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166 Maintenance

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Table of Contents5
Safety Instructions17
Contents of this Chapter17
Use of Warnings and Notes17
General Safety in Installation, Start-Up and Maintenance18
Electrical Safety in Installation, Start-Up and Maintenance20
Electrical Safety Precautions20
Additional Instructions and Notes21
Printed Circuit Boards21
Grounding22
General Safety in Operation23
Additional Instructions for Permanent Magnet Motor Drives23
Safety in Installation, Start-Up, Maintenance23
Safety in Operation24
Introduction to the Manual25
Contents of this Chapter25
Target Audience25
Purpose of the Manual25
Categorization by Frame Size and Option Code25
Quick Installation, Commissioning and Operation Flowchart26
Terms and Abbreviations27
Related Documents29
Operation Principle31
Contents of this Chapter31
Active Braking Function (Option +N8056 )32
DC Voltage Boost Function32
Benefits of the DC Voltage Boost33
Impact of DC Voltage Boost on Input Current33
DC Connection33
Layout34
Overview of Power and Control Connections36
Control Panel37
Control Panel Door Mounting Kits38
Control Panel Mounting Platform Cover (Option +J424)38
Remote Control Panel, Panel Bus38
Type Designation Label40
Type Designation Key41
Basic Code41
Option Codes41
Mechanical Installation43
Contents of this Chapter43
Cabinet Installation (Option +P940)43
Flange Mounting (Option +C135)43
Safety44
Examining the Installation Site44
Installation Positions44
Free Space Requirements45
Necessary Tools46
Moving the Drive47
Unpacking and Examining Delivery47
Installing the Drive Vertically53
Installing the Drive Vertically Side by Side55
Installing the Drive Horizontally55
Guidelines for Planning the Electrical Installation57
Contents of this Chapter57
Limitation of Liability57
Selecting the Main Supply Disconnecting Device57
European Union and United Kingdom58
North America58
Other Regions58
Implementing a Fast Switch over between the Power Line and Generator58
Selecting the Main Contactor58
North America59
Other Regions59
Examining the Compatibility of the Motor and Drive59
Protecting the Motor Insulation and Bearings59
Requirements Tables60
Requirements for ABB Motors, P60
Kw (134 Hp)60
Requirements for ABB Motors, P61
Requirements for Non-ABB Motors, P < 100 Kw (134 Hp)62
Requirements for Non-ABB Motors, P63
Abbreviations64
Availability of D U /D T Filter and Common Mode Filter by Drive Type64
Additional Requirements for Explosion-Safe (EX) Motors64
Additional Requirements for ABB Motors of Types Other than M2_, M3_, M4_, HX_ and am64
Additional Requirements for Braking Applications64
Additional Requirements for the Regenerative and Low Harmonics Drives64
Additional Requirements for ABB High-Output and IP23 Motors64
Additional Requirements for Non-ABB High-Output and IP23 Motors65
Additional Data for Calculating the Rise Time and the Peak Line-To-Line Voltage66
Additional Note for Sine Filters67
Selecting the Power Cables68
General Guidelines68
Typical Power Cable Sizes68
Power Cable Types68
Preferred Power Cable Types68
Alternate Power Cable Types69
Not Allowed Power Cable Types70
Additional Guidelines - North America70
Metal Conduit71
Power Cable Shield71
Grounding Requirements72
Additional Grounding Requirements - IEC73
Additional Grounding Requirements - UL (NEC)74
Selecting the Control Cables74
Shielding74
Signals in Separate Cables74
Signals that Can be Run in the same Cable74
Relay Cable75
Control Panel to Drive Cable75
PC Tool Cable75
Routing the Cables75
General Guidelines - IEC75
General Guidelines - North America76
Continuous Motor Cable Shield/Conduit or Enclosure for Equipment on the Motor Cable77
Separate Control Cable Ducts78
Protecting the Drive, Input Power Cable, Motor and Motor Cable in Short Circuit Situations and against Thermal Overload78
Protecting the Drive and the Input Power Cable in Short-Circuits78
Circuit Breakers79
Protecting the Motor and Motor Cable in Short-Circuits79
Protecting the Motor Cables against Thermal Overload79
Protecting the Motor against Thermal Overload80
Protecting the Motor against Overload Without Thermal Model or Temperature Sensors80
Implementing a Motor Temperature Sensor Connection80
Connecting a Motor Temperature Sensor to the Drive through an Option81
Module81
Protecting the Drive against Ground Faults82
Residual Current Device Compatibility82
Implementing the Emergency Stop Function82
Implementing the Safe Torque off Function82
Implementing the Power Loss Ride-Through Function82
Using Power Factor Compensation Capacitors with the Drive83
Using a Safety Switch between the Drive and the Motor84
