ABB ACH580 Series - Installation, Operation And Maintenance Manual

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ACH580

Installation, Operation and Maintenance Manual (I, O & M)

ACH580-01 HVAC Drives (0.75…250 kW, 1…350 HP)

ACH580-BCR/BDR/VCR/VDR E-Clipse Bypass Drives

(0.75…150 kW, 1…200 HP)

ACH580-PCR/PDR Packaged Drives with Disconnect

(0.75…150 kW, 1…200 HP)

Main Page

Safety Instructions2
General Safety in Installation, Start-Up and Maintenance2
Use of Warnings and Notes in this Manual2
Electrical Safety in Installation, Start-Up and Maintenance3
Precautions before Electrical Work3
Additional Instructions and Notes4
Grounding4
Additional Instructions for Permanent Magnet Motor Drives5
Additional Instructions for Safety Functions5
Safety in Installation, Start-Up and Maintenance5
General Safety in Operation6
Cybersecurity Disclaimer6
Start-Up and Operation6
Contents7
ACH580-01 Installation8
Vertically Alone8
Vertically Side by Side9
Prepare for Installation9
Unpack the Drive9
Tools Required10
Flange Mounting10
Install the Drive11
Install the Cable Box, Frames R1…R211
Installing the Drive Vertically, Frame R512
Installing the Drive Vertically, Frames R6…R914
Installing the Drive Vertically Side by Side15
Install Wiring16
Checking the Insulation of the Assembly16
Ground Connections16
Checking Compatibility with IT and Corner-Grounded TN Systems17
Ground-To-Phase Varistor18
Power Cable Terminal and Lead-Through Data19
Maximum Recommended Motor Cable Length20
Operational Functionality and Motor Cable Length20
Control Cable Terminal and Lead-Through Data21
Fuses24
208…240 Volt, Fuse Requirements24
380…480 Volt, Fuse Requirements25
500…600 Volt, Fuse Recommendations26
External Control Connection Terminals27
External Control Connection Terminals, Frames R628
Wiring R1…R229
Power Wiring Torque Table30
Wiring R331
Wiring R433
Wiring R535
Wiring R6…R937
Communications41
Switches41
Check Installation42
Re-Install Cover43
Frame R5 Cover Installations43
Before Start-Up44
Motor Data44
Default Configurations44
Operation45
Control Panel Features45
Left Softkey45
Right Softkey45
Control Panel Display46
For Initial Start-Up, Follow Steps 1 through 4 below47
Make First Start Assistant-Guided Settings: Language, Motor Nominal Values, and Date and Time47
Complete Commissioning50
Default Configurations — HVAC and PID Control50
Other Ways to Complete Commissioning51
Make Additional Settings in the Primary Settings Menu – I/O Menu52
Check Setup with the Diagnostics Menu53
How to Control the Drive through the I/O Interface54
Preliminary Settings54
Starting and Controlling the Speed of the Motor54
Stopping the Motor54
Diagnostics57
Warning Messages57
Fault Messages68
Maintenance Schedule81
Description of Symbols81
Recommended Annual Actions by the User81
Heatsink82
Main Cooling Fan Replacement82
Frame Size R1...R382
To Replace the Fan82
Frame Size R483
Frame Sizes R5…R883
Frame Size R984
Auxiliary Cooling Fan Replacement84
IP55/UL (NEMA) Type 12 Frame Size R487
Second Auxiliary Cooling Fan Replacement87
Capacitors88
Reforming the Capacitors88
Control Panel88
Battery88
ACH580 E-Clipse Bypass89
Installation – Drive89
Installation - Bypass90
Connection Diagrams – Vertical E-Clipse Bypass91
Connection Diagrams – Box E-Clipse Bypass93
Power Connections – Box E-Clipse Bypass Configurations98
Line Input Connections98
Power Connections - Standard E-Clipse Bypass Configurations (Wall Mounted)98
Install the Control Wiring99
Basic Connections99
Drive’s Power Connection Terminals100
Branch Circuit Protection104
208/230 Volt Fuses for Vertical Enclosures104
460 Volt Fuses for Vertical Enclosures105
575 Volt Fuses for Vertical Enclosures105
208/230 Volt Fuses for Box Enclosures106
460 Volt Fuses for Box Enclosures106
575 Volt Fuses for Box Enclosures107
Basic Control Connections for E-Clipse HVAC Default108
Parameters Changed Relative to E-Clipse HVAC Default108
Check Installation – Bypass109
Control Panel Settings and Checks109
Drive Link Recovery Procedure109
System Check: Motor Connected to ACH580 with E-Clipse Bypass110
System Check: Motor Disconnected from the ACH580 with E-Clipse Bypass112
Check Jumpers and Switches114
Jumper and Switch Locations114
DIP Switch Settings114
E-Clipse Bypass Configurations115
Operation115
Bypass Control118
Ready (Power On) Indication118
Enabled LED118
Motor Run LED118
Drive Selected LED119
Bypass Selected LED119
Drive Faulted LED119
Automatic Transfer119
Auto Key120
Hand Key120
Bypass Control Panel Modes120
Start-Up by Changing the Parameters from the Start-Up List121
Start-Up by Changing the Parameters Individually from Parameter List121
Fault Listing123
Warning Listing129
Bypass Status Listing133
Error Messages134
Maintenance134
Ach580-Pcr/Pdr135
Connection Diagrams – Vertical Packaged Drive with Input Disconnect136
Connection Diagrams – Box Packaged Drive with Input Disconnect138
Power Connection Terminals142
208 Volt Fuses for Packaged Drive145
460 Volt Fuses for Packaged Drive146
575 Volt Fuses for Packaged Drive146
Input Disconnect Configuration148
Maintenance Intervals150
Filter Material150
Enclosure Air Filter Replacement B3 - UL (NEMA) Type 12 Hinged Door Wall Mount Enclosures150
Complete ACH580 Drive Parameter List151

ABB ACH580 Series - Installation, Operation And Maintenance Manual

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