ABB ACQ580-07 - Control Unit; Contents of this Chapter

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Control unit

Contents of this chapter

This chapter contains the default I/O connection diagram, descriptions of the terminals

and technical data for the drive control unit (CCU-24).

Control unit 139

Main Page

Table of Contents10
Table of Contents13
Cabinet Layout - R10 and R11 (Top Entry and Exit of Cables, Options +H351 and +H353)51
Mounting Plate - R10 and R1152
Cooling Air Flow54
Door Switches and Lights55
Main Switch-Disconnector Q155
Control Panel55
Control by PC Tools56
Common Mode Filter56
Overview of Power and Control Connections57
Descriptions of Options58
Degree of Protection58
Definitions58
IP21 (UL Type 1)58
IP42 (UL Type 1 Filtered) (Option +B054)58
IP54 (UL Type 12) (Option +B055)58
UL Listed (Option +C129)58
Plinth Height (Options +C164 and +C179)59
Empty Cubicles on Right (Options +C19659
Empty Cubicles on Left (Options +C19959
Du/Dt Filter (Option +E205)59
Common Mode Filter (Option +E208)59
Molded Case Circuit Breaker (MCCB, Option +F289)59
Cabinet Heater with External Supply (Option +G300)60
Terminals for External Control Voltage (Option +G307)60
Ready/Run/Fault Lights (Options +G32760
Top Cable Entry/Exit (Options +H351 and +H353)60
Cable Conduit Entry (Option +H358)60
Additional Terminal Block X504 (Option +L504)61
Starter for Auxiliary Motor Fan (Options +M6Xx)61
What the Option Contains61
Description61
Cables Accepted by the Terminals of the Additional I/O Terminal Block (Option +L504)61
Type Designation Label62
Type Designation Key62
Basic Code62
Option Codes63
Mechanical Installation67
Contents of this Chapter67
Examining the Installation Site67
Necessary Tools68
Moving and Unpacking the Drive68
Unpacking the Transport Package71
Examining the Delivery72
Lifting the Cabinet72
Lifting Lugs74
Moving the Cabinet after Unpacking76
Moving the Cabinet with Rollers77
Moving the Cabinet to Its Final Placement with a Slate Bar77
Attaching the Cabinet to the Floor and Wall or Roof77
General Rules77
Attaching the Cabinet (Non-Marine Units)78
Alternative 1 - Clamping78
Alternative 2 - Using the Holes Inside the Cabinet80
Alternative 3 - Cabinets with Plinth Options +C164 and +C17981
Miscellaneous82
Cable Duct in the Floor below the Cabinet82
Arc Welding82
Guidelines for Planning the Electrical Installation83
Contents of this Chapter83
Limitation of Liability83
Selecting the Supply Disconnecting Device83
Selecting the Main Contactor or Breaker83
Examining the Compatibility of the Motor and Drive84
Protecting the Motor Insulation and Bearings84
Requirements Table84
Availability of Du/Dt Filter and Common Mode Filter by Drive Type87
Additional Requirements for Explosion-Safe (EX) Motors87
Additional Requirements for ABB Motors of Types Other than M2_, M3_, M4_, HX_ and am87
Additional Requirements for ABB High-Output and IP23 Motors87
Additional Requirements for Non-ABB High-Output and IP23 Motors88
Additional Data for Calculating the Rise Time and the Peak Line-To-Line Voltage89
Selecting the Power Cables91
General Guidelines91
Typical Power Cable Sizes92
Power Cable Types92
Preferred Power Cable Types92
Alternate Power Cable Types93
Not Allowed Power Cable Types94
Additional Guidelines, North America94
Metal Conduit95
Power Cable Shield95
Selecting the Control Cables96
Shielding96
Signals in Separate Cables96
Signals that Can be Run in the same Cable96
Relay Cable96
Control Panel to Drive Cable96
PC Tool Cable96
Routing the Cables97
General Guidelines - IEC97
General Guidelines - North America98
