ABB ACS580 Series

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Table of Contents5
Table of Contents7
Safety Instructions21
Contents of this Chapter21
Use of Warnings and Notes21
General Safety in Installation, Start-Up and Maintenance22
Electrical Safety in Installation, Start-Up and Maintenance24
Electrical Safety Precautions24
Additional Instructions and Notes25
Printed Circuit Boards25
Grounding26
General Safety in Operation27
Additional Instructions for Permanent Magnet Motor Drives27
Safety in Installation, Start-Up, Maintenance27
Safety in Operation28
Introduction to the Manual29
Contents of this Chapter29
Applicability29
Target Audience29
Categorization by Frame Size29
Quick Installation and Commissioning Flowchart30
Terms and Abbreviations31
Related Documents33
Operation Principle and Hardware Description35
Contents of this Chapter35
Operation Principle36
Layout36
Overview of Power and Control Connections48
External Control Connection Terminals, Frames R149
External Control Connection Terminals, Frames R650
Control Panel51
Control Panel Door Mounting Kits52
Type Designation Label52
Locations of the Labels on the Drive53
Type Designation Key54
Option Codes55
Manual Kit Ordering Codes57
Mechanical Installation59
Contents of this Chapter59
Safety59
Cabinet Installation (Option +P944)60
Examining the Installation Site60
Installation Alternatives61
Necessary Tools66
Moving the Drive66
Unpacking and Examining Delivery, Frames R1 and R267
Frames R1 and R2 Cable Box (IP21, UL Type 1)69
Unpacking and Examining Delivery, Frame R370
Unpacking and Examining Delivery, Frames R172
Unpacking and Examining Delivery, Frames R474
Unpacking and Examining Delivery, Frame R5 and R676
Frame R5 Cable Box (IP21, UL Type 1)77
Frame R6 Cable Box (IP21, UL Type 1)78
Unpacking and Examining Delivery, Frame R779
Frame R7 Cable Box (IP21, UL Type 1)81
Unpacking and Examining Delivery, Frames R8 and R982
Frame R8 Cable Box (IP21, UL Type 1)84
Frame R9 Cable Box (IP21, UL Type 1)85
Installing the Drive86
Installing the Drive Vertically, Frames R186
Installing the Cable Box, Frames R187
Installing the Drive Vertically, Frame R588
IP21 (UL Type 1)89
IP21 (UL Type 1), IP55 (UL Type 12)90
Installing the Drive Vertically, Frames R691
IP21 (UL Type 1)92
IP55 (UL Type 12)93
Installing the Drive Vertically Side by Side93
Installing the Drive Horizontally, Frames R193
Flange Mounting93
Strut Channel Installation (US Only)94
Installation Instructions94
Cabinet Installation (Options +P940 and +P944)94
Guidelines for Planning the Electrical Installation95
Contents of this Chapter95
Limitation of Liability95
North America95
Selecting the Main Supply Disconnecting Device95
Selecting the Main Contactor96
Examining the Compatibility of the Motor and Drive96
Protecting the Motor Insulation and Bearings96
Requirements Tables97
Requirements for ABB Motors, P98
Requirements for ABB Motors, P99
Requirements for Non-ABB Motors, P N < 100 Kw (134 Hp)100
Requirements for Non-ABB Motors, P101
Abbreviations102
Availability of D U /D T Filter and Common Mode Filter by Drive Type102
Additional Requirements for Explosion-Safe (EX) Motors102
Additional Requirements for ABB Motors of Types Other than M2_, M3_, M4_, HX_ and am102
Additional Requirements for Braking Applications102
Additional Requirements for the Regenerative and Low Harmonics Drives102
Additional Requirements for ABB High-Output and IP23 Motors103
Additional Requirements for Non-ABB High-Output and IP23 Motors103
Additional Data for Calculating the Rise Time and the Peak Line-To-Line Voltage104
Additional Note for Sine Filters105
Selecting the Power Cables106
General Guidelines106
Typical Power Cable Sizes106
Power Cable Types107
Preferred Power Cable Types107
Alternate Power Cable Types108
Not Allowed Power Cable Types109
Additional Guidelines - North America109
Metal Conduit110
Power Cable Shield110
