ABB ACH580-31 Series - User Manual

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ABB DRIVES FOR HVAC

ACH580-31 drives

Hardware manual

Main Page

Table of Contents5
Safety Instructions15
Contents of this Chapter15
Use of Warnings and Notes in this Manual15
General Safety in Installation, Start-Up and Maintenance16
Electrical Safety in Installation, Start-Up and Maintenance18
Precautions before Electrical Work18
Additional Instructions and Notes19
Grounding20
Additional Instructions for Permanent Magnet Motor Drives22
Safety in Installation, Start-Up and Maintenance22
Additional Instruction for DC Connection22
Introduction to the Manual23
Contents of this Chapter23
Applicability23
Target Audience23
Purpose of the Manual23
Categorization by Frame (Size)23
Quick Installation and Commissioning Flowchart24
Terms and Abbreviations24
Related Documents27
Operation Principle and Hardware Description29
Contents of this Chapter29
Operation Principle30
DC Connection30
Layout31
Overview of Power and Control Connections34
Control Panel35
Control Panel Mounting Platform Cover (Option +J424)36
Control Panel Door Mounting Kits36
Remote Control Panel, Panel Bus36
Type Designation Label37
Type Designation Key38
Mechanical Installation41
Contents of this Chapter41
Cabinet Installation (Option +P940)41
Flange Mounting (Option +C135)41
Safety42
Examining the Installation Site43
Required Tools45
Moving the Drive45
Unpacking and Examining Delivery46
Installing the Drive Vertically51
Installing the Drive Vertically Side by Side53
Installing the Drive Horizontally53
Guidelines for Planning the Electrical Installation55
Contents of this Chapter55
Selecting the Supply Disconnecting Device55
European Union55
Other Regions56
Examining the Compatibility of the Motor and Drive56
Protecting the Motor Insulation and Bearings56
Requirements Table57
Additional Requirements for ABB Motors of Types Other than M2_, M3_, M4_, HX_ and59
Additional Requirements for the Regenerative and Low Harmonic Drives59
Additional Requirements for ABB High-Output and IP23 Motors59
Additional Requirements for Non-ABB High-Output and IP23 Motors60
Additional Data for Calculating the Rise Time and Peak Line-To-Line Voltage60
Additional Note for Sine Filters62
Selecting the Power Cables62
General Guidelines, IEC and North America62
Additional Guidelines, IEC and North America63
Preferred Power Cable Types63
Power Cable Types for Limited Use64
Not Allowed Power Cable Types65
Additional Guidelines, North America65
Conductor Type, IEC and North America67
Power Cable Shield, IEC and North America67
Typical Power Cable Sizes68
IEC Ratings69
UL (NEC) Ratings70
Selecting the Control Cables70
Shielding70
Signals in Separate Cables71
Signals Allowed to be Run in the same Cable71
Relay Cable71
Control Panel Cable71
Drive Composer PC Tool Cable71
Routing the Cables71
General Guidelines, IEC71
General Guidelines, North America72
Separate Control Cable Ducts74
Continuous Motor Cable Shield or Enclosure for Equipment on the Motor Cable74
Implementing Thermal Overload and Short-Circuit Protection75
Protecting the Drive and Input Power Cable in Short-Circuits75
Circuit Breakers75
Protecting the Motor and Motor Cable in Short-Circuits75
Protecting the Drive and the Input Power and Motor Cables against Thermal Overload75
Protecting the Motor against Thermal Overload75
Implementing a Ground Fault Detection Function76
Residual Current Device Compatibility76
Implementing the Emergency Stop Function76
Implementing the Safe Torque off Function76
Implementing the ATEX-Certified Safe Motor Disconnection Function (Option +Q971)76
Implementing the Undervoltage Control (Power-Loss Ride-Through)76
Using a Safety Switch between the Drive and the Motor77
Using a Contactor between the Drive and the Motor77
Protecting the Contacts of Relay Outputs77
Limiting Relay Output Maximum Voltages at High Installation Altitudes78
Implementing a Motor Temperature Sensor Connection79
Connection of Motor Temperature Sensor to the Drive Via an Option Module80
Connection of Motor Temperature Sensor to the Drive Via a Relay81
Ptc (Iec 60800-5-1)81
Pt100 (IEC 60800-5-1)81
