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Table of Contents5
Safety Instructions19
Contents of this Chapter19
Use of Warnings and Notes19
General Safety in Installation, Start-Up and Maintenance20
Electrical Safety in Installation, Start-Up and Maintenance22
Electrical Safety Precautions22
Additional Instructions and Notes23
Printed Circuit Boards23
Grounding24
General Safety in Operation25
Additional Instructions for Permanent Magnet Motor Drives25
Safety in Installation, Start-Up, Maintenance25
Safety in Operation26
Introduction to the Manual27
Contents of this Chapter27
Applicability27
Target Audience27
Categorization by Frame Size27
Quick Installation and Commissioning Flowchart28
Terms and Abbreviations29
Related Documents30
Operation Principle and Hardware Description35
Contents of this Chapter35
Operation Principle36
Layout36
Overview of Power and Control Connections44
External Control Connection Terminals, Frames R145
External Control Connection Terminals, Frames R646
Control Panel47
Control Panel Door Mounting Kits48
Type Designation Label48
Locations of the Labels on the Drive49
Type Designation Key50
Option Codes51
Manual Kit Ordering Codes52
Mechanical Installation53
Contents of this Chapter53
Safety53
Examining the Installation Site54
Required Tools59
Moving the Drive59
Unpacking and Examining Delivery, Frames R1 and R260
Frames R1 and R2 Cable Box (IP21, UL Type 1)63
Unpacking and Examining Delivery, Frame R364
Unpacking and Examining Delivery, Frames R466
Unpacking and Examining Delivery, Frame R568
Frame R5 Cable Box (IP21, UL Type 1)69
Unpacking and Examining Delivery, Frames R670
Frame R6 Cable Box (IP21, UL Type 1)72
Frame R7 Cable Box (IP21, UL Type 1)73
Frame R8 Cable Box (IP21, UL Type 1)74
Frame R9 Cable Box (IP21, UL Type 1)75
Installing the Drive76
Installing the Drive Vertically, Frames R176
Installing the Cable Box, Frames R177
Installing the Drive Vertically, Frame R579
IP21 (UL Type 1)80
IP21 (UL Type 1), IP55 (UL Type 12)81
Installing the Drive Vertically, Frames R682
IP21 (UL Type 1)83
IP55 (UL Type 12)83
Installing the Drive Vertically Side by Side84
Installing the Drive Horizontally, Frames R184
Flange Mounting84
Strut Channel Installation (US Only)84
Installation Instructions85
Guidelines for Planning the Electrical Installation87
Contents of this Chapter87
Limitation of Liability87
Selecting the Main Supply Disconnecting Device87
European Union and United Kingdom88
North America88
Other Regions88
Examining the Compatibility of the Motor and Drive88
Protecting the Motor Insulation and Bearings88
Requirements Table89
Availability of Du/Dt Filter and Common Mode Filter by Drive Type92
Additional Requirements for Explosion-Safe (EX) Motors92
Additional Requirements for ABB Motors of Types Other than M2_, M3_, M4_, HX_ and am92
Additional Requirements for Braking Applications92
Additional Requirements for the Regenerative and Low Harmonics Drives92
Additional Requirements for ABB High-Output and IP23 Motors92
Additional Requirements for Non-ABB High-Output and IP23 Motors93
Additional Data for Calculating the Rise Time and the Peak Line-To-Line Voltage94
Additional Note for Sine Filters95
Selecting the Power Cables96
General Guidelines96
Typical Power Cable Sizes96
Power Cable Types96
Preferred Power Cable Types96
Alternate Power Cable Types97
Not Allowed Power Cable Types98
Additional Guidelines, North America99
Metal Conduit99
Power Cable Shield100
Grounding Requirements100
