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ABB
DC Drives
ACH580-31
Hardware Manual
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ABB ACH580-31 - Page 126
284 pages
Manual
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R6
7
7
7
8
8
PE
(Ground):
2.9
N·m
(2.1
lbf·ft)
L1,
L2,
L3,
T1/U,
T2/V,
T3/W,
UDC+,
UDC-:
15
N·m
(11.0
lbf·ft)
126
Electrical
installation
–
North
America
(NEC)
125
127
Table of Contents
Main Page
Table of Contents
5
Safety Instructions
17
Contents of this Chapter
17
Use of Warnings and Notes
17
General Safety in Installation, Start-Up and Maintenance
18
Electrical Safety in Installation, Start-Up and Maintenance
20
Electrical Safety Precautions
20
Additional Instructions and Notes
21
Printed Circuit Boards
21
Grounding
22
General Safety in Operation
23
Additional Instructions for Permanent Magnet Motor Drives
23
Safety in Installation, Start-Up, Maintenance
23
Safety in Operation
24
Introduction to the Manual
25
Contents of this Chapter
25
Target Audience
25
Purpose of the Manual
25
Categorization by Frame Size and Option Code
25
Quick Installation, Commissioning and Operation Flowchart
26
Terms and Abbreviations
27
Related Documents
29
Operation Principle
31
Contents of this Chapter
31
Active Braking Function (Option +N8056 )
32
DC Voltage Boost Function
32
Benefits of the DC Voltage Boost
33
Impact of DC Voltage Boost on Input Current
33
DC Connection
33
Layout
34
Overview of Power and Control Connections
36
Control Panel
37
Control Panel Door Mounting Kits
38
Control Panel Mounting Platform Cover (Option +J424)
38
Remote Control Panel, Panel Bus
38
Type Designation Label
40
Type Designation Key
41
Basic Code
41
Option Codes
41
Mechanical Installation
43
Contents of this Chapter
43
Cabinet Installation (Option +P940)
43
Flange Mounting (Option +C135)
43
Safety
44
Examining the Installation Site
44
Installation Positions
44
Free Space Requirements
45
Necessary Tools
46
Moving the Drive
47
Unpacking and Examining Delivery
47
Installing the Drive Vertically
53
Installing the Drive Vertically Side by Side
55
Installing the Drive Horizontally
55
Guidelines for Planning the Electrical Installation
57
Contents of this Chapter
57
Limitation of Liability
57
Selecting the Main Supply Disconnecting Device
57
European Union and United Kingdom
58
North America
58
Other Regions
58
Implementing a Fast Switch over between the Power Line and Generator
58
Selecting the Main Contactor
58
North America
59
Other Regions
59
Examining the Compatibility of the Motor and Drive
59
Protecting the Motor Insulation and Bearings
59
Requirements Tables
60
Requirements for ABB Motors, P
60
Kw (134 Hp)
60
Requirements for ABB Motors, P
61
Requirements for Non-ABB Motors, P < 100 Kw (134 Hp)
62
Requirements for Non-ABB Motors, P
63
Abbreviations
64
Availability of D U /D T Filter and Common Mode Filter by Drive Type
64
Additional Requirements for Explosion-Safe (EX) Motors
64
Additional Requirements for ABB Motors of Types Other than M2_, M3_, M4_, HX_ and am
64
Additional Requirements for Braking Applications
64
Additional Requirements for the Regenerative and Low Harmonics Drives
64
Additional Requirements for ABB High-Output and IP23 Motors
64
Additional Requirements for Non-ABB High-Output and IP23 Motors
65
Additional Data for Calculating the Rise Time and the Peak Line-To-Line Voltage
66
Additional Note for Sine Filters
67
Selecting the Power Cables
68
General Guidelines
68
Typical Power Cable Sizes
68
Power Cable Types
68
Preferred Power Cable Types
68
Alternate Power Cable Types
69
Not Allowed Power Cable Types
70
Additional Guidelines - North America
70
Metal Conduit
71
Power Cable Shield
71
Grounding Requirements
72
Additional Grounding Requirements - IEC
73