Continuous Motor Cable Shield/Conduit or Enclosure for Equipment on the Motor Cable99
Separate Control Cable Ducts99
Implementing Short-Circuit and Thermal Overload Protection99
Protecting the Input Cabling and Drive in Short-Circuits99
Protecting the Motor and Motor Cable in Short-Circuits100
Protecting the Drive and the Power Cables against Thermal Overload100
Protecting the Motor against Thermal Overload100
Protecting the Drive against Ground Faults101
Residual Current Device Compatibility101
Implementing the Emergency Stop Function101
Implementing the Safe Torque off Function101
Implementing the Power Loss Ride-Through Function101
Using Power Factor Compensation Capacitors with the Drive102
Using a Safety Switch between the Drive and the Motor103
Implementing an ATEX-Certified Motor Thermal Protection103
Controlling a Contactor between Drive and Motor103
Implementing a Bypass Connection104
Protecting the Contacts of Relay Outputs104
Implementing a Motor Temperature Sensor Connection105
Connecting Motor Temperature Sensor to the Drive Via an Option Module106
Supplying Power for the Auxiliary Circuits107
Electrical Installation109
Contents of this Chapter109
Warning109
Attaching the Device Stickers on the Cabinet Door109
Layout of the Cable Entries (Frames R6110
Layout of the Cable Entries (Frames R10 and R11)111
Connecting the Motor Cable at the Motor End111
Measuring the Insulation112
Measuring the Insulation of the Drive112
Measuring the Insulation of the Input Power Cable112
Measuring the Insulation of the Motor and Motor Cable112
Grounding System Compatibility Check113
Connecting the Power Cables113
Preparing the Cable Ends and Making 360-Degree Grounding at the Cable Entry113
Connection Diagram115
Connection Procedure (Frames R6117
Connection Procedure (Frames R6 and R7 with Options +H351 and +H353)118
H353)120
Connection Procedure120
Tighten the Power Cable Screws to the Torque Given in Terminal and Entry Data for the Power Cables122
Reinstall the Shrouds and Mounting Plate122
Connection Procedure (Frames R10 and R11)123
H353)124
Do the Steps in Section Electrical Safety Precautions (Page 20) before You Start the Work124
Open the Cabinet Door124
Remove the Door Fan Mounting Plate. See Section125
R10 and R11)125
Connect the Twisted Shields of the Motor Cables to the Ground Bar and the Phase Conductors to the U2, V2 and W2 Terminals of the Drive Module126
Connect the Twisted Shields of the Input Cables and Separate Ground Cable (if Present)126
To the PE Terminal of the Cabinet and the Phase Conductors to the L1, L2 and L3126
Connecting the Control Cables127
Overview of Control Cable Connection Procedure128
Grounding the Outer Shields of the Control Cables at the Cabinet Entry128
Routing the Control Cables Inside the Cabinet132
Connecting External Wiring to the Control Unit or Optional I/O Terminal Block135
Connecting the Emergency Stop Push Buttons (Options +Q951 and +Q963)136
Frames R6136
Frames R10 and R11137
Connecting the Safe Torque off Circuit137
G300)137
Setting the Voltage Range of the Auxiliary Control Voltage Transformer (T21)138
Connecting a PC139
Installing Option Modules140
Option Slot 2 (I/O Extension Modules)140
Option Slot 1 (Fieldbus Adapter Modules)141
Wiring the Optional Modules141
Control Unit143
Contents of this Chapter143
Layout144
Default I/O Connection Diagram145
DI6 for Internal Overtemperature Supervision with Option +E205 in Frames R10 and R11146
PNP and NPN Configurations for Digital Inputs147
PNP Configurations with Option +L504147
NPN Configurations with Option +L504147