Additional Grounding Requirements - IEC101
Additional Grounding Requirements - UL (NEC)102
Selecting the Control Cables102
Shielding102
Signals in Separate Cables102
Signals that Can be Run in the same Cable102
Relay Cable103
Control Panel to Drive Cable103
PC Tool Cable103
FPBA-01 PROFIBUS DP Adapter Module Connectors103
Routing the Cables103
General Guidelines - IEC103
General Guidelines - North America104
Continuous Motor Cable Shield/Conduit or Enclosure for Equipment on the Motor Cable105
Separate Control Cable Ducts106
Implementing Short-Circuit and Thermal Overload Protection106
Protecting the Drive and the Input Power Cable in Short-Circuits106
Protecting the Motor and Motor Cable in Short-Circuits107
Protecting the Motor Cables against Thermal Overload107
Protecting the Motor against Thermal Overload107
Protecting the Motor against Overload Without Thermal Model or Temperature Sensors107
Protecting the Drive against Ground Faults108
Residual Current Device Compatibility108
Implementing the Emergency Stop Function108
Implementing the Safe Torque off Function108
Implementing an ATEX-Certified Motor Thermal Protection108
Using a Safety Switch between the Drive and the Motor109
Implementing the Power-Loss Ride-Through Function109
Controlling a Contactor between Drive and Motor109
Protecting the Contacts of Relay Outputs109
Limiting Relay Output Maximum Voltages at High Installation Altitudes110
Implementing a Motor Temperature Sensor Connection110
Connecting Motor Temperature Sensor to the Drive Via an Option Module111
Connection of Motor Temperature Sensor to the Drive Via a Relay112
Ptc (Iec 60800-5-1)112
Pt100 (IEC 90800-5-1)112
Electrical Installation - IEC113
Contents of this Chapter113
Warnings113
Required Tools113
Grounding the Motor Cable Shield at the Motor End114
Measuring the Insulation114
Measuring the Insulation Resistance of the Drive114
Measuring the Insulation Resistance of the Input Power Cable114
Measuring the Insulation Resistance of the Motor and Motor Cable114
Brake Resistor Assembly for R1115
Grounding System Compatibility Check115
EMC Filter115
Ground-To-Phase Varistors116
When to Disconnect EMC Filter or Ground-To-Phase Varistor: TN-S, IT, Corner-Grounded Delta and Midpoint-Grounded Delta Systems116
Guidelines for Installing the Drive to a TT System117
Identifying the Grounding System of the Electrical Power Network119
Disconnecting Internal EMC Filter or Ground-To-Phase Varistor - Frames R1119
Disconnecting Internal EMC Filter or Ground-To-Phase Varistor - Frames R4120
Connecting the Power Cables122
Connection Diagram122
Connection Procedure, Frames R1123
Motor Cable124
Input Power Cable126
Grounding Shelf127
Brake Resistor Cable (if Used)128
Finalization129
Connection Procedure, Frame R5129
IP21 (UL Type 1)129
IP55 (UL Type 12)129
Connection Procedure, Frames R6134
Motor Cable135
Input Power Cable136
Detaching and Reinstalling the Connectors136
DC Connection139
Connecting the Control Cables140
Default I/O Connection Diagram (HVAC Default Configuration)141
Switches143
Additional Information on I/O Connections144
PNP Configuration for Digital Inputs144
NPN Configuration for Digital Inputs144
Connection for Obtaining 0145
Connection Examples of Two-Wire and Three-Wire Sensors145
DI5 as Frequency Input146
DI6 as PTC Input146
AI1 and AI2 as Pt100, Pt1000, Ni1000, KTY83 and KTY84 Sensor Inputs (X1)146
Safe Torque off (X4)147
Control Cable Connection Procedure R1147
