth of the drive inwards from the mounting surface of the flange plate Depth of the drive outwards from the outer surface of the flange plate Thickness of the flange plate Note:...
Page 316 316 Technical data Frame Free space, IP21 (UL Type 1) size Vertical mounting stand alone Vertical mounting side by side Above Below Beside Above Between Below 2.56 3.39 5.91 7.87 7.87 2.56 3.39 5.91 7.87 7.87 2.56 2.09 5.91 7.87 7.87 2.09 7.87...
Page 317 3) Free space below is always measured from the drive frame, not from the cable box. 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 318: Losses, Cooling Data And Noise
The heat loss values can vary depending on voltage, cable conditions, motor efficiency and power factor. To obtain more accurate values for given conditions, use ABB DriveSize tool (http://new.abb.com/drives/software-tools/drivesize). IEC - IP21 and IP55 (UL Type 1 and 12)
Page 319 Technical data 319 ACS580- Air flow Noise Frame size Typical heat dissipa- 01-… tion m 3 /h BTU/h dB(A) 012A-2 018A-2 025A-2 032A-2 1225 047A-2 1819 060A-2 2665 089A-2 2989 091A-2 R4 v2 115A-2 1285 4385 144A-2 1932 6592 171A-2 2000 6824 213A-2...
Page 320: Iec - Ip66 (Ul Type 4X)
320 Technical data ACS580- Air flow Noise Frame size Typical heat dissipa- 01-… tion m 3 /h BTU/h dB(A) 088A-4 1139 3886 089A-4 1059 3613 R4 v2 106A-4 1290 4402 145A-4 1960 6688 169A-4 2021 6896 206A-4 2785 9503 246A-4 3131 10683 293A-4...
Page 321: Ul (Nec) - Ip21 And Ip55 (Ul Type 1 And 12)
Technical data 321 ACS580-01-… Air flow Noise Frame size Typical heat dissipa- tion m 3 /h BTU/h dB(A) 05A7-4+B063 07A3-4+B063 09A5-4+B063 12A7-4+B063 018A-4+B063 026A-4+B063 1303 033A-4+B063 1658 039A-4+B063 1764 046A-4+B063 2276 1) When disconnect option is included, add 5 W (17 BTU/h) for R1 and R2; add 12 W for R3 (41 BTU/h) UL (NEC) - IP21 and IP55 (UL Type 1 and 12) ACS580- Air flow...
Page 322 322 Technical data ACS580- Air flow Noise Frame size Typical heat dissipa- 01-… tion m 3 /h BTU/h dB(A) 143A-2 1916 6538 169A-2 1965 6705 211A-2 2809 9585 273A-2 3518 12004 343A-2 2547 8691 1150 396A-2 3060 10441 1150 3-phase U 1 = 440…480 V, P n at U n = 480 V, 60 Hz 02A1-4 03A0-4 03A5-4...
Page 323 Technical data 323 ACS580- Air flow Noise Frame size Typical heat dissipa- 01-… tion m 3 /h BTU/h dB(A) 302A-4 3253 11100 1150 361A-4 4836 16501 1150 414A-4 5691 19418 1150 3-phase U 1 = 525…600 V, P n at U n = 575 V, 60 Hz 02A7-6 03A9-6 06A1-6...
Page 324: Ul (Nec) - Ip66 (Ul Type 4X)
324 Technical data UL (NEC) - IP66 (UL Type 4X) ACS580-01-… Air flow Noise Frame size Typical heat dissipa- tion m 3 /h BTU/h dB(A) 3-phase U 1 = 200…240 V, P n at U n = 208/230 V, 60 Hz 04A6-2+B066 06A6-2+B066 07A5-2+B066...
Page 325: Cooling Air Flow And Heat Dissipation For Flange Mounting (Option +C135)
Technical data 325 ACS580-01-… Air flow Noise Frame size Typical heat dissipa- tion m 3 /h BTU/h dB(A) 022A-6 +B066 1467 027A-6 +B066 1788 032A-6 +B066 2112 1) When disconnect and fuse option is included, add 8 W (27 BTU/h) for R1; 11 W (38 BTU/h) for R2; 24 W (82 BTU/h) for R3 ￭...
Page 326: Iec - Ip66 (Ul Type 4X)
326 Technical data ACS580- Heat dissipation Air flow (+C135) Frame 01-… (+C135) size Heatsink Front Heatsink Front m 3 /h m 3 /h 073A-4 R4 v2 088A-4 089A-4 R4 v2 106A-4 1099 145A-4 1733 169A-4 1758 206A-4 2464 246A-4 2743 293A-4 3601 363A-4...