PNP Configurations Without Option +L504148
NPN Configurations Without Option +L504148
Switches149
Additional Information on I/O Connections149
Connection for Obtaining 0149
Connection Examples of Two-Wire and Three-Wire Sensors to Analog Input (AI2)150
DI5 as Frequency Input150
DI6 as PTC Input150
AI1 and AI2 as Pt100, Pt1000, Ni1000, KTY83 and KTY84 Sensor Inputs (X1)151
Safe Torque off (X4)151
Technical Data152
Installation Checklist157
Contents of this Chapter157
Checklist157
Start-Up159
Contents of this Chapter159
Start-Up Procedure159
Fault Tracing161
Contents of this Chapter161
Warning and Fault Messages161
Maintenance163
Contents of this Chapter163
Maintenance Intervals163
Descriptions of Symbols163
Recommended Annual Maintenance Actions by the User164
Recommended Maintenance Intervals after Start-Up164
Cleaning the Interior of the Cabinet165
Cleaning the Air Inlet (Door) Meshes (IP42 / UL Type 1 Filtered)165
Replacing the Air Filters (IP54 / UL Type 12)166
Inlet (Door) Filters (IP54 / UL Type 12)167
Outlet (Roof) Filters (IP54 / UL Type 12)167
Heatsink (Frames R6 to R9)168
Fans168
Replacing the Door Fan (Frames R6168
Replacing the Cabinet Fan (Frames R6169
Replacing the Door Fan (Frames R10 and R11)170
Replacing the Cabinet Fan (Frames R10 and R11, IP54 / UL Type 12)172
Replacing the Drive Module Main Fans (Frames R6173
Replacing the Drive Module Main Fans (Frame R9)174
Replacing the Drive Module Main Fans (Frames R10 and R11)175
Replacing the Auxiliary Cooling Fan of the Drive Module (Frames R6176
Replacing the Circuit Board Compartment Cooling Fans (Frames R10 and R11)178
Replacing the Drive Module (Frames R6178
Replacing the Drive Module (Frames R10 and R11)186
Replacing the Drive Module (Frames R10 and R11, IP54 / UL Type 12)192
Capacitors198
Reforming the Capacitors198
Fuses198
Replacing AC Fuses (Frames R6 and R7)198
Replacing AC Fuses199
Control Panel200
Cleaning the Control Panel200
Replacing the Battery200
Technical Data201
Contents of this Chapter201
Ratings201
IEC Ratings201
UL (NEC) Ratings202
Definitions203
Output Derating203
Ambient Temperature Derating203
Drive Types Other than -0414A-4 and -0430A-4203
Drive Types -0414A-4 and -0430A-4204
Altitude Derating204
Deratings for Special Settings in the Drive Control Program205
Fuses (IEC)206
Fuses (UL)208
Fuses for Branch Circuit Protection209
Dimensions and Weights209
Free Space Requirements210
Maximum Allowed Plinth Height for the Extraction/Installation Ramp211
Typical Power Cable Sizes211
Losses, Cooling Data and Noise212
Terminal and Entry Data for the Power Cables213
IEC - Standard Configuration213
IEC - with Option +E205214
Standard Configuration214
With Option +E205215
Connection Drawings216
Terminal and Connection Data for Auxiliary Control Circuits242
Electrical Power Network Specification243
Motor Connection Data243
Control Unit Connection Data244
Efficiency244
Protection Classes244
Ambient Conditions245
Auxiliary Circuit Power Consumption246
Materials246
Cabinet246
Finish246
Package246
Vertical Package246
Horizontal Package247
Package Dimensions and Weights for Drives Without Empty Cubicles (Without Options +C196247
Package Weights248
Applicable Standards249
Markings250
CE Marking250
Compliance with the European Low Voltage Directive250
Compliance with the European EMC Directive251
Compliance with the European Machinery Directive251
Compliance with the en 61800-3:2004252
Definitions252
Category C2252
Category C3252
Category C4253
UL Marking254
UL and CSA Checklist254
Design Lifetime Expectancy255
Disclaimers256
Generic Disclaimer256
Cybersecurity Disclaimer256