Installing Option Modules153
Option Slot 2 (I/O Extension Modules)154
Option Slot 1 (Fieldbus Adapter Modules)155
Wiring the Optional Modules155
Reinstalling Grommets156
Reinstalling Covers157
Reinstalling Cover, Frames R1157
Reinstalling Covers, Frame R5158
IP21 (UL Type 1)158
IP55 (UL Type 12)158
Reinstalling Side Plates and Covers, Frames R6159
IP21 (UL Type 1)159
IP55 (UL Type 12)159
Connecting a PC160
Connecting a Remote Panel, or Chaining One Panel to Several Drives161
Electrical Installation - North America163
Contents of this Chapter163
Warnings163
Required Tools164
Grounding the Motor Cable Shield at the Motor End164
Measuring the Insulation164
Measuring the Insulation Resistance of the Drive164
Measuring the Insulation Resistance of the Input Power Cable164
Measuring the Insulation Resistance of the Motor and Motor Cable164
Brake Resistor Assembly for R1165
Grounding System Compatibility Check166
EMC Filter166
Ground-To-Phase Varistors166
When to Connect EMC Filter or Disconnect Ground-To-Phase Varistor: TN-S, IT, Corner-Grounded Delta and Midpoint-Grounded Delta Systems166
Guidelines for Installing the Drive to a TT System168
Identifying the Grounding System of the Electrical Power Network169
Frames R1169
Frames R4170
Connecting the Power Cables172
Connection Diagram172
Connection Procedure, Frames R1174
Motor Cabling175
Input Power Cabling176
Brake Resistor Cabling (if Used)177
Finalization178
Connection Procedure, Frame R5178
IP21 (UL Type 1)178
IP55 (UL Type 12)178
Connection Procedure, Frames R6182
Motor Cabling183
Input Power Cabling184
Detaching and Reinstalling the Connectors185
DC Connection186
Connecting the Control Cables187
Default I/O Connection Diagram (HVAC Default Configuration)188
Switches190
Additional Information on I/O Connections191
PNP Configuration for Digital Inputs191
NPN Configuration for Digital Inputs191
Connection for Obtaining 0192
Connection Examples of Two-Wire and Three-Wire Sensors192
DI5 as Frequency Input193
DI6 as PTC Input193
AI1 and AI2 as Pt100, Pt1000, Ni1000, KTY83 and KTY84 Sensor Inputs (X1)193
Safe Torque off (X4)194
Control Cable Connection Procedure R1194
Installing Option Modules201
Mechanical Installation of Option Modules201
Option Slot 2 (I/O Extension Modules)201
Option Slot 1 (Fieldbus Adapter Modules)201
Wiring the Modules203
Reinstalling Grommets204
Reinstalling Covers204
Reinstalling Cover, Frames R1204
Reinstalling Covers, Frame R5205
IP21 (UL Type 1)205
IP55 (UL Type 12)205
Reinstalling Side Plates and Covers, Frames R6206
IP21 (UL Type 1)206
IP55 (UL Type 12)207
Installing UL Type 12 Hood207
Connecting a PC208
Connecting a Remote Panel, or Chaining One Panel to Several Drives208
Installation Checklist209
Contents of this Chapter209
Checklist209
Maintenance213
Contents of this Chapter213
Maintenance Intervals213
Description of Symbols213
Recommended Maintenance Intervals after Start-Up214
Cleaning the Exterior of the Drive215
Cleaning the Heatsink216
Fans217
Replacing the Main Cooling Fan, IP21 and IP55 (UL Type 1 and UL Type 12) Frames R1218
Replacing the Main Cooling Fan, IP21 and IP55 (UL Type 1 and UL Type 12) Frames R5220
Replacing the Main Cooling Fans, IP21 and IP55 (UL Type 1 and UL Type 12) Frame R9221
Replacing the Auxiliary Cooling Fan, IP21 and IP55 (UL Type 1 and UL Type 12) Frames R6222
Replacing the Auxiliary Cooling Fan, IP55 (UL Type 12) Frames R1223
Replacing the Auxiliary Cooling Fan, IP55 (UL Type 12) Frame R3224
