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ABB ACS580-07-0495A-4 Hardware Manual

Acs580-07 series 250 to 500 kw
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ACS580-07 drives
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Summary of Contents for ABB ACS580-07-0495A-4

  • Page 1 ABB general purpose drives Hardware manual ACS580-07 drives (250 to 500 kW)
  • Page 2 Document library on the Internet on the inside of the back cover. For manuals not available in the Document library, contact your local ABB representative. The code below opens an online listing of the manuals applicable to this product. ACS580-07 manuals Videos: https://www.youtube.com/watch?v=z34USv99vPs&feature=youtu.be...
  • Page 3 Hardware manual ACS580-07 drives Table of contents 1. Safety instructions 4. Mechanical installation 6. Electrical installation 9. Start-up  2016 ABB Oy. All Rights Reserved. 3AXD50000032622 Rev A EFFECTIVE: 2016-03-16...
  • Page 5 Update notice 1 Update notice This notice concerns ACS580-07 hardware manual Code: 3AXD50000131464 Rev A (3AXD50000032622 [English]) Rev A. Valid: from 2.6.2017 until the release of revision B of the manual. Contents: new or changed instructions Safety ADDED: • Before you activate the automatic fault reset or automatic restart functions of the drive control program, make sure that no dangerous situations can occur.
  • Page 6 2 Update notice ADDED: Changing internal overtemperature supervision from DI6 to another digital input By default, digital input DI6 is used for the internal overtemperature supervision of the drive cabinet. If it is required to use DI6 for an other purpose, change the overtemperature supervision wiring from DI6 to another free digital input either on the control unit or on the CMOD-01 multifunction extension module.
  • Page 7 Update notice 3 NPN configuration for digital inputs (DIGITAL IN) CHANGED: Internal +24 V power supply External +24 V power supply NPN connection (sink) NPN connection (sink) X504:10 X504:10 +24V +24V DGND DGND +24 V DC DCOM DCOM 0 V DC X504:18 X504:18 Note! By default, digital input DI6 is used for the internal overtemperature supervision of...
  • Page 8 4 Update notice...

  • Page 9: Table Of Contents

    Table of contents 1. Safety instructions Contents of this chapter ..........13 Use of warnings .
  • Page 10 AM_ ............52 Additional requirements for ABB high-output and IP23 motors ....52 Additional requirements for non-ABB high-output and IP23 motors .
  • Page 11 Continuous motor cable shield or enclosure for equipment on the motor cable ..57 Implementing thermal overload and short-circuit protection ..... . 58 Protecting the drive and input power cable in short-circuits .
  • Page 12 7. Control unit Contents of this chapter ..........79 Layout .
  • Page 13 Replacing the circuit board compartment cooling fan ......106 Replacing the IP54 (UL type 12) roof fan ....... . . 107 Replacing the drive module .
  • Page 14 Activation switch ........... 138 Cable types and lengths .
  • Page 15 Providing feedback on ABB Drives manuals ....... . . 169...

  • Page 17: Safety Instructions

    Safety instructions 13 Safety instructions Contents of this chapter This chapter contains the safety instructions which you must obey when you install and operate the drive and do maintenance on the drive. If you ignore the safety instructions, injury, death or damage can occur. Use of warnings Warnings tell you about conditions which can cause injury or death, or damage to the equipment.

  • Page 18: General Safety In Installation, Start-Up And Maintenance

    14 Safety instructions General safety in installation, start-up and maintenance These instructions are for all personnel that install the drive and do maintenance work on WARNING! Obey these instructions. If you ignore them, injury or death, or damage to the equipment can occur.
  • Page 19 Safety instructions 15 • Do not use the module installation ramp with plinth heights which exceed the maximum height (50 mm [1.97 in]) marked on the ramp. • Secure the module installation ramp carefully. • To prevent the drive module from falling, attach its top lifting lugs with chains to the cabinet lifting lug before you push the module into the cabinet and pull it from the cabinet.

  • Page 20: Electrical Safety In Installation, Start-Up And Maintenance

    16 Safety instructions Note: • If you select an external source for start command and it is on, the drive will start immediately after fault reset unless you configure the drive for pulse start. See the firmware manual. • When the control location is not set to Local, the stop key on the control panel will not stop the drive.

  • Page 21: Additional Instructions And Notes

    Safety instructions 17 Additional instructions and notes  WARNING! Obey these instructions. If you ignore them, injury or death, or damage to the equipment can occur. • If you are not a qualified electrician, do not do installation or maintenance work. •...

  • Page 22: Grounding

    18 Safety instructions Grounding  These instructions are for all personnel who are responsible for the grounding of the drive. WARNING! Obey these instructions. If you ignore them, injury or death and equipment malfunction can occur, and electromagnetic interference can increase. •...

  • Page 23: Additional Instructions For Permanent Magnet Motor Drives

    Safety instructions 19 Additional instructions for permanent magnet motor drives Safety in installation, start-up and maintenance  These are additional warnings concerning permanent magnet motor drives. The other safety instructions in this chapter are also valid. WARNING! Obey these instructions. If you ignore them, injury or death and equipment malfunction can occur.
  • Page 24 20 Safety instructions...

  • Page 25: Introduction To The Manual

    Introduction to the manual 21 Introduction to the manual Contents of this chapter This chapter describes the manual. It contains a flowchart of steps in checking the delivery, installing and starting up the drive. The flowchart refers to chapters/sections in this manual and to other manuals.