Page 327: Ul (Nec) - Ip21 And Ip55 (Ul Type 1 And 12)
Technical data 327 ACS580-01-… Heat dissipation Air flow (+C135) Frame size (+C135) Heatsink Front Heatsink Front m 3 /h m 3 /h 03A4-4+B063 04A1-4+B063 05A7-4+B063 07A3-4+B063 09A5-4+B063 12A7-4+B063 018A-4+B063 026A-4+B063 033A-4+B063 039A-4+B063 046A-4+B063 UL (NEC) - IP21 and IP55 (UL Type 1 and 12) ACS580- Heat dissipation Air flow (with flange kit)
Page 328: Ul (Nec) - Ip66 (Ul Type 4X)
328 Technical data ACS580- Heat dissipation Air flow (with flange kit) Frame 01-… (with flange kit) size Heatsink Front Heatsink Front m 3 /h m 3 /h 044A-4 052A-4 052A-4 R4 v2 065A-4 065A-4 R4 v2 077A-4 R4 v2 078A-4 096A-4 1099 124A-4...
Page 329 Technical data 329 ACS580-01-… Heat dissipation Air flow (+C135) Frame size (+C135) Heatsink Front Heatsink Front m 3 /h m 3 /h 031A-2+B066 046A-2+B066 059A-2+B066 3-phase U 1 = 440…480 V, P n at U n = 480 V, 60 Hz 02A1-4 +B066 03A0-4 +B066 03A5-4 +B066...
Page 330: Terminal And Entry Data For The Power Cables
330 Technical data Terminal and entry data for the power cables ￭ Input (except IP66 (UL Type 4X) with disconnect), motor, resistor and DC cable entries, maximum wire sizes (per phase) and terminal screw sizes and tightening torques ( T ) are given below. Frame Cable L1, L2, L3, T1/U, T2/V, T3/W terminals...
Page 331 Technical data 331 2) Note: Minimum wire size does not necessarily have enough current capability for full load. Make sure the installation complies with local laws and regulations. 3) Note: Either cable lug (R5, see page 152) or clamp (R6…R9, see page 155) is used for grounding. For IP66 (UL Type 4X) with disconnect option, input cable entries, maximum wire sizes (per phase), terminal screw sizes and tightening torques (T) are given below.
Page 332 332 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/Bol t N·m R4 v2 1.5/1.5 2×50 2×150 3-phase U n = 400 or 480 V 0.20/0.25...
Page 333: Ul (Nec)
Technical data 333 ￭ UL (NEC) Input (except IP66 (UL Type 4X) with disconnect), motor, resistor and DC cable entries, maximum wire sizes (per phase) and terminal screw sizes and tightening torques ( T ) are given below. Frame Cable L1, L2, L3, T1/U, T2/V, T3/W terminals Grounding terminals size...
Page 334 334 Technical data 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 3-phase U 1 = 525…600 V, P n at U n = 575 V, 60 Hz 1.38 1.73 2.01...
Page 335 Technical data 335 Frame Cable entries 2T1, 4T2, 6T3 Terminals Grounding terminals size Min. wire size Max. wire size Max. wire Ø cable (solid/stran- size (solid/stran- type ded) ded) lbf·ft lbf·ft 0.87 0.87 1.12 1) Diameter of the cable entry plate hole. 2) Note: Minimum wire size does not necessarily have enough current ampacity for full load.
Page 336 336 Technical data Frame Cable entries R+, R-, UDC+ and UDC- terminals size Per cable Ø Wire range size (stranded/solid) type Screw/Bol t lbf·ft 1.11 1.11 1.38 1.73 R4 v2 1.73 1.73 11.1 1.97 300 MCM 22.1 2.44 500 MCM 29.5 2.44 2×1/0...
Page 337: Power Cables
Technical data 337 Power cables ￭ Typical power cables, IEC 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. See page for the cable entry sizes allowed for the selected drive frame size.
Page 338: Typical Power Cables Ul (Nec)
338 Technical data ACS580-01-… Frame size Cu cable type AI cable type mm 2 mm 2 12A7-4 3×2.5 + 2.5 018A-4 3×2.5 + 2.5 026A-4 3×6 + 6 033A-4 3×10 + 10 039A-4 3×10 + 10 046A-4 3×10 + 10 062A-4 R4, R4 v2 3×25 + 16...
Page 339 Technical data 339 ACS580-01-… Frame size Cu cable type AWG/kcmil 017A-2 024A-2 031A-2 046A-2 059A-2 075A-2 R4, R4 v2 090A-2 R4 v2 088A-2 114A-2 143A-2 169A-2 211A-2 300 MCM 273A-2 2×2/0 343A-2 2×250 MCM 396A-2 2×300 MCM 3-phase U 1 = 440…480 V, P n at U n = 480 V, 60 Hz 02A1-4 03A0-4 03A5-4...