Dimension Drawings257
Frames R6 and R7 (IP21, UL Type 1)258
Frames R6 and R7 (+B054: IP42, UL Type 1 Filtered)259
Frames R6 and R7 (+B055: IP54, UL Type 12)260
Frames R6 and R7 (+H351 and +H353: Top Entry and Exit)261
Frames R6 and R7 (+F289)262
Frames R6 and R7 (+F289, +H351, +H353)263
Frames R8 and R9 (IP21, UL Type 1)264
Frames R8 and R9 (+B054: IP42, UL Type 1 Filtered)265
Frames R8 and R9 (+B055: IP54, UL Type 12)266
Frames R8 and R9 (+H351 and +H353: Top Entry and Exit)267
Frames R8 and R9 (+F289)268
Frames R8 and R9 (+F289, +H351, +H353)269
Frames R10 and R11 (IP21, UL Type 1)270
Frames R10 and R11 (+B054: IP42, UL Type 1 Filtered)271
Frames R10 and R11 (+B055: IP54, UL Type 12)272
Frames R10 and R11 (+F289)273
Frames R10 and R11 (+H351, +H353)274
Frames R10 and R11 (+B054: IP42, UL Type 1 Filtered, +H351, +H353)275
Frames R10 and R11 (+B055: IP54, UL Type 12, +H351, +H353)276
The Safe Torque off Function277
Contents of this Chapter277
Description277
Compliance with the European Machinery Directive278
Wiring279
Connection Principle279
Single ACQ580-07 Drive, Internal Power Supply279
Single ACQ580-07 Drive, External Power Supply280
Wiring Examples280
Single ACQ580-07 Drive, Internal Power Supply280
Single ACQ580-07 Drive, External Power Supply281
Multiple ACQ580-07 Drives, Internal Power Supply282
Multiple ACQ580-07 Drives, External Power Supply283
Activation Switch284
Cable Types and Lengths284
Grounding of Protective Shields284
Operation Principle285
Start-Up Including Acceptance Test286
Competence286
Acceptance Test Reports286
Acceptance Test Procedure286
Use288
Maintenance290
Competence290
Fault Tracing291
Safety Data292
Abbreviations293
TÜV Certificate294
Declaration of Conformity295
CHDI-01 115/230 V Digital Input Extension Module297
Contents of this Chapter297
Product Overview297
Layout and Connection Examples298
Mechanical Installation299
Necessary Tools299
Unpacking and Examining the Delivery299
Installing the Module299
Electrical Installation299
Wiring299
Start-Up299
Setting the Parameters299
Parameter Setting Example for Relay Output300
Fault and Warning Messages300
Technical Data300
Dimension Drawing301
CMOD-01 Multifunction Extension Module303
Contents of this Chapter303
Product Overview303
Layout and Example Connections304
Mechanical Installation305
Necessary Tools305
Unpacking and Examining the Delivery305
Installing the Module305
Electrical Installation305
Wiring305
Start-Up306
Setting the Parameters306
Diagnostics307
Faults and Warning Messages307
Leds307
Technical Data307
Dimension Drawing308
CMOD-02 Multifunction Extension Module311
Contents of this Chapter311
Product Overview311
Layout and Example Connections312
Mechanical Installation313
Necessary Tools313
Unpacking and Examining the Delivery313
Installing the Module313
Electrical Installation313
Necessary Tools and Instructions313
Wiring314
Start-Up314
Setting the Parameters314
Diagnostics314
Faults and Warning Messages314
Leds314
Technical Data314
Dimension Drawing315
Disconnecting EMC Filter and Ground-To-Phase Varistor317
When to Disconnect the Ground-To-Phase Varistor: TN-S, IT, Corner-Grounded Delta and Midpoint-Grounded Delta Systems317
Guidelines for Installing the Drive to a TT System319
Identifying the Grounding System of the Electrical Power Network319
Disconnecting the EMC Filter and Ground-To-Phase Varistor (Frames R6321
Disconnecting the Ground-To-Phase Varistor (Frames R10 and R11)321
Further Information323

ABB ACQ580-07 - Control Unit; Contents of this Chapter

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