Replacing the Auxiliary Cooling Fan, IP55 (UL Type 12) Frame R4; IP21 and IP55 (UL Type 1 and UL Type 12) Frame R5225
Replacing the Second Auxiliary Cooling Fan, IP55 (UL Type 12) Frames R8226
Capacitors227
Reforming the Capacitors227
Control Panel227
Leds227
Drive Leds227
Control Panel Leds228
Functional Safety Components229
Technical Data231
Contents of this Chapter231
Ratings231
Iec231
Definitions234
Ul (Nec)235
Definitions238
Conversion Tables for IEC and North American Type Codes238
Sizing239
Deratings240
Surrounding Air Temperature Derating, IP21 (UL Type 1)242
Surrounding Air Temperature Derating, IP55 (UL Type 12)243
Altitude Derating245
Switching Frequency Derating by Derating Factor246
Switching Frequency Derating with Actual Output Current Values248
Output Frequency Derating253
Fuses (IEC)253
Gg Fuses253
Ur and Ar Fuses255
Circuit Breakers (IEC)257
Fuses (UL)259
Circuit Breakers (UL)261
Dimensions, Weights and Free Space Requirements265
Losses, Cooling Data and Noise273
Cooling Air Flow, Heat Dissipation and Noise for Stand-Alone Drives273
Iec273
Ul (Nec)274
Cooling Air Flow and Heat Dissipation for Flange Mounting (Option +C135)276
Iec276
Ul (Nec)277
Terminal and Entry Data for the Power Cables278
Iec278
Ul (Nec)280
Power Cables283
Typical Power Cable Sizes, IEC283
Terminal and Entry Data for the Control Cables284
Iec284
Ul (Nec)285
Electrical Power Network Specification286
Motor Connection Data288
Brake Resistor Connection Data for Frames R1291
Control Connection Data291
Auxiliary Circuit Power Consumption298
Efficiency298
Energy Efficiency Data (Ecodesign)298
Protection Classes for Module298
Materials299
Applicable Standards299
Ambient Conditions300
Markings302
CE Marking303
Compliance with the European Low Voltage Directive303
Compliance with the European EMC Directive303
Compliance with the European ROHS II Directive 2011/65/EU303
Compliance with the European WEEE Directive 2002/96/EC304
Compliance with the European Machinery Directive 2006/42/EC 2Nd Edition - June 2010304
Validating the Operation of the Safe Torque off Function304
Compliance with the en 61800-3:2004 + A1:2012304
Definitions304
Category C1304
Category C2305
Category C3305
Category C4306
UL Checklist307
Disclaimers308
Generic Disclaimer308
Cybersecurity Disclaimer308
Dimension Drawings309
Contents of this Chapter309
Frame R1, IP21 (UL Type 1)310
Frame R1, IP55 (UL Type 12)311
Frame R1, IP55+F278 (UL Type 12)312
Frame R2, IP21 (UL Type 1)313
Frame R2, IP55 (UL Type 12)314
Frame R2, IP55+F278 (UL Type 12)315
Frame R3, IP21 (UL Type 1)316
Frame R3, IP55 (UL Type 12)317
Frame R3, IP55+E223 (UL Type 12)318
Frame R3, IP55+F278/F316 (UL Type 12)319
Frame R4, IP21 (UL Type 1)320
Frame R4, IP55 (UL Type 12)321
Frame R4, IP55+E223 (UL Type 12)322
Frame R4, IP55+F278/F316 (UL Type 12)323
Frame R5, IP21 (UL Type 1)324
Frame R5, IP55 (UL Type 12)325
Frame R5, IP55+E223 (UL Type 12)326
Frame R5, IP55+F278/F316 (UL Type 12)327
Frame R6, IP21 (UL Type 1)328
Frame R6, IP55 (UL Type 12)329
Frame R7, IP21 (UL Type 1)330
Frame R7, IP55 (UL Type 12)331
Frame R8, IP21 (UL Type 1)332
Frame R8, IP55 (UL Type 12)333
Frame R9, IP21 (UL Type 1)334
Frame R9, IP55 (UL Type 12)335
Resistor Braking337
Contents of this Chapter337
Operation Principle and Hardware Description337
Resistor Braking, Frames R1337
Planning the Braking System337
Selecting the Brake Resistor337
Selecting and Routing the Brake Resistor Cables340
Placing the Brake Resistor341
Protecting the System in Brake Circuit Fault Situations341