Page 340 340 Technical data ACS580-01-… Frame size Cu cable type AWG/kcmil 077A-4 R4 v2 078A-4 096A-4 124A-4 156A-4 180A-4 240A-4 2×1/0 or 350 MCM 260A-4 2×2/0 302A-4 2×3/0 361A-4 2×4/0 414A-4 2×300 MCM 3-phase U 1 = 525…600 V, P n at U n = 575 V, 60 Hz 02A7-6 03A9-6 06A1-6...
Page 341: Terminal And Entry Data For The Control Cables
Technical data 341 ACS580-01-… Frame size Cu cable type AWG/kcmil 271A-6 2×250 MCM Temperature: For IEC, select a cable rated for at least 70 °C maximum permissible temperature of conductor in continuous use. For North America, power cables must be rated for 75 °C (167 °F) or higher. Note: For drives with option +B056 (IP55, UL Type 12), select a cable rated for at least 90 °C (194 °F) maximum permissible temperature of conductor in continuous use.
Page 342: Ul (Nec)
342 Technical data ￭ UL (NEC) Control cable entries, wire sizes and tightening torques (T) are given below. 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...
Page 343 Technical data 343 Network type Public low voltage networks. Symmetrically grounded TN- S system, IT (ungrounded), corner-grounded delta, mid- point-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 132) Guidelines for in- stalling the drive to a TT system (page...
Page 344 344 Technical data Minimum short-circuit power The minimum short-circuit power Sce given for each drive (IEC/EN 61000-3-12) type for the Rsce (transformer short circuit ratio) value of 350. ACS580- Input rat- Min. short circuit Frame 01-… power size 400 V 480 V 3-phase U n = 400 V and 480 V, IEC ratings 02A7-4...
Page 345: Motor Connection Data
Technical data 345 Motor connection data Motor types Asynchronous AC induction motors, permanent magnet motors and synchronous reluctance motors Short-circuit current protec- The drive provides solid state short circuit protection for tion (IEC/EN 61800-5-1) the motor connection per IEC/EN 61800-5-1 and UL 61800- 5-1.
Page 346 Longer motor cables cause a motor voltage decrease which limits the available motor power. The decrease depends on the motor cable length and characteristics. Contact your local ABB representative for more inform- ation. When using longer motor cables than 50 m (165 ft), 8 and 12 kHz switching frequencies are not allowed.
Page 347 Technical data 347 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 348: Brake Resistor Connection Data For Frames R1
348 Technical data Note: Radiated and conducted emissions are according to category C2 with an internal EMC filter. The internal EMC filter must be connected. Categories C1 and C2 meet requirements for connecting equipment to the public low-voltage networks. Not applicable to 600 V ratings. Radiated and conducted emissions are according to category C3 with an internal EMC filter.
Page 349: Energy Efficiency Data (Ecodesign)
Technical data 349 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) (IEC/EN 60529) IP20 (option +P940, +P944) IP55 (option +B056) Enclosure types (UL...
Page 350: Ambient Conditions
350 Technical data Ambient conditions Environmental limits for the drive are given below. The drive is to be used in a heated, indoor, controlled environment . All printed circuit boards are conformal coated. Operation Storage Transportation installed for in the package in the package stationary use Installation site altitude...
Page 351: Storage Conditions
IP66 (UL Type 4X) drive can be used outdoors if protected from the heat of the sun and indoors or outdoors in a dusty environment. Note: There are special considerations in corner-grounded installations above 2000 m. Contact your local ABB representative for further information. Storage conditions Store the drive in humidity controlled enclosed environments. Keep the drive in...
Page 352: Colors
352 Technical data Colors Drive enclosure • NCS 1502-Y (RAL 9002 / PMS 1C Cool Grey), RAL 9002 and PMS 425 C. • NCS 1502-Y Materials ￭ Drive Refer to ACx580-01 drives recycling instructions and environmental information (3AXD50000040612 [English]). ￭ Package materials for small wall-mounted drives and converter modules •...
Page 353: Materials Of Manuals
Substances of Concern In articles as such or in complex objects (Products) established under the Waste Framework Directive (2008/98/EC). For further information, contact your local ABB distributor or consult European Chemicals Agency's SCIP database to find out which SVHCs are used in the drive, and to find out where those components are located.
Page 354: Markings
354 Technical data IEC 61000-3-2:2018, Electromagnetic compatibility (EMC) – Limits for harmonic current emissions (input current > 16 A per phase) EN 61000-3-2:2014 EN 61000-3-12:2011 Electromagnetic compatibility (EMC) – Limits for harmonic currents produced by equipment connected to public low- voltage systems with input current input current >...