Electrical Installation - IEC83
Contents of this Chapter83
Warnings83
Grounding the Motor Cable Shield at the Motor End84
Measuring the Insulation84
Drive84
Input Power Cable84
Motor and Motor Cable84
Brake Resistor Assembly85
Tems86
EMC Filter86
Ground-To-Phase Varistor86
When to Disconnect EMC Filter or Ground-To-Phase Varistor: TN-S, IT, Corner-Grounded Delta and Midpoint-Grounded Delta Systems and TT Systems87
Identifying Different Types of Electrical Power Systems89
Disconnecting Internal EMC Filter and Ground-To-Phase Varistor - Frame R390
Disconnecting Internal EMC Filter and Ground-To-Phase Varistor - Frame R691
Disconnecting Internal EMC Filter and Ground-To-Phase Varistor -Frame R892
Connecting the Power Cables93
Connection Diagram93
Connection Procedure94
R8 Power Cable Connection if You Detach the Cable Connectors101
Connecting the Control Cables103
Default I/O Connection Diagram (HVAC Default Configuration)104
Switches105
Additional Information on I/O Connections105
PNP Configuration for Digital Inputs106
NPN Configuration for Digital Inputs106
Connection for Obtaining 0107
Connection Examples of Two-Wire and Three-Wire Sensors108
DI5 as Frequency Input108
DI6 as PTC Input108
AI1 and AI2 as Pt100, Pt1000, Ni1000, KTY83 and KTY84 Sensor Inputs (X1)109
Safe Torque off (X4)109
Control Cable Connection Procedure110
Installing Optional Modules114
Mechanical Installation of Option Modules114
Option Slot 2 (I/O Extension Modules)114
Option Slot 1 (Fieldbus Adapter Modules)115
Wiring the Optional Modules115
Reinstalling Cover(S)116
Connecting a PC117
Connecting a Remote Panel, or Chaining One Panel to Several Drives117
Electrical Installation - North America119
Contents of this Chapter119
Warnings119
Required Tools119
Measuring the Insulation119
Drive120
Input Power Cable120
Motor and Motor Cable120
Brake Resistor Assembly120
Tems121
Connecting the Power Cables122
Connection Diagram122
Connection Procedure123
R8 Power Cable Connection if You Detach the Connectors130
Connecting the Control Cables132
Default I/O Connection Diagram (HVAC Default Configuration)133
Switches134
Additional Information on Control Connections134
Control Cable Connection Procedure135
Installing Optional Modules139
Reinstalling Cover(S)139
Connecting a PC139
Connecting a Remote Panel, or Chaining One Panel to Several Drives140
Installation Checklist141
Contents of this Chapter141
Warnings141
Checklist141
Start-Up143
Contents of this Chapter143
Start-Up Procedure143
Maintenance and Hardware Diagnostics145
Contents of this Chapter145
Maintenance Intervals145
Description of Symbols146
Recommended Annual Maintenance Actions by the User146
Recommended Maintenance Actions by the User146
Heatsink147
Fans147
Replacing the Main Cooling Fan, Frame R3148
Replacing the Main Cooling Fan, Frame R6149
Replacing the Main Cooling Fan, Frame R8150
Replacing the Main Cooling Fan, Frame R6150
Replacing the Auxiliary Cooling Fan, IP55 (UL Type 12) Frame R3151
Replacing the Auxiliary Cooling Fan, Frame R6152
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. See Section Electrical Work on Page152
Replacing the Auxiliary Cooling Fan, Frame R8153
Replacing the Second Auxiliary Cooling Fan IP55 (UL Type 12), Frame R8154
Capacitors156
Reforming the Capacitors156
Control Panel156
Drive Leds157
Technical Data159
Contents of this Chapter159
Ratings159
IEC Ratings159
UL (NEC) Ratings160
Definitions161
Sizing161
Derating161
Derating in Case of Several Situations161
Example161
Ambient Temperature Derating, IP21 (UL Type 1)162
Ambient Temperature Derating, IP55 (UL Type 12)163
Ambient Temperature Derating in Table Format164
Altitude Derating165
Switching Frequency Derating167
Fuses (IEC)169
Ar Fuses DIN 43653 Stud-Mount169
Ar Fuses DIN 43620 Blade Style169
Gg Fuses DIN 43620 Blade Style170
Calculating the Short-Circuit Current of the Installation171
Fuses (UL)173
Circuit Breakers174
Dimensions, Weights and Free Space Requirements174
Free Space Requirements174
Losses, Cooling Data and Noise175
Cooling Air Flow and Heat Dissipation for Flange Mounting (Option +C135)176
Terminal and Entry Data for the Power Cables177
Iec177
UL Listed Cable Lugs and Tools179