Grounding Requirements111
Additional Grounding Requirements - IEC112
Additional Grounding Requirements - UL (NEC)113
Selecting the Control Cables113
Shielding113
Signals in Separate Cables113
Signals that Can be Run in the same Cable113
Relay Cable114
Control Panel to Drive Cable114
PC Tool Cable114
FPBA-01 PROFIBUS DP Adapter Module Connectors114
Routing the Cables114
General Guidelines - IEC114
General Guidelines - North America115
Continuous Motor Cable Shield/Conduit and Metal Enclosure for Equipment on the Motor Cable116
Separate Control Cable Ducts117
Implementing Short-Circuit and Thermal Overload Protection117
Protecting the Drive and the Input Power Cable in Short-Circuits117
Protecting the Motor and Motor Cable in Short-Circuits118
Protecting the Motor Cables against Thermal Overload118
Protecting the Motor against Thermal Overload118
Protecting the Motor against Overload Without Thermal Model or Temperature Sensors119
Protecting the Drive against Ground Faults119
Residual Current Device Compatibility119
Implementing the Emergency Stop Function120
Implementing the Safe Torque off Function120
Using Power Factor Compensation Capacitors with the Drive120
Controlling a Contactor between Drive and Motor120
Implementing an ATEX-Certified Motor Thermal Protection121
Implementing the Power Loss Ride-Through Function121
Using a Safety Switch between the Drive and the Motor122
Implementing a Bypass Connection122
Example Bypass Connection123
Switching the Motor Power Supply from Drive to Direct-On-Line124
Switching the Motor Power Supply from Direct-On-Line to Drive124
Protecting the Contacts of Relay Outputs124
Limiting Relay Output Maximum Voltages at High Installation Altitudes125
Implementing a Motor Temperature Sensor Connection125
Connecting a Motor Temperature Sensor to the Drive through an Option Module126
Electrical Installation - Global (IEC)129
Contents of this Chapter129
Warnings129
Required Tools129
Grounding the Motor Cable Shield at the Motor End130
Measuring the Insulation130
Measuring the Insulation Resistance of the Drive130
Measuring the Insulation Resistance of the Input Power Cable130
Measuring the Insulation Resistance of the Motor and Motor Cable130
Brake Resistor Assembly for R1131
Grounding System Compatibility Check132
EMC Filter132
Ground-To-Phase Varistors132
When to Disconnect EMC Filter or Ground-To-Phase Varistor: TN-S, IT, Corner-Grounded Delta and Midpoint-Grounded Delta Systems132
Guidelines for Installing the Drive to a TT System134
Identifying the Grounding System of the Electrical Power Network135
Disconnecting Internal EMC Filter or Ground-To-Phase Varistor - Frames R1135
Disconnecting Internal EMC Filter or Ground-To-Phase Varistor - Frames R4136
Connecting the Power Cables139
Connection Diagram139
Connection Procedure, Frames R1140
Motor Cable141
Input Power Cable144
Grounding Shelf146
Brake Resistor Cable (if Used)146
Finalization148
Connection Procedure, Frame R5148
IP21 (UL Type 1)148
IP55 (UL Type 12)148
Connection Procedure, Frames R6153
Motor Cable154
Input Power Cable155
Detaching and Reinstalling the Connectors156
DC Connection158
Connecting the Control Cables159
Connection Diagram159
Control Cable Connection Procedure R1159
Installing Option Modules164
Option Slot 2 (I/O Extension Modules)165
Option Slot 1 (Fieldbus Adapter Modules)166
Wiring the Optional Modules166
Reinstalling Grommets167
Reinstalling Covers168
Reinstalling Cover, Frames R1168
Reinstalling Covers, Frame R5169
IP21 (UL Type 1)169
IP55 (UL Type 12)169
Reinstalling Side Plates and Covers, Frames R6170
IP21 (UL Type 1)170
IP55 (UL Type 12)170
Installing IP66 (UL Type 4X) Sun Shield171
Connecting a PC171
Connecting a Remote Panel, or Chaining One Panel to Several Drives172
Electrical Installation - North America173
Contents of this Chapter173
Warnings173
Required Tools174
Grounding the Motor Cable Shield at the Motor End174