Mechanical Installation342
Electrical Installation342
Start-Up343
Resistor Braking, Frames R4343
Planning the Braking System343
Iec343
Ul (Nec)344
Parameter Settings for External Braking Chopper and Resistor345
The Safe Torque off Function347
Contents of this Chapter347
Description347
Compliance with the European Machinery Directive and the UK Supply of Machinery (Safety) Regulations348
Wiring349
Connection Principle349
Single ACH580-01 Drive, Internal Power Supply349
Single ACH580-01 Drive, External Power Supply350
Wiring Examples350
Single ACH580-01 Drive, Internal Power Supply350
Single ACH580-01 Drive, External Power Supply351
Multiple ACH580-01 Drives, Internal Power Supply352
Multiple ACH580-01 Drives, External Power Supply353
Activation Switch354
Cable Types and Lengths354
Grounding of Protective Shields354
Operation Principle355
Start-Up Including Validation Test356
Competence356
Validation Test Reports356
Validation Test Procedure356
Use358
Maintenance360
Competence360
Fault Tracing361
Safety Data362
Terms and Abbreviations363
TÜV Certificate364
Declarations of Conformity365
Optional I/O Extension and Adapter Modules367
Contents of this Chapter367
CAIO-01 Bipolar Analog I/O Adapter Module367
Product Overview367
Layout368
Mechanical Installation369
Necessary Tools369
Unpacking and Examining the Delivery369
Installing the Module369
Electrical Installation369
Wiring369
Start-Up370
Setting the Parameters370
Diagnostics371
Leds371
Technical Data372
Isolation Areas372
Dimension Drawings373
CHDI-01 115/230 V Digital Input Extension Module374
Product Overview374
Layout and Connection Examples375
Mechanical Installation376
Necessary Tools376
Unpacking and Examining the Delivery376
Installing the Module376
Electrical Installation376
Wiring376
Start-Up376
Setting the Parameters376
Fault and Warning Messages377
Technical Data377
Dimension Drawing378
CMOD-01 Multifunction Extension Module (External 24 V AC/DC and Digital I/O)379
Product Overview379
Layout and Example Connections379
Mechanical Installation380
Necessary Tools380
Unpacking and Examining the Delivery380
Installing the Module380
Electrical Installation380
Necessary Tools381
Wiring381
Start-Up381
Setting the Parameters381
Diagnostics382
Technical Data382
Dimension Drawing383
CMOD-02 Multifunction Extension Module (External 24 V AC/DC and Isolated PTC Interface)385
Product Overview385
Layout and Example Connections385
Mechanical Installation386
Necessary Tools386
Unpacking and Examining the Delivery386
Installing the Module386
Electrical Installation386
Necessary Tools387
Wiring387
Start-Up387
Setting the Parameters387
Diagnostics387
Faults and Warning Messages387
Leds387
Technical Data388
Dimension Drawing389
Common Mode, Du/Dt and Sine Filters391
Content of this Chapter391
Common Mode Filters391
When Is a Common Mode Filter Needed391
Common Mode Filter Types391
IEC Ratings at U N = 400 V and 480 V, UL (NEC) Ratings at U N = 480 V391
Du/Dt Filters392
When Is a Du/Dt Filter Needed392
Du/Dt Filter Types392
IEC Ratings at U N = 230 V, UL (NEC) Ratings at U N = 208/230 V392
UL (NEC) Ratings at U393
Description, Installation and Technical Data of the FOCH Filters394
Description, Installation and Technical Data of the noch Filters394
Sine Filters394
IEC Ratings at U N = 400 V, UL (NEC) Ratings at U N = 480 V394
Description, Installation and Technical Data395
Further Information397

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