Page 355 Product is compliant with the People’s Republic of China Electronic Industry Standard (SJ/T 11364-2014) about hazardous substances. The EFUP is 20 years. China RoHS II Declaration of Conformity is available from https://library.abb.com. UKCA (UK Conformity Assessed) mark Product complies with the applicable United Kingdom’s legislation (Statutory In- struments).
Page 356: Ce Marking
356 Technical data Note: The ACS580-01 230 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. CE marking A CE mark is attached to the drive to verify that the drive follows the provisions of the European Low Voltage, EMC and RoHS Directives.The CE marking also verifies that the drive, in regard to its safety functions (such as Safe torque off), conforms with the Machinery Directive as a safety component.
Page 357: Validating The Operation Of The Safe Torque Off Function
Technical data 357 Validating the operation of the Safe torque off function See chapter The Safe torque off function (page 409). 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.
Page 358: Category C2
358 Technical data WARNING! In a domestic environment, this product may cause radio inference, in which case supplementary mitigation measures may be required. ￭ Category C2 The emission limits are complied with the following provisions: The motor and control cables are selected as specified in this manual. 2.
Page 359: Category C4
Technical data 359 WARNING! A drive of category C3 is not intended to be used on a low-voltage public network which supplies domestic premises. Radio frequency interference is expected if the drive is used on such a network. ￭ Category C4 The drive complies with the C4 category with these provisions: It is made sure that no excessive emission is propagated to neighboring low-voltage networks.
Page 360: Ul Checklist
360 Technical data 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 361: Design Lifetime Expectancy
Technical data 361 Suitable UL fuses are listed in section Fuses (UL) (page 299) and circuit breakers in section Circuit breakers (IEC) (page 298). WARNING! The opening of the branch-circuit protective device may be an indication that a fault current has been interrupted. To reduce the risk of fire or electric shock, current-carrying parts and other components of the device should be examined and replaced if damaged.
Page 362 ABB and its affiliates are not liable for damages and/or losses related to such security breaches, any unauthorized access, interference, intrusion, leakage and/or...
Page 363: Dimension Drawings
Dimension drawings 363 Dimension drawings Contents of this chapter This chapter shows the dimension drawings of the ACS580-01. Note: The dimensions are given in millimeters and [inches].
Page 364: Frame R1, Ip21 (Ul Type 1)
364 Dimension drawings Frame R1, IP21 (UL Type 1)
Page 365: Frame R1, Ip55 (Ul Type 12)
Dimension drawings 365 Frame R1, IP55 (UL Type 12)
Page 366: Frame R1, Ip55+F278 (Ul Type 12)
366 Dimension drawings Frame R1, IP55+F278 (UL Type 12)
Page 367: Frame R1, Ip66 (Ul Type 4X) +B066
Dimension drawings 367 Frame R1, IP66 (UL Type 4X) +B066...
Page 368: Frame R1, Ip66 (Ul Type 4X) +B063
368 Dimension drawings Frame R1, IP66 (UL Type 4X) +B063...
Page 369: Frame R1, Ip66 (Ul Type 4X) +C193
Dimension drawings 369 Frame R1, IP66 (UL Type 4X) +C193...
Page 370: Frame R2, Ip21 (Ul Type 1)
370 Dimension drawings Frame R2, IP21 (UL Type 1)
Page 371: Frame R2, Ip55 (Ul Type 12)
Dimension drawings 371 Frame R2, IP55 (UL Type 12)
Page 372: Frame R2, Ip55+F278 (Ul Type 12)
372 Dimension drawings Frame R2, IP55+F278 (UL Type 12)
Page 373: Frame R2, Ip66 (Ul Type 4X) +B066
Dimension drawings 373 Frame R2, IP66 (UL Type 4X) +B066...
Page 374: Frame R2, Ip66 (Ul Type 4X) +B063
374 Dimension drawings Frame R2, IP66 (UL Type 4X) +B063...
Page 375: Frame R2, Ip66 (Ul Type 4X) +C193
Dimension drawings 375 Frame R2, IP66 (UL Type 4X) +C193...
Page 376: Frame R3, Ip21 (Ul Type 1)
376 Dimension drawings Frame R3, IP21 (UL Type 1)
Page 377: Frame R3, Ip55 (Ul Type 12)
Dimension drawings 377 Frame R3, IP55 (UL Type 12)
Page 378: Frame R3, Ip55+E223 (Ul Type 12)
378 Dimension drawings Frame R3, IP55+E223 (UL Type 12)
Page 379: Frame R3, Ip55+F278/F316 (Ul Type 12)
Dimension drawings 379 Frame R3, IP55+F278/F316 (UL Type 12)
Page 380: Frame R3, Ip66 (Ul Type 4X) +B066
380 Dimension drawings Frame R3, IP66 (UL Type 4X) +B066...
Page 381: Frame R3, Ip66 (Ul Type 4X) +B063
Dimension drawings 381 Frame R3, IP66 (UL Type 4X) +B063...