Measuring the Insulation174
Measuring the Insulation Resistance of the Drive174
Measuring the Insulation Resistance of the Input Power Cable174
Measuring the Insulation Resistance of the Motor and Motor Cable174
Brake Resistor Assembly for R1175
Grounding System Compatibility Check176
EMC Filter176
Ground-To-Phase Varistors (VAR)176
When to Connect EMC Filter or Disconnect Ground-To-Phase Varistor: TN-S, IT, Corner-Grounded Delta and Midpoint-Grounded Delta Systems177
Guidelines for Installing the Drive to a TT System178
Identifying the Grounding System of the Electrical Power Network179
Disconnecting Internal EMC Filter or Ground-To-Phase Varistor - Frames R1180
Disconnecting Internal EMC Filter or Ground-To-Phase Varistor - Frames R4181
Connecting the Power Cables184
Connection Diagram184
Connection Procedure, Frames R1186
Motor Cabling187
Input Power Cabling190
Brake Resistor Cabling (if Used)192
Finalization193
Connection Procedure, Frame R5194
IP21 (UL Type 1)194
IP55 (UL Type 12)194
Connection Procedure, Frames R6198
Motor Cabling199
Input Power Cabling200
Detaching and Reinstalling the Connectors200
DC Connection202
Connecting the Control Cables202
Connection Diagram202
Control Cable Connection Procedure R1202
Installing Option Modules208
Reinstalling Grommets208
Reinstalling Covers209
Reinstalling Cover, Frames R1209
Reinstalling Covers, Frame R5210
IP21 (UL Type 1)210
IP55 (UL Type 12)210
Reinstalling Side Plates and Covers, Frames R6211
IP21 (UL Type 1)211
IP55 (UL Type 12)211
Installing UL Type 12 Hood212
Installing IP66 (UL Type 4X) Sun Shield212
Connecting a PC212
Connecting a Remote Panel, or Chaining One Panel to Several Drives213
Control Unit215
Contents of this Chapter215
Layout216
Default I/O Connection Diagram218
Additional Information on the Control Connections223
Embedded EIA-485 Fieldbus Connection223
Connecting Motor Temperature Sensors to the Drive224
PNP Configuration for Digital Inputs (X2 & X3)224
NPN Configuration for Digital Inputs (X2 & X3)225
Connection for Obtaining 0225
Connection Examples of Two-Wire and Three-Wire Sensors to Analog Input (AI2)226
DI5 as Frequency Input226
Safe Torque off (X4)226
Technical Data228
Installation Checklist237
Contents of this Chapter237
Checklist237
Start-Up241
Contents of this Chapter241
Reforming the Capacitors241
Start-Up Procedure241
Maintenance243
Contents of this Chapter243
Maintenance Intervals243
Description of Symbols243
Recommended Maintenance Intervals after Start-Up243
Cleaning the Exterior of the Drive, IP21 and IP55246
UL Type 12)246
Cleaning the Exterior of the Drive, IP66 (UL Type 4X)247
Cleaning the Heatsink, IP21, IP55 (UL Type 1, 12)248
Cleaning the Heatsink, IP 66 (UL Type 4X)249
Fans250
Replacing the Main Cooling Fan, IP21, IP55 and IP66 (UL Type 1, UL Type 12 and UL Type 4X) Frames R1251
Replacing the Main Cooling Fan, IP21 and IP55 (UL Type 1 and UL Type 12) Frames R5253
Replacing the Main Cooling Fans, IP21 and IP55 (UL Type 1 and UL Type 12) Frame R9254
Replacing the Auxiliary Cooling Fan, IP21 and IP55 (UL Type 1 and UL Type 12) Frames R6255
Replacing the Auxiliary Cooling Fan, IP55 (UL Type 12) Frames R1256
Replacing the Auxiliary Cooling Fan, IP55 and IP66 (UL Type 12 and UL Type 4X) Frame R3257
Replacing the Auxiliary Cooling Fan, IP55 (UL Type 12) Frame R4; IP21 and IP55 (UL Type 1 and UL Type 12) Frame R5259
Replacing the Second Auxiliary Cooling Fan, IP55 (UL Type 12) Frames R8260
Capacitors261
Reforming the Capacitors261
Control Panel261
Leds262
Drive Leds262
Control Panel Leds263
Functional Safety Components264
Technical Data265
Contents of this Chapter265
Electrical Ratings266
Iec266
Definitions270
Ul (Nec)270
Definitions274
UL Listed Multiple Ratings275
Conversion Tables for IEC and North American Type Codes275
Sizing276
Deratings277
Surrounding Air Temperature Derating, IP21 (UL Type 1)279
