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Hardware manual

ACS530-04 drive modules

(250 to 500 kW)

3AXD50000810598 Rev A

EN

EFFECTIVE: 2021-08-15

 2021 ABB Oy. All Rights Reserved.

1. Safety instructions

6. Installation instructions

Table of contents

9. Start-up

Table of Contents

Default Chapter5
- Table of Contents5
1 Safety Instructions13
- Contents of this Chapter13
- Use of Warnings and Notes13
- General Safety in Installation, Start-Up and Maintenance14
- Electrical Safety in Installation, Start-Up and Maintenance16
- Additional Instructions for Permanent Magnet Motor Drives19
  - Safety in Installation, Start-Up and Maintenance19
2 Introduction to the Manual21
- Contents of this Chapter21
- Target Audience21
- Contents of the Manual22
- Categorization by Frame Size and Option Code23
- Quick Installation, Commissioning and Operating Flowchart23
- Terms and Abbreviations25
3 Operation Principle and Hardware Description27
- Contents of this Chapter27
- Product Overview27
- Layout28
- Overview of Power and Control Connections32
  - Control Connection Terminals33
- Type Designation Label34
- Type Designation Key34
4 Guidelines for Planning the Cabinet Installation37
- Contents of this Chapter37
- Limitation of Liability37
- Installation Positions of the Drive Module37
- Basic Requirements for the Cabinet37
- Planning the Layout of the Cabinet38
- Arranging the Grounding Inside the Cabinet41
- Selecting the Busbar Material and Preparation of the Joints41
- Tightening Torques41
- Planning the Fastening of the Cabinet41
- Planning the Cabinet Placement on a Cable Channel42
- Planning the Electromagnetic Compatibility (EMC) of the Cabinet42
- Planning the Cooling44
- Preventing the Recirculation of Hot Air45
  - Standard Drive Module Configuration46
  - Drive Module with Option +B05148
- Required Free Space49
  - Free Space at the Top of the Drive Module49
  - Free Space Around the Drive Module49
- Other Installation Positions49
  - Drive Module on Its Back49
- Planning the Placement of the Control Panel50
- Planning the Use of Cubicle Heaters50
- Arc Welding50
5 Guidelines for Planning the Electrical Installation51
- Contents of this Chapter51
- Selecting the Supply Disconnecting Device52
  - European Union52
  - Other Regions52
- Selecting the Main Contactor52
- Examining the Compatibility of the Motor and Drive52
  - Protecting the Motor Insulation and Bearings52
  - Requirements Table53
- Selecting the Power Cables55
- Selecting the Control Cables59
- Implementing Thermal Overload and Short-Circuit Protection61
- Protecting the Drive against Ground Faults62
  - Residual Current Device Compatibility62
- Implementing the Emergency Stop Function63
- Implementing the Safe Torque off Function63
- Implementing the Power Loss Ride-Through Function63
- Using Power Factor Compensation Capacitors with the Drive63
- Implementing a Safety Switch between the Drive and the Motor63
- Using a Contactor between the Drive and the Motor64
- Implementing a Bypass Connection64
  - Example Bypass Connection65
- Protecting the Contacts of Relay Outputs66
- Connecting a Motor Temperature Sensor to the Drive I/O67
- Example Circuit Diagram67
6 Installation Instructions69
- Contents of this Chapter69
- Safety69
- Checking the Installation Site69
- Moving and Unpacking the Unit70
- Checking the Delivery74
- Installing the Motor Cable at the Motor End74
- Checking the Insulation of the Assembly75
- Installation Alternatives75
- Connecting the Power Cables79
- Connecting the Control Cables82
  - Default I/O Connection Diagram (ABB Standard Macro)84
- Connecting a Control Panel89
- Installing Option Modules90
- Connecting a PC91
7 Installation Example of Drive Module with IP20 Shrouds (Option +B051)93
- Contents of this Chapter93
- Limitation of Liability93
- Safety93
- Required Parts94
- Required Tools94
- Overall Flowchart of the Installation Process94
- Installing the Drive Module into a Cabinet95
- Connecting the Power Cables and Installing the Shrouds95
- Installing the Roof and Door97
- Miscellaneous98
8 Installation Checklist99
- Contents of this Chapter99
9 Start-Up103
- Contents of this Chapter103
- Start-Up Procedure103
10 Fault Tracing105
- Contents of this Chapter105
- Warning and Fault Messages105
11 Maintenance107
- Contents of this Chapter107
- Maintenance Intervals107
- Cabinet108
  - Cleaning the Interior of the Cabinet108
- Heatsink109
  - Cleaning the Interior of the Heatsink109
- Fans110
  - Replacing the Circuit Board Compartment Cooling Fan110
  - Replacing the Main Cooling Fans111
- Replacing the Drive Module112
- Capacitors113
  - Reforming the Capacitors113
- Control Panel114
  - Cleaning the Control Panel114
  - Replacing the Battery in the Assistant Control Panel114
12 Technical Data117
- Contents of this Chapter117
- Ratings117
  - IEC Ratings117
  - Output Derating118
- Fuses (IEC)119
- Dimensions, Weights and Free Space Requirements119
- Losses, Cooling Data and Noise120
- Terminal and Lead-Through Data for the Power Cables120
- Terminal Data for the Control Cables120
- Electrical Power Network Specification121
- Motor Connection Data121
- DC Connection Data121
- Control Unit (CCU-24) Connection Data121
- Control Panel Type123
- Efficiency (EU Ecodesign)123
- Degree of Protection123
- Ambient Conditions124
- CE Marking125
  - Compliance with the European Low Voltage Directive125
- Materials125
- Applicable Standards125
  - Compliance with the European EMC Directive126
  - Compliance with the European Rohs Directive126
- Compliance with the European Machinery Directive126
- Compliance with en 61800-3:2004126
  - Definitions126
  - Category C3127
  - Category C4127
- China Rohs Marking128
- WEEE Marking128
- Cybersecurity Disclaimer128
- Disclaimer128
13 Dimension Drawings129
- Contents of this Chapter129
- R10 Standard Configuration130
- R10 with Options +E208+0H354+H356+0H370+0H371131
- R10 with Option +B051132
- R11 Standard Configuration133
- R11 with Options +E208+0H354+H356+0H370+0H371134
- R11 with Option +B051135
- Air Baffles for the Drive Module with Option +B051136
14 Example Circuit Diagram137
- Contents of this Chapter137
15 Safe Torque off Function139
- Contents of this Chapter139
- Description139
  - Compliance with the European Machinery Directive140
- Wiring140
- Operation Principle147
- Start-Up Including Acceptance Test147
- Use148
- Maintenance149
  - Competence150
- Fault Tracing150
- Safety Data150
  - Declaration of Conformity152
16 Optional I/O Extension Modules153
- Contents of this Chapter153
- CHDI-01 115/230 V Digital Input Extension Module153
- CMOD-01 Multifunction Extension Module (External 24 V AC/DC and Digital I/O)159
- CMOD-02 Multifunction Extension Module (External 24 V AC/DC and Isolated PTC Interface)166
- CPTC-02 ATEX-Certified Thermistor Protection Module, (External 24 V AC/DC and Isolated PTC Interface)172
17 Du/Dt Filters173
- Contents of this Chapter173
18 Step-By-Step Drawings for an Installation Example of Drive Module with Options179
Further Information179
- Product and Service Inquiries179
- Product Training179
- Providing Feedback on ABB Manuals179
- Document Library on the Internet179

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