Page 382: Frame R3, Ip66 (Ul Type 4X) +C193
382 Dimension drawings Frame R3, IP66 (UL Type 4X) +C193...
Page 383: Frame R4, Ip21 (Ul Type 1)
Dimension drawings 383 Frame R4, IP21 (UL Type 1)
Page 384: Frame R4, Ip55 (Ul Type 12)
384 Dimension drawings Frame R4, IP55 (UL Type 12)
Page 385: Frame R4, Ip55+E223 (Ul Type 12)
Dimension drawings 385 Frame R4, IP55+E223 (UL Type 12)
Page 386: Frame R4, Ip55+F278/F316 (Ul Type 12)
386 Dimension drawings Frame R4, IP55+F278/F316 (UL Type 12)
Page 387: Frame R5, Ip21 (Ul Type 1)
Dimension drawings 387 Frame R5, IP21 (UL Type 1)
Page 388: Frame R5, Ip55 (Ul Type 12)
388 Dimension drawings Frame R5, IP55 (UL Type 12)
Page 389: Frame R5, Ip55+E223 (Ul Type 12)
Dimension drawings 389 Frame R5, IP55+E223 (UL Type 12)
Page 390: Frame R5, Ip55+F278/F316 (Ul Type 12)
390 Dimension drawings Frame R5, IP55+F278/F316 (UL Type 12)
Page 391: Frame R6, Ip21 (Ul Type 1)
Dimension drawings 391 Frame R6, IP21 (UL Type 1)
Page 392: Frame R6, Ip55 (Ul Type 12)
392 Dimension drawings Frame R6, IP55 (UL Type 12)
Page 393: Frame R7, Ip21 (Ul Type 1)
Dimension drawings 393 Frame R7, IP21 (UL Type 1)
Page 394: Frame R7, Ip55 (Ul Type 12)
394 Dimension drawings Frame R7, IP55 (UL Type 12)
Page 395: Frame R8, Ip21 (Ul Type 1)
Dimension drawings 395 Frame R8, IP21 (UL Type 1)
Page 396: Frame R8, Ip55 (Ul Type 12)
396 Dimension drawings Frame R8, IP55 (UL Type 12)
Page 397: Frame R9, Ip21 (Ul Type 1)
Dimension drawings 397 Frame R9, IP21 (UL Type 1)
Page 398: Frame R9, Ip55 (Ul Type 12)
398 Dimension drawings Frame R9, IP55 (UL Type 12)
Page 399: Resistor Braking
Resistor braking 399 Resistor braking Contents of this chapter This chapter contains information and instructions on resistor braking, brake choppers and brake resistors. 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 400 400 Resistor braking 4. Select the resistor so that the following conditions are met: • The rated power of the resistor must be greater than or equal to P Rmax • Resistance R must be between R and R given in the table for the used drive type.
Page 401 Resistor braking 401 ACS580-01-… R min R max P BRmax Reference resistor types 047A-2 SAFUR90F575 060A-2 SAFUR90F575 3-phase U n = 400 or 480 V 02A7-4 Danotherm CBH 360 C T 406 210R 03A4-4 Danotherm CBH 360 C T 406 210R 04A1-4 Danotherm CBH 360 C T 406 210R 05A7-4...
Page 402 402 Resistor braking ACS580-01-… R min R max P BRmax Reference resistor types 02A1-4 Danotherm CBH 360 C T 406 210R 03A0-4 Danotherm CBH 360 C T 406 210R 03A5-4 Danotherm CBH 360 C T 406 210R 04A8-4 Danotherm CBH 360 C T 406 210R 06A0-4 Danotherm CBR-V 330 D T 406 78R UL 07A6-4...
Page 403: Selecting And Routing The Brake Resistor Cables
IGBT semiconductors of the brake chopper. 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 404: Protecting The System In Brake Circuit Fault Situations
(1) inside the resistor assembly. The switch indicates overtemperature. 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.
Page 405: Mechanical Installation
Resistor braking 405 ￭ 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 Brake resistor assembly for R1…R3 (page 131) Brake resistor assembly for R1…R3 (page 175) (North America).
Page 406: Resistor Braking, Frames R4
406 Resistor braking WARNING! If you disable the brake chopper by parameter, also disconnect the brake resistor cable from the drive. Otherwise, there is a risk of resistor overheating and damage. Resistor braking, frames R4…R9 ￭ Planning the braking system Frames R4…R9 need external brake choppers and resistors.