Surrounding Air Temperature Derating, IP55 (UL Type 12)280
Altitude Derating282
Switching Frequency Derating by Derating Factor283
Switching Frequency Derating with Actual Output Current Values286
Output Frequency Derating290
Fuses (IEC)290
Gg Fuses291
Ur and Ar Fuses293
Calculating the Short-Circuit Current of the Installation296
Calculation Example296
Circuit Breakers (IEC)298
Fuses (UL)299
Circuit Breakers (UL)303
Dimensions, Weights and Free Space Requirements307
Dimensions with Flange313
Losses, Cooling Data and Noise318
Cooling Air Flow, Heat Dissipation and Noise for Stand-Alone Drives318
IEC - IP21 and IP55 (UL Type 1 and 12)318
IEC - IP66 (UL Type 4X)320
UL (NEC) - IP21 and IP55 (UL Type 1 and 12)321
UL (NEC) - IP66 (UL Type 4X)324
Cooling Air Flow and Heat Dissipation for Flange Mounting (Option +C135)325
IEC - IP21 and IP55 (UL Type 1 and 12)325
IEC - IP66 (UL Type 4X)326
UL (NEC) - IP21 and IP55 (UL Type 1 and 12)327
UL (NEC) - IP66 (UL Type 4X)328
Terminal and Entry Data for the Power Cables330
Iec330
Ul (Nec)333
Power Cables337
Typical Power Cables, IEC337
Typical Power Cables UL (NEC)338
Terminal and Entry Data for the Control Cables341
Iec341
Ul (Nec)342
Electrical Power Network Specification342
Motor Connection Data345
Brake Resistor Connection Data for Frames R1348
Auxiliary Circuit Power Consumption348
Efficiency348
Energy Efficiency Data (Ecodesign)349
Protection Classes for Module349
Ambient Conditions350
Storage Conditions351
Colors352
Materials352
Drive352
Package Materials for Small Wall-Mounted Drives and Converter Modules352
Package Materials for Large Wall-Mounted Drives and Converter Modules352
Package Materials for Options, Accessories and Spare Parts352
Materials of Manuals353
Disposal353
Applicable Standards353
Markings354
CE Marking356
Compliance with the European Low Voltage Directive356
Compliance with the European EMC Directive356
Compliance with the European ROHS II Directive 2011/65/EU356
Compliance with the European WEEE Directive 2002/96/EC356
Compliance with the European Machinery Directive 2006/42/EC 2Nd Edition - June 2010356
Validating the Operation of the Safe Torque off Function357
Compliance with the en 61800-3:2004 + A1:2012357
Definitions357
Category C1357
Category C2358
Category C3358
Category C4359
UL Checklist360
Design Lifetime Expectancy361
Disclaimers361
Generic Disclaimer361
Cyber Security Disclaimer361
Dimension Drawings363
Contents of this Chapter363
Frame R1, IP21 (UL Type 1)364
Frame R1, IP55 (UL Type 12)365
Frame R1, IP55+F278 (UL Type 12)366
Frame R1, IP66 (UL Type 4X) +B066367
Frame R1, IP66 (UL Type 4X) +B063368
Frame R1, IP66 (UL Type 4X) +C193369
Frame R2, IP21 (UL Type 1)370
Frame R2, IP55 (UL Type 12)371
Frame R2, IP55+F278 (UL Type 12)372
Frame R2, IP66 (UL Type 4X) +B066373
Frame R2, IP66 (UL Type 4X) +B063374
Frame R2, IP66 (UL Type 4X) +C193375
Frame R3, IP21 (UL Type 1)376
Frame R3, IP55 (UL Type 12)377
Frame R3, IP55+E223 (UL Type 12)378
Frame R3, IP55+F278/F316 (UL Type 12)379
Frame R3, IP66 (UL Type 4X) +B066380
Frame R3, IP66 (UL Type 4X) +B063381
Frame R3, IP66 (UL Type 4X) +C193382
Frame R4, IP21 (UL Type 1)383
Frame R4, IP55 (UL Type 12)384
Frame R4, IP55+E223 (UL Type 12)385
Frame R4, IP55+F278/F316 (UL Type 12)386
Frame R5, IP21 (UL Type 1)387
Frame R5, IP55 (UL Type 12)388
Frame R5, IP55+E223 (UL Type 12)389
Frame R5, IP55+F278/F316 (UL Type 12)390
Frame R6, IP21 (UL Type 1)391
Frame R6, IP55 (UL Type 12)392
Frame R7, IP21 (UL Type 1)393
Frame R7, IP55 (UL Type 12)394
Frame R8, IP21 (UL Type 1)395
Frame R8, IP55 (UL Type 12)396
Frame R9, IP21 (UL Type 1)397
Frame R9, IP55 (UL Type 12)398
Resistor Braking399
Contents of this Chapter399
Operation Principle and Hardware Description399
Resistor Braking, Frames R1399
Planning the Braking System399
Selecting the Brake Resistor399
Selecting and Routing the Brake Resistor Cables403
Placing the Brake Resistor403