  • Page 26: Related Manuals

    22 Introduction to the manual Electrical installation gives instructions on wiring the drive. Control unit contains the default I/O connection diagram and references for the descriptions of the terminals and technical data of the control unit. Installation checklist contains a list for checking the mechanical and electrical installation of the drive.

  • Page 27: Terms And Abbreviations

    Introduction to the manual 23 Task Unpack and check the units (only intact units may be started up). Mechanical installation (page 39) Examine that all necessary option modules and equipment are If the drive has been non- present and correct. operational for more than one year, the converter DC link capacitors Mount the drive.
  • Page 28 24 Introduction to the manual Term/ Explanation Abbreviation Input/Output CCU-12 Drive control unit. As standard, the external I/O control signals are connected to the control unit, or optional I/O extensions mounted on it. CEIA-01 Embedded EIA-485 fieldbus adapter module CHDI-01 Optional 115/230 V digital input extension module CMOD-01 Optional multifunction extension module (external 24 V AC/DC and digital I/O extension)

  • Page 29: Operation Principle And Hardware Description

    Operation principle and hardware description 25 Operation principle and hardware description Contents of this chapter This chapter briefly describes the operation principle and construction of the drive. Product overview The ACS580-07 is an air-cooled cabinet-installed drive for controlling asynchronous AC induction motors and permanent magnet motors.

  • Page 30: Single-Line Circuit Diagram Of The Drive

    26 Operation principle and hardware description Single-line circuit diagram of the drive  Switch-disconnector Optional line contactor (+F250) Auxiliary voltage transformer supplying 24 V and 230/115 V control voltage for, eg, cabinet fan(s), control devices and I/O extension adapter module. Drive module with common mode filter Optional du/dt filter (+E205) General information on the cabinet layout...

  • Page 31: Cabinet Layout - Bottom Entry And Exit Of Cables

    Operation principle and hardware description 27 Cabinet layout – bottom entry and exit of cables  The cabinet layout is shown below. See also the next page. A – Main breaker and power cabling cubicle B – Drive module cubicle Drive control panel See the next page.
  • Page 32 28 Operation principle and hardware description The cabinet layout without shrouds, with the swing-out frame open is shown below. A – Main breaker and power cabling cubicle B – Drive module cubicle Main fuses for control devises, IP54 fan Drive module transformer (with option +B055) AC fuses Control unit, see page 79.

  • Page 33: Overview Of Power And Control Connections

    Operation principle and hardware description 29 Overview of power and control connections  The diagram shows the power connections and control interfaces of the drive. SLOT 1 SLOT 3 SLOT 2 M 3 ~ Option slot 1 for optional fieldbus adapter modules Option slot 2 for optional I/O extension modules Option slot 3 for optional embedded fieldbus adapter modules Panel port...
  • Page 34 30 Operation principle and hardware description The layout of external control connection terminals at the side of the drive cabinet is shown below. The composition depends on the options selected. X965 Terminals for X969 -X969 X250 Auxiliary contacts of optional line contactor (+F250) X506 Not in use...

  • Page 35: Door Switches And Lights

    Operation principle and hardware description 31 Door switches and lights  Label in English Label in local Description language READY Ready pilot light (option +G327) Run pilot light (option+G328) FAULT Fault pilot light (option +G329) MAIN CONT. Operating switch with option +F250 Opens the main contactor (Q2) and disables starting of the drive Closes the main contactor (Q2)

  • Page 36: Control Panel

    Examining the compatibility of the motor and drive on page 50. Descriptions of cabinet options Note: All options are not available for all drive types, do not coexist with certain other options, or may require additional engineering. Check actual availability with ABB.

  • Page 37: Degree Of Protection

    Operation principle and hardware description 33 Degree of protection  Definitions According to IEC/EN 60529, the degree of protection is indicated by an IP code where the first numeral means protection against ingress of solid foreign objects, and the second numeral protection against ingress of water.

  • Page 38: Uk Gland/Conduit Plate (Option +H358)

    34 Operation principle and hardware description See also • Connecting the external power supply cables for the cabinet heater and lighting and motor heater (options +G300) • Auxiliary circuit power consumption on page • circuit diagrams delivered with drive for the actual wiring. UK gland/conduit plate (option +H358) ...

  • Page 39: Type Designation Key

    Operation principle and hardware description 35 Description Valid markings Serial number. The first digit of the serial number refers to the manufacturing plant. The next four digits refer to the unit’s manufacturing year and week, respectively. The remaining digits complete the serial number so that there are no two units with the same number.
  • Page 40 36 Operation principle and hardware description Code Description Filters E205 du/dt filter (page 33) Line options F250 Line contactor Heaters and auxiliary control voltage G300 Cabinet heater (external supply). See page 33. Lights G327 Ready pilot light, white G328 Run pilot light, green G329 Fault pilot light, red Cabling...
  • Page 41 Operation principle and hardware description 37 Code Description R703 Dutch R704 Danish R705 Swedish R706 Finnish R707 French R708 Spanish R709 Portuguese R711 Russian...
  • Page 42 38 Operation principle and hardware description...

  • Page 43: Mechanical Installation

    Mechanical installation 39 Mechanical installation Contents of this chapter This chapter describes the mechanical installation procedure of the drive. Examining the installation site Examine the installation site: • The installation site is sufficiently ventilated or cooled to transfer away the drive losses.

  • Page 44: Necessary Tools

    40 Mechanical installation Note: For easy maintenance, do not install the drives on a higher level than the floor in front of it. Otherwise the ramp supplied with the drive cannot be used when replacing the