Terminal and Entry Data for the Control Cables180
Iec180
Electrical Power Network Specification180
Voltage (U1)180
Motor Connection Data182
CCU-24 Control Unit Connection Data184
Efficiency188
Degree of Protection188
Materials188
Applicable Standards190
Ambient Conditions191
Markings192
EMC Compliance (IEC/EN 61800-3:2004 + A1:2012)193
Definitions193
Category C2194
Category C3194
Category C4195
UL Checklist195
EU Declaration of Conformity (Machinery Directive)197
Disclaimers197
General Disclaimer197
Cybersecurity Disclaimer197
Dimension Drawings199
Contents of this Chapter199
R3, IP21 (UL Type 1)200
R3 - Option +B056 (IP55, UL Type 12)201
R6, IP21 (UL Type 1)202
R6 - Option +B056 (IP55, UL Type 12)203
R8, IP21 (UL Type 1)204
R8 - Option +B056 (IP55, UL Type 12)205
The Safe Torque off Function207
Contents of this Chapter207
Description207
Compliance with the European Machinery Directive208
Wiring208
Connection with Internal +24 V DC Power Supply209
Connection with External +24 V DC Power Supply210
Wiring Examples210
Activation Switch211
Cable Types and Lengths211
Grounding of Protective Shields212
Operation Principle212
Start-Up Including Acceptance Test212
Competence212
Acceptance Test Reports212
Acceptance Test Procedure212
Use214
Maintenance215
Competence216
Fault Tracing216
Safety Data (SIL, PL)217
Abbreviations218
Resistor Braking219
Contents of this Chapter219
Operation Principle and Hardware Description219
Planning the Braking System219
Selecting the Brake Circuit Components219
Selecting a Custom Resistor220
Selecting and Routing the Brake Resistor Cables220
Minimizing Electromagnetic Interference221
Maximum Cable Length221
EMC Compliance of the Complete Installation221
Placing the Brake Resistors221
Protecting the System against Thermal Overload222
Protecting the System in Fault Situations222
Protecting the Resistor Cable against Short-Circuits222
Mechanical Installation223
Electrical Installation223
Measuring the Insulation223
Connection Diagram223
Connection Procedure223
Start-Up223
Technical Data223
Ratings223
Terminals and Cable Lead-Through Data223
Common Mode, Du/Dt and Sine Filters225
Contents of this Chapter225
Common Mode Filters225
Du/Dt Filters226
When Is a Du/Dt Filter Needed226
Du/Dt Filter Types226
Description, Installation and Technical Data of the Filters227
Sine Filters228
Derating228
Optional I/O Extension Modules229
What this Chapter Contains229
CHDI-01 115/230 V Digital Input Extension Module229
Hardware Description229
Product Overview229
Layout230
Mechanical Installation230
Necessary Tools and Instructions230
Unpacking and Checking the Delivery230
Installing the Module231
Electrical Installation231
Warnings231
Necessary Tools and Instructions231
Terminal Designations231
General Cabling Instructions232
Wiring232
Start-Up233
Setting the Parameters233
Diagnostics233
Faults and Warning Messages233
Leds233
Technical Data234
CMOD-01 Multifunction Extension Module (External 24 V AC/DC and Digital I/O)236
Hardware Description236
Product Overview236
Layout237
Mechanical Installation237
Necessary Tools and Instructions237
Diagnostic LED237
Unpacking and Checking the Delivery238
Installing the Module238
Electrical Installation238
Warnings238
Necessary Tools and Instructions238
Terminal Designations238
Open the Option Package238
Make Sure that the Package Contains238
Support Part238
Make Sure that There Are no Signs of Damage238
General Cabling Instructions239
Wiring239
Start-Up241
Setting the Parameters241
Diagnostics242
Faults and Warning Messages242
Leds242
Technical Data243
Hardware Description245
Product Overview245
Layout246
Mechanical Installation246
Necessary Tools and Instructions246
Unpacking and Checking the Delivery247
Installing the Module247
Electrical Installation247
Warnings247
Necessary Tools and Instructions247
Terminal Designations247
General Cabling Instructions248
Wiring248
Start-Up249
Setting the Parameters249
Diagnostics250

Brand	ABB
Model	ACH580-31 Series
Category	DC Drives
Language	English

ABB ACH580-31 Series - User Manual

Table of Contents

ABB ACH580-31 Series Specifications

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