Protecting the System in Brake Circuit Fault Situations404
Mechanical Installation405
Electrical Installation405
Start-Up405
Resistor Braking, Frames R4406
Planning the Braking System406
Iec406
Ul (Nec)407
Parameter Settings for External Braking Chopper and Resistor408
The Safe Torque off Function409
Contents of this Chapter409
Description409
Compliance with the European Machinery Directive and the UK Supply of Machinery (Safety) Regulations410
Wiring411
Connection Principle411
Single ACS580-01 Drive, Internal Power Supply411
Single ACS580-01 Drive, External Power Supply412
Wiring Examples412
Single ACS580-01 Drive, Internal Power Supply412
Single ACS580-01 Drive, External Power Supply413
Multiple ACS580-01 Drives, Internal Power Supply414
Multiple ACS580-01 Drives, External Power Supply415
Activation Switch416
Cable Types and Lengths416
Grounding of Protective Shields416
Operation Principle417
Start-Up Including Validation Test418
Competence418
Validation Test Reports418
Validation Test Procedure418
Use420
Maintenance422
Competence422
Fault Tracing423
Safety Data424
Terms and Abbreviations427
TÜV Certificate428
Declarations of Conformity429
Optional I/O Extension and Adapter Modules431
Contents of this Chapter431
CAIO-01 Bipolar Analog I/O Adapter Module431
Product Overview431
Layout432
Mechanical Installation433
Necessary Tools433
Unpacking and Examining the Delivery433
Installing the Module433
Electrical Installation433
Wiring433
Start-Up434
Setting the Parameters434
Diagnostics435
Leds435
Technical Data435
Isolation Areas436
Dimension Drawings437
CBAI-01 Bipolar Analog IO Adapter Module438
Contents of this Chapter438
Product Overview438
Layout438
Mechanical Installation439
Necessary Tools439
Unpacking and Examining the Delivery439
Installing the Module439
Electrical Installation439
Wiring439
Start-Up440
Setting the Parameters440
Diagnostics441
Leds441
Technical Data441
Dimension Drawing442
CHDI-01 115/230 V Digital Input Extension Module443
Contents of this Chapter443
Product Overview443
Layout and Connection Examples444
Mechanical Installation445
Necessary Tools445
Unpacking and Examining the Delivery445
Installing the Module445
Electrical Installation445
Wiring445
Start-Up445
Setting the Parameters445
Fault and Warning Messages446
Technical Data446
Dimension Drawing447
CMOD-01 Multifunction Extension Module (External 24 V AC/DC and Digital I/O)448
Contents of this Chapter448
Product Overview448
Layout and Example Connections448
Mechanical Installation449
Necessary Tools449
Unpacking and Examining the Delivery449
Installing the Module450
Electrical Installation450
Necessary Tools450
Wiring450
Start-Up450
Setting the Parameters450
Diagnostics451
Technical Data452
Dimension Drawing453
CMOD-02 Multifunction Extension Module (External 24 V AC/DC and Isolated PTC Interface)454
Contents of this Chapter454
Product Overview454
Layout and Example Connections455
Mechanical Installation456
Necessary Tools456
Unpacking and Examining the Delivery456
Installing the Module456
Electrical Installation456
Wiring456
Start-Up456
Setting the Parameters456
Diagnostics457
Faults and Warning Messages457
Leds457
Technical Data457
Dimension Drawing458
Common Mode, D U /D T and Sine Filters461
Content of this Chapter461
Common Mode Filters461
When Is a Common Mode Filter Needed461
Common Mode Filter Types461
IEC Ratings at U N = 400 V and 480 V, UL (NEC) Ratings at U N = 480 V461
Du/Dt Filters462
When Is a D U /D T Filter Needed462
D U /D T Filter Types462
IEC Ratings at U = 208/230 V462
= 230 V, UL (NEC) Ratings at U462
Description, Installation and Technical Data of the FOCH Filters464
Description, Installation and Technical Data of the noch Filters465
Sine Filters465
IEC Ratings at U N = 400 V, UL (NEC) Ratings at U N = 480 V465
Description, Installation and Technical Data466

ABB ACS580 Series - Page 240

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