Page 407: Ul (Nec)
Resistor braking 407 UL (NEC) ACS580-01-… R min R max P BRmax Reference resistor types 3-phase U 1 = 208…240 V, P n at U n = 208/230 V 075A-2 SAFUR125F500 088A-2 SAFUR125F500 114A-2 SAFUR125F500 143A-2 SAFUR200F500 169A-2 SAFUR200F500 211A-2 2xSAFUR210F575 273A-2 2xSAFUR210F575...
Page 408: Parameter Settings For External Braking Chopper And Resistor
408 Resistor braking ACS580-01-… R min R max P BRmax Reference resistor types 099A-6 11.5 SAFUR80F500 125A-6 SAFUR80F500 144A-6 SAFUR80F500 192A-6 SAFUR125F500 242A-6 2xSAFUR200F500 271A-6 2xSAFUR200F500 Symbols R min = minimum allowed brake resistor that can be connected to the brake chopper R max = maximum allowed brake resistor that allows P BRmax P BRmax...
Page 409: The Safe Torque Off Function
The Safe torque off function 409 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 410: Compliance With The European Machinery Directive And The Uk Supply Of Machinery (Safety) Regulations
410 The Safe torque off function The Safe torque off function complies with these standards: Standard Name IEC 60204-1:2021 Safety of machinery – Electrical equipment of machines – Part 1: General requirements EN 60204-1:2018 IEC 61000-6-7:2014 Electromagnetic compatibility (EMC) – Part 6-7: Generic standards –...
Page 411: Wiring
The Safe torque off function 411 Wiring For the electrical specifications of the STO connection, see the technical data of the control unit. ￭ Connection principle Single ACS580-01 drive, internal power supply OUT1 + 24 V DC OUT2 + 24 V DC SGND UDC+ UDC-...
Page 412: Single Acs580-01 Drive, External Power Supply
412 The Safe torque off function Single ACS580-01 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 Single ACS580-01 drive, internal power supply OUT1 OUT2...
Page 413: Single Acs580-01 Drive, External Power Supply
The Safe torque off function 413 Safety PLC Safety relay Single ACS580-01 drive, external power supply 24 V DC OUT1 OUT2 SGND Drive Safety PLC Safety relay...
Page 414: Multiple Acs580-01 Drives, Internal Power Supply
414 The Safe torque off function Multiple ACS580-01 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 415: Multiple Acs580-01 Drives, External Power Supply
The Safe torque off function 415 Multiple ACS580-01 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 416: Activation Switch
A CPTC thermistor protection module or an FSPS safety functions module can also be used. For more information, see the module documentation. ￭ 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 417: Operation Principle
The Safe torque off function 417 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 418: Start-Up Including Validation Test
418 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 419 The Safe torque off function 419 Action Close the disconnector and switch the power on. Test the operation of the STO function when the motor is stopped. • Give a stop command for the drive (if running) and wait until the motor shaft is at a standstill.
Page 420: Use
420 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 421 The Safe torque off function 421 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 422: 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 418). Use only spare parts approved by ABB. Record all maintenance and proof test activities in the machine logbook. ￭ Competence...
Page 423: 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 424: Safety Data
424 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 425 The Safe torque off function 425...
Page 426 426 The Safe torque off function...
Page 427: Terms And Abbreviations
The Safe torque off function 427 • The STO is a type A safety component as defined in IEC 61508-2. • Relevant failure modes: • The STO trips spuriously (safe failure) • The STO does not activate when requested • A fault exclusion on the failure mode “short circuit on printed circuit board”...
Page 428: Tüv Certificate
IEC 61508-6 Dangerous failure rate (per hour) of the diagnostics function of STO λ Diag_s IEC 61508-6 Safe failure rate (per hour) of the diagnostics function of STO ￭ TÜV certificate The TÜV certificate is available on the Internet at www.abb.com/drives/documents.
Page 429: Declarations Of Conformity
The product(s) referred in this Declaration of conformity fulfil(s) the relevant provisions of other European Union Directives which are notified in Single EU Declaration of conformity 3AXD10000497690. Authorized to compile the technical file: ABB Oy, Hiomotie 13, 00380 Helsinki, Finland. Helsinki, August 31, 2022...
Page 430 The product(s) referred in this declaration of conformity fulfil(s) the relevant provisions of other UK statutory requirements, which are notified in a single declaration of conformity 3AXD10001325742. Authorized to compile the technical file: ABB Limited, Daresbury Park, Cheshire, United Kingdom, WA4 4BT. Helsinki, August 31, 2022...
Page 431: Optional I/O Extension And Adapter Modules
Optional I/O extension and adapter modules 431 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 and CBAI-01 adapter module.
Page 432: Layout
432 Optional I/O extension and adapter modules ￭ Layout 1, 2, 3 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 signal AGND Analog ground potential SHIELD...