Additional Grounding Requirements - UL (NEC)
74
Selecting the Control Cables
74
Shielding
74
Signals in Separate Cables
74
Signals that Can be Run in the same Cable
74
Relay Cable
75
Control Panel to Drive Cable
75
PC Tool Cable
75
Routing the Cables
75
General Guidelines - IEC
75
General Guidelines - North America
76
Continuous Motor Cable Shield/Conduit or Enclosure for Equipment on the Motor Cable
77
Separate Control Cable Ducts
78
Protecting the Drive, Input Power Cable, Motor and Motor Cable in Short Circuit Situations and against Thermal Overload
78
Protecting the Drive and the Input Power Cable in Short-Circuits
78
Circuit Breakers
79
Protecting the Motor and Motor Cable in Short-Circuits
79
Protecting the Motor Cables against Thermal Overload
79
Protecting the Motor against Thermal Overload
80
Protecting the Motor against Overload Without Thermal Model or Temperature Sensors
80
Implementing a Motor Temperature Sensor Connection
80
Connecting a Motor Temperature Sensor to the Drive through an Option
81
Module
81
Protecting the Drive against Ground Faults
82
Residual Current Device Compatibility
82
Implementing the Emergency Stop Function
82
Implementing the Safe Torque off Function
82
Implementing the Power Loss Ride-Through Function
82
Using Power Factor Compensation Capacitors with the Drive
83
Using a Safety Switch between the Drive and the Motor
84
Implementing an ATEX-Certified Motor Thermal Protection
84
Controlling a Contactor between Drive and Motor
84
Implementing a Bypass Connection
85
Example Bypass Connection
86
Switching the Motor Power Supply from Drive to Direct-On-Line
86
Switching the Motor Power Supply from Direct-On-Line to Drive
87
Protecting the Contacts of Relay Outputs
87
Limiting Relay Output Maximum Voltages at High Installation Altitudes
88
Implementing a Motor Temperature Sensor Connection
88
Connecting a Motor Temperature Sensor to the Drive through an Option
89
Module
89
Electrical Installation - IEC
91
Contents of this Chapter
91
Safety
91
Required Tools
91
Grounding the Motor Cable Shield at the Motor End
91
Measuring the Insulation
92
Measuring the Insulation Resistance of the Drive
92
Measuring the Insulation Resistance of the Input Power Cable
92
Measuring the Insulation Resistance of the Motor and Motor Cable
92
Measuring the Insulation Resistance of the Brake Resistor Circuit
93
Grounding System Compatibility Check
93
EMC Filter
93
Ground-To-Phase Varistor
94
When to Disconnect EMC Filter or Ground-To-Phase Varistor: TN-S, IT, Corner-Grounded Delta and Midpoint-Grounded Delta Systems and TT Systems
94
Identifying the Grounding System of the Electrical Power Network
97
Disconnecting Integrated EMC Filter and Ground-To-Phase Varistor - Frame R3
98
Disconnecting Integrated EMC Filter and Ground-To-Phase Varistor - Frame R6
99
Disconnecting Integrated EMC Filter and Ground-To-Phase Varistor - Frame R8
100
Connecting the Power Cables
101
Connection Diagram
101
Connection Procedure
102
R8 Power Cable Connection if You Detach the Cable Connectors
109
Connecting the Control Cables
110
Connection Diagram
110
Connection Procedure
110
Installing Option Modules
115
Option Slot 2 (I/O Extension Modules)
115
Option Slot 1 (Fieldbus Adapter Modules)
116
Wiring the Optional Modules
116
Reinstalling Cover(S)
117
Connecting a PC
118
Connecting a Remote Panel, or Chaining One Panel to Several Drives
118
Electrical Installation - North America (NEC)
119
Contents of this Chapter
119
Safety
119
Required Tools
119
Measuring the Installation
120
Grounding System Compatibility Check
120
Connecting the Power Cables
120
Connection Diagram
120
Connection Procedure
121
Connecting the Control Cables
128
Connection Diagram
128
Connection Procedure
128
Installing Optional Modules