Implementing an ATEX-Certified Motor Thermal Protection84
Controlling a Contactor between Drive and Motor84
Implementing a Bypass Connection85
Example Bypass Connection86
Switching the Motor Power Supply from Drive to Direct-On-Line86
Switching the Motor Power Supply from Direct-On-Line to Drive87
Protecting the Contacts of Relay Outputs87
Limiting Relay Output Maximum Voltages at High Installation Altitudes88
Implementing a Motor Temperature Sensor Connection88
Connecting a Motor Temperature Sensor to the Drive through an Option89
Module89
Electrical Installation - IEC91
Contents of this Chapter91
Safety91
Required Tools91
Grounding the Motor Cable Shield at the Motor End91
Measuring the Insulation92
Measuring the Insulation Resistance of the Drive92
Measuring the Insulation Resistance of the Input Power Cable92
Measuring the Insulation Resistance of the Motor and Motor Cable92
Measuring the Insulation Resistance of the Brake Resistor Circuit93
Grounding System Compatibility Check93
EMC Filter93
Ground-To-Phase Varistor94
When to Disconnect EMC Filter or Ground-To-Phase Varistor: TN-S, IT, Corner-Grounded Delta and Midpoint-Grounded Delta Systems and TT Systems94
Identifying the Grounding System of the Electrical Power Network97
Disconnecting Integrated EMC Filter and Ground-To-Phase Varistor - Frame R398
Disconnecting Integrated EMC Filter and Ground-To-Phase Varistor - Frame R699
Disconnecting Integrated EMC Filter and Ground-To-Phase Varistor - Frame R8100
Connecting the Power Cables101
Connection Diagram101
Connection Procedure102
R8 Power Cable Connection if You Detach the Cable Connectors109
Connecting the Control Cables110
Connection Diagram110
Connection Procedure110
Installing Option Modules115
Option Slot 2 (I/O Extension Modules)115
Option Slot 1 (Fieldbus Adapter Modules)116
Wiring the Optional Modules116
Reinstalling Cover(S)117
Connecting a PC118
Connecting a Remote Panel, or Chaining One Panel to Several Drives118
Electrical Installation - North America (NEC)119
Contents of this Chapter119
Safety119
Required Tools119
Measuring the Installation120
Grounding System Compatibility Check120
Connecting the Power Cables120
Connection Diagram120
Connection Procedure121
Connecting the Control Cables128
Connection Diagram128
Connection Procedure128
Installing Optional Modules132
Reinstalling Cover(S)133
Connecting a PC134
Connecting a Remote Panel, or Chaining One Panel to Several Drives134
Control Unit135
Contents of this Chapter135
Layout136
Default I/O Connection Diagram137
Switches139
Additional Information on I/O Connections139
PNP Configuration for Digital Inputs (X2 & X3)139
NPN Configuration for Digital Inputs (X2 & X3)140
Connection for Obtaining 0140
Connection Examples of Two-Wire and Three-Wire Sensors to Analog Input (AI2)140
DI5 as Frequency Input141
DI6 as PTC Input141
AI1 and AI2 as Pt100, Pt1000, Ni1000, KTY83 and KTY84 Sensor Inputs (X1)141
Safe Torque off (X4)142
Technical Data142
Installation Checklist147
Contents of this Chapter147
Checklist147
Start-Up151
Contents of this Chapter151
Reforming the Capacitors151
Start-Up Procedure151
Maintenance153
Contents of this Chapter153
Maintenance Intervals153
Description of Symbols153
Recommended Maintenance Intervals after Start-Up153
Cleaning the Exterior of the Drive155
Cleaning the Heatsink156
Fans156
Replacing the Main Cooling Fan, Frame R3157
Replacing the Main Cooling Fan, Frame R6158
Replacing the Main Cooling Fan, Frame R8159
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 R6161
Replacing the Second Auxiliary Cooling Fan, IP55 (UL Type 12) Frame R6162
Replacing the Auxiliary Cooling Fan, Frame R8163
Replacing the Second Internal Auxiliary Cooling Fan, IP55 (UL Type 12) Frame R8164
Replacing the Auxiliary Cooling Fan in the IP55 (UL Type 12) Cover, Frame R8165
Capacitors167
Reforming the Capacitors167
Control Panel167
Drive Leds167
Functional Safety Components168
Technical Data169
Contents of this Chapter169
Electrical Ratings169
IEC Ratings169
UL (NEC) Ratings170
Definitions171
Sizing172
Deratings172
Derating in Case of Several Situations172
Surrounding Air Temperature Derating173
Altitude Derating174
Switching Frequency Derating175
Output Voltage Boost Derating177
Fuses (IEC)178
Ar Fuses DIN 43653 Stud-Mount179
Ar Fuses DIN 43620 Blade Style180
Gg Fuses DIN 43620 Blade Style180
Calculating the Short-Circuit Current of the Installation181
Calculation Example181
Fuses (UL)182
Circuit Breakers (IEC)184
ABB Miniature and Molded Case Circuit Breakers184
Circuit Breakers (UL)185
Dimensions, Weights and Free Space Requirements188
Free Space Requirements188
Package Dimensions and Weights189