Page 433: Mechanical Installation
Optional I/O extension and adapter modules 433 ￭ Mechanical installation Necessary tools • Screwdriver and a set of suitable bits. Unpacking and examining the delivery Open the option package. Make sure that the package contains: • the option module • a mounting screw.
Page 434: Start-Up
434 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 435: Diagnostics
Optional I/O extension and adapter modules 435 ￭ 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 436: Isolation Areas
436 Optional I/O extension and adapter modules Isolation areas Plugged to drive control unit SLOT 2 Reinforced insulation (IEC 61800-5-1:2007)
Page 437: Dimension Drawings
Optional I/O extension and adapter modules 437 ￭ Dimension drawings The dimensions are in millimeters.
Page 438: Cbai-01 Bipolar Analog Io Adapter Module
438 Optional I/O extension and adapter modules CBAI-01 bipolar analog IO adapter module ￭ Contents of this chapter This chapter describes how to install and start up the optional CBAI-01 adapter module. The chapter also contains diagnostics and technical data. ￭...
Page 439: Mechanical Installation
Optional I/O extension and adapter modules 439 Analog output scale switch (2) Grounding hole Control unit SLOT 2 interface Diagnostic LED Grounding hole ￭ Mechanical installation Necessary tools • Screwdriver and a set of suitable bits. Unpacking and examining the delivery Open the option package.
Page 440: Start-Up
440 Optional I/O extension and adapter modules CBAI-01 CCU-23/24 0...10 V +10 V AI3+ AI3- -10 V AGND AGND 0...10 V +10 V AI4+ AI4- AGND -10 V AGND ￭ Start-up Setting the parameters Power up the drive. 2. Verify that the diagnostic LED is on. Parameter setting example for AI1 This example shows how to set the control unit parameters for a bipolar speed reference ranging from -50 Hz to 50 Hz, with detection of a wire break between...
Page 441: Diagnostics
Optional I/O extension and adapter modules 441 ￭ Diagnostics LEDs The adapter module has one diagnostic LED. Color Description Green The adapter module is powered up. ￭ Technical data Installation Into SLOT 2 on the drive control unit Degree of protection IP20 Ambient conditions See the drive technical data.
Page 442: Dimension Drawing
364 Optional I/O extension modules 442 Optional I/O extension and adapter modules Isolation areas: CBAI-01 Symbol Description Plugged to drive control unit SLOT2 Plugged to drive SLOT2 SWITCH Switch Reinforced insulation (IEC 61800-5-1:2007) Reinforced insulation (IEC 61800-5-1:2007) Functional insulation (IEC 61800-5-1:2007) Functional insulation (IEC 61800-5-1:2007) Analog inputs (80...82, 83...85) ￭...
Page 443: Chdi-01 115/230 V Digital Input Extension Module
Optional I/O extension and adapter modules 443 CHDI-01 115/230 V digital input extension module ￭ Contents of this chapter This chapter describes how to install and start up the optional CHDI-01 multifunction extension module. The chapter also contains diagnostics and technical data.
Page 444: Layout And Connection Examples
444 Optional I/O extension and adapter modules ￭ 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 445: Mechanical Installation
Optional I/O extension and adapter modules 445 ￭ Mechanical installation Necessary tools • Screwdriver and a set of suitable bits. Unpacking and examining the delivery Open the option package. Make sure that the package contains: • the option module • a mounting screw.
Page 446: Fault And Warning Messages
446 Optional I/O extension and adapter modules 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. Parameter Setting 15.07 RO4 source...
Page 447: Dimension Drawing
Optional I/O extension and adapter modules 447 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 448: Cmod-01 Multifunction Extension Module (External 24 V Ac/Dc And Digital I/O)
448 Optional I/O extension and adapter modules CMOD-01 multifunction extension module (external 24 V AC/DC and digital I/O) ￭ Contents of this chapter This chapter describes how to install and start up the optional CMOD-01 multifunction extension module. The chapter also contains diagnostics and technical data.
Page 449: Mechanical Installation
Optional I/O extension and adapter modules 449 RO4C 24V AC/DC + in RO4A 24 V DC 24 V AC/DC RO4B 24V AC/DC - in 24 V AC/DC + in External 24 V (AC/DC) in- RO4C Common, C 24 V AC/DC - in External 24 V (AC/DC) in- RO4A Normally closed, NC...
Page 450: Installing The Module
450 Optional I/O extension and adapter modules Installing the module See section Installing option modules (page 164). ￭ Electrical installation WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. Stop the drive and do the steps in section Electrical safety precautions (page 24) before you start the work.