132
Reinstalling Cover(S)
133
Connecting a PC
134
Connecting a Remote Panel, or Chaining One Panel to Several Drives
134
Control Unit
135
Contents of this Chapter
135
Layout
136
Default I/O Connection Diagram
137
Switches
139
Additional Information on I/O Connections
139
PNP Configuration for Digital Inputs (X2 & X3)
139
NPN Configuration for Digital Inputs (X2 & X3)
140
Connection for Obtaining 0
140
Connection Examples of Two-Wire and Three-Wire Sensors to Analog Input (AI2)
140
DI5 as Frequency Input
141
DI6 as PTC Input
141
AI1 and AI2 as Pt100, Pt1000, Ni1000, KTY83 and KTY84 Sensor Inputs (X1)
141
Safe Torque off (X4)
142
Technical Data
142
Installation Checklist
147
Contents of this Chapter
147
Checklist
147
Start-Up
151
Contents of this Chapter
151
Reforming the Capacitors
151
Start-Up Procedure
151
Maintenance
153
Contents of this Chapter
153
Maintenance Intervals
153
Description of Symbols
153
Recommended Maintenance Intervals after Start-Up
153
Cleaning the Exterior of the Drive
155
Cleaning the Heatsink
156
Fans
156
Replacing the Main Cooling Fan, Frame R3
157
Replacing the Main Cooling Fan, Frame R6
158
Replacing the Main Cooling Fan, Frame R8
159
Replacing the Auxiliary Cooling Fan of Frame R3, IP55 (UL Type 12) and +C135 IP21 (UL Type 1)
160
Replacing the Auxiliary Cooling Fan, Frame R6
161
Replacing the Second Auxiliary Cooling Fan, IP55 (UL Type 12) Frame R6
162
Replacing the Auxiliary Cooling Fan, Frame R8
163
Replacing the Second Internal Auxiliary Cooling Fan, IP55 (UL Type 12) Frame R8
164
Replacing the Auxiliary Cooling Fan in the IP55 (UL Type 12) Cover, Frame R8
165
Capacitors
167
Reforming the Capacitors
167
Control Panel
167
Drive Leds
167
Functional Safety Components
168
Technical Data
169
Contents of this Chapter
169
Electrical Ratings
169
IEC Ratings
169
UL (NEC) Ratings
170
Definitions
171
Sizing
172
Deratings
172
Derating in Case of Several Situations
172
Surrounding Air Temperature Derating
173
Altitude Derating
174
Switching Frequency Derating
175
Output Voltage Boost Derating
177
Fuses (IEC)
178
Ar Fuses DIN 43653 Stud-Mount
179
Ar Fuses DIN 43620 Blade Style
180
Gg Fuses DIN 43620 Blade Style
180
Calculating the Short-Circuit Current of the Installation
181
Calculation Example
181
Fuses (UL)
182
Circuit Breakers (IEC)
184
ABB Miniature and Molded Case Circuit Breakers
184
Circuit Breakers (UL)
185
Dimensions, Weights and Free Space Requirements
188
Free Space Requirements
188
Package Dimensions and Weights
189
Losses, Cooling Data and Noise
190
Cooling Air Flow and Heat Dissipation for Flange Mounting (Option +C135)
192
Terminal and Entry Data for the Power Cables
194
Iec
194
Ul
194
Terminal and Entry Data for the Control Cables
195
Iec
195
Ul
195
Typical Power Cables
195
Electrical Power Network Specification
198
Motor Connection Data
200
CCU-24 Control Unit Connection Data
201
Efficiency
201
Energy Efficiency Data (EU Ecodesign)
201
Protection Classes for Module
202
Colors
202
Materials
202
Drive
202
Package Materials for Small Wall-Mounted Drives and Converter Modules
202
Package Materials for Large Wall-Mounted Drives and Converter Modules
202
Package Materials for Options, Accessories and Spare Parts
203
Materials of Manuals
203
Disposal
203
Applicable Standards
203
Ambient Conditions
204
Markings
205
Compliance with the en 61800-3:204 + A1:2012
206
Definitions
206
Category C2
207
Category C3
208
Category C4
208
UL Checklist
209
Declarations of Conformity
210
Design Lifetime Expectancy
211
Disclaimers
211
Generic Disclaimer
211
Cybersecurity Disclaimer
211
Dimension Drawings
213
R3, IP21 (UL Type 1)
214
R3 - Option +B056 (IP55, UL Type 12)
215
R6, IP21 (UL Type 1)
216
R6 - Option +B056 (IP55, UL Type 12)
217
R8, IP21 (UL Type 1)