Losses, Cooling Data and Noise190
Cooling Air Flow and Heat Dissipation for Flange Mounting (Option +C135)192
Terminal and Entry Data for the Power Cables194
Iec194
Ul194
Terminal and Entry Data for the Control Cables195
Iec195
Ul195
Typical Power Cables195
Electrical Power Network Specification198
Motor Connection Data200
CCU-24 Control Unit Connection Data201
Efficiency201
Energy Efficiency Data (EU Ecodesign)201
Protection Classes for Module202
Colors202
Materials202
Drive202
Package Materials for Small Wall-Mounted Drives and Converter Modules202
Package Materials for Large Wall-Mounted Drives and Converter Modules202
Package Materials for Options, Accessories and Spare Parts203
Materials of Manuals203
Disposal203
Applicable Standards203
Ambient Conditions204
Markings205
Compliance with the en 61800-3:204 + A1:2012206
Definitions206
Category C2207
Category C3208
Category C4208
UL Checklist209
Declarations of Conformity210
Design Lifetime Expectancy211
Disclaimers211
Generic Disclaimer211
Cybersecurity Disclaimer211
Dimension Drawings213
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 Function221
Contents of this Chapter221
Description221
Compliance with the European Machinery Directive and the UK Supply of Machinery (Safety) Regulations222
Wiring223
Connection Principle223
Single ACH580-31 Drive, Internal Power Supply223
Single ACH580-31 Drive, External Power Supply224
Wiring Examples224
Single ACH580-31 Drive, Internal Power Supply224
Single ACH580-31 Drive, External Power Supply225
Multiple ACH580-31 Drives, Internal Power Supply226
Multiple ACH580-31 Drives, External Power Supply227
Activation Switch228
Cable Types and Lengths228
Grounding of Protective Shields228
Operation Principle229
Start-Up Including Validation Test230
Competence230
Validation Test Reports230
Validation Test Procedure230
Use232
Maintenance234
Competence234
Fault Tracing235
Safety Data236
Terms and Abbreviations238
TÜV Certificate240
Declarations of Conformity240
Resistor Braking243
Contents of this Chapter243
Operation Principle243
Planning the Braking System243
Selecting the Default Brake System Components243
Selecting a Custom Brake Resistor244
Selecting and Routing the Brake Resistor Cables245
Minimizing Electromagnetic Interference245
Maximum Cable Length245
Placing the Brake Resistors246
Protecting the System against Thermal Overload246
Protecting the System in Fault Situations246
Protecting the Resistor Cable against Short-Circuits247
Mechanical Installation247
Electrical Installation247
Measuring the Installation247
Connection Diagram248
Connection Procedure248
Start-Up248
Technical Data249
Ratings249
Terminals and Cable Entry Data249
Common Mode, D U /D T and Sine Filters251
Contents of this Chapter251
Common Mode Filters251
D U /D T Filters251
When Is a D U /D T Filter Needed251
D U /D T Filter Types252
Description, Installation and Technical Data of the Filters253
Sine Filters253
CAIO-01 Bipolar Analog I/O Adapter Module255
Contents of this Chapter255
Product Overview255
Layout256
Mechanical Installation257
Necessary Tools257
Unpacking and Examining the Delivery257
Installing the Module257
Electrical Installation257
Wiring257
Start-Up258
Setting the Parameters258
Diagnostics259
Leds259
Technical Data259
Isolation Areas260
Dimension Drawings261
CHDI-01 115/230 V Digital Input Extension Module263
Contents of this Chapter263
Product Overview263
Layout and Connection Examples264
Mechanical Installation265
Necessary Tools265
Unpacking and Examining the Delivery265
Installing the Module265
Electrical Installation265
Wiring265
Start-Up265
Setting the Parameters265
Parameter Setting Example for Relay Output266
Fault and Warning Messages266
Technical Data266
Dimension Drawing267
CMOD-01 Multifunction Extension Module269
Contents of this Chapter269
Product Overview269
Layout and Example Connections270
Mechanical Installation271
Necessary Tools271
Unpacking and Examining the Delivery271
Installing the Module271
Electrical Installation271
Wiring271
Start-Up272
Setting the Parameters272
Diagnostics273
Faults and Warning Messages273
Leds273
Technical Data273
Dimension Drawing274
CMOD-02 Multifunction Extension Module (External 24 V AC/DC and Isolated PTC Interface)277
Contents of this Chapter277
Product Overview277
Layout and Example Connections278
Mechanical Installation279
Necessary Tools279
Unpacking and Examining the Delivery279
Installing the Module279
Electrical Installation279
Wiring279
Start-Up280
Setting the Parameters280
Diagnostics280
Faults and Warning Messages280
Leds280
Technical Data280
Dimension Drawing281
Further Information283

ABB ACH580-31 - Page 166

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