Page 451: Diagnostics
Optional I/O extension and adapter modules 451 Parameter Setting 15.07 RO4 source Reverse 15.08 RO4 ON delay 15.09 RO4 OFF delay Parameter setting example for digital output This example shows how to make digital output DO1 of the extension module indicate the reverse direction of rotation of the motor with a one-second delay.
Page 452: Technical Data
452 Optional I/O extension and adapter modules 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 See the drive technical data. Package Cardboard Reley outputs (50…52, 53…55)
Page 453: Dimension Drawing
Optional I/O extension and adapter modules 453 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 454: Cmod-02 Multifunction Extension Module (External 24 V Ac/Dc And Isolated Ptc Interface)
454 Optional I/O extension and adapter modules CMOD-02 multifunction extension module (external 24 V AC/DC and isolated PTC interface) ￭ Contents of this chapter This chapter describes how to install and start up the optional CMOD-02 multifunction extension module. The chapter also contains diagnostics and technical data.
Page 455: Layout And Example Connections
Optional I/O extension and adapter modules 455 ￭ Layout and example connections 2-pin terminal block for external power 2-pin terminal block for relay output supply CMOD-02 RO PTC C 24V AC/DC + in 24 V AC/DC 24V AC/DC - in PTC B OUT1 OUT2...
Page 456: Mechanical Installation
456 Optional I/O extension and adapter modules ￭ Mechanical installation Necessary tools • Screwdriver and a set of suitable bits. Unpacking and examining the delivery Open the option package. Make sure that the package contains: • the option module • a mounting screw.
Page 457: Diagnostics
Optional I/O extension and adapter modules 457 If the warning A7AB Extension I/O configuration failure is shown, • make sure that the value of parameter 15.02 is CMOD-02. • set the parameter 15.01 value to CMOD-02. You can now see the parameters of the extension module in parameter group 15 I/O extension module.
Page 458: Dimension Drawing
458 Optional I/O extension and adapter modules Maximum contact 250 V AC / 30 V DC / 5 A rating Maximum breaking 1000 VA capacity External power supply (40…41) 1.5 mm 2 Maximum wire size Input voltage 24 V AC / V DC ±10% (GND, user potential) Maximum power con- 25 W, 1.04 A at 24 V DC sumption...
Page 459 Optional I/O extension and adapter modules 459...
Page 461: Common Mode, D U /D T And Sine Filters
Examining the compatibility of the motor and drive (page 96). Common mode filter kits are available from ABB, see the table on page 461. A kit includes three wound cores. For installation instructions of the cores, see the instruction included in the core package.
Page 462: Du/Dt Filters
462 Common mode, d u /d t and sine filters IEC type Common mode filters Frame size North Americ- an type ACS580-01-… ABB drives ACS580-01- 088A-4 64315811 078A-4 106A-4 64315811 096A-4 145A-4 3AXD50000017269 124A-4 169A-4 3AXD50000017270 156A-4 206A-4 3AXD50000017270 180A-4...
Page 463 Common mode, d u /d t and sine filters 463 IEC type Frame size d u /d t filters North Americ- an type ACS580-01-… ABB drives ACS580-01-… 115A-2 NOCH0120-6x 114A-2 144A-2 FOCH0260-70 143A-2 171A-2 FOCH0260-70 169A-2 213A-2 FOCH0260-70 211A-2 276A-2...
Page 464: Description, Installation And Technical Data Of The Foch Filters
464 Common mode, d u /d t and sine filters IEC type Frame size d u /d t filters North Americ- an type ACS580-01-… ABB drives ACS580-01-… 246A-4 FOCH0260-70 240A-4 293A-4 FOCH0260-70 260A-4 363A-4 FOCH0320-50 361A-4 430A-4 FOCH0320-50 414A-4 UL (NEC) ratings at U...
Page 465: Description, Installation And Technical Data Of The Noch Filters
Common mode, d u /d t and sine filters 465 ￭ Description, installation and technical data of the NOCH filters AOCH and NOCH du/dt filters hardware manual (3AFE58933368 [English]). Sine filters ￭ IEC ratings at U = 400 V, UL (NEC) ratings at U = 480 V Note: Sine filter node supports only scalar control.
Page 466: Description, Installation And Technical Data
466 Common mode, d u /d t and sine filters 046A-4 45.0 B84143V0043R231 B84143V0050R229 + 044A-4 B84143Q0010R229 062A-4 62.0 B84143V0064R231 B84143V0066R229 + 052A-4 B84143Q0010R229 073A-4 73.0 B84143V0064R231 B84143V0066R229 + 065A-4 B84143Q0010R229 088A-4 88.0 B84143V0077R231 B84143V0095R229 + 078A-4 B84143Q0012R229 106A-4 106.0 B84143V0091R231 B84143V0095R229 + 096A-4...
Page 467 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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