218
R8 - Option +B056 (IP55, UL Type 12)
219
The Safe Torque off Function
221
Contents of this Chapter
221
Description
221
Compliance with the European Machinery Directive and the UK Supply of Machinery (Safety) Regulations
222
Wiring
223
Connection Principle
223
Single ACH580-31 Drive, Internal Power Supply
223
Single ACH580-31 Drive, External Power Supply
224
Wiring Examples
224
Single ACH580-31 Drive, Internal Power Supply
224
Single ACH580-31 Drive, External Power Supply
225
Multiple ACH580-31 Drives, Internal Power Supply
226
Multiple ACH580-31 Drives, External Power Supply
227
Activation Switch
228
Cable Types and Lengths
228
Grounding of Protective Shields
228
Operation Principle
229
Start-Up Including Validation Test
230
Competence
230
Validation Test Reports
230
Validation Test Procedure
230
Use
232
Maintenance
234
Competence
234
Fault Tracing
235
Safety Data
236
Terms and Abbreviations
238
TÜV Certificate
240
Declarations of Conformity
240
Resistor Braking
243
Contents of this Chapter
243
Operation Principle
243
Planning the Braking System
243
Selecting the Default Brake System Components
243
Selecting a Custom Brake Resistor
244
Selecting and Routing the Brake Resistor Cables
245
Minimizing Electromagnetic Interference
245
Maximum Cable Length
245
Placing the Brake Resistors
246
Protecting the System against Thermal Overload
246
Protecting the System in Fault Situations
246
Protecting the Resistor Cable against Short-Circuits
247
Mechanical Installation
247
Electrical Installation
247
Measuring the Installation
247
Connection Diagram
248
Connection Procedure
248
Start-Up
248
Technical Data
249
Ratings
249
Terminals and Cable Entry Data
249
Common Mode, D U /D T and Sine Filters
251
Contents of this Chapter
251
Common Mode Filters
251
D U /D T Filters
251
When Is a D U /D T Filter Needed
251
D U /D T Filter Types
252
Description, Installation and Technical Data of the Filters
253
Sine Filters
253
CAIO-01 Bipolar Analog I/O Adapter Module
255
Contents of this Chapter
255
Product Overview
255
Layout
256
Mechanical Installation
257
Necessary Tools
257
Unpacking and Examining the Delivery
257
Installing the Module
257
Electrical Installation
257
Wiring
257
Start-Up
258
Setting the Parameters
258
Diagnostics
259
Leds
259
Technical Data
259
Isolation Areas
260
Dimension Drawings
261
CHDI-01 115/230 V Digital Input Extension Module
263
Contents of this Chapter
263
Product Overview
263
Layout and Connection Examples
264
Mechanical Installation
265
Necessary Tools
265
Unpacking and Examining the Delivery
265
Installing the Module
265
Electrical Installation
265
Wiring
265
Start-Up
265
Setting the Parameters
265
Parameter Setting Example for Relay Output
266
Fault and Warning Messages
266
Technical Data
266
Dimension Drawing
267
CMOD-01 Multifunction Extension Module
269
Contents of this Chapter
269
Product Overview
269
Layout and Example Connections
270
Mechanical Installation
271
Necessary Tools
271
Unpacking and Examining the Delivery
271
Installing the Module
271
Electrical Installation
271
Wiring
271
Start-Up
272
Setting the Parameters
272
Diagnostics
273
Faults and Warning Messages
273
Leds
273
Technical Data
273
Dimension Drawing
274
CMOD-02 Multifunction Extension Module (External 24 V AC/DC and Isolated PTC Interface)
277
Contents of this Chapter
277
Product Overview
277
Layout and Example Connections
278
Mechanical Installation
279
Necessary Tools
279
Unpacking and Examining the Delivery
279
Installing the Module
279
Electrical Installation
279
Wiring
279
Start-Up
280
Setting the Parameters
280
Diagnostics
280
Faults and Warning Messages
280
Leds
280
Technical Data
280
Dimension Drawing
281
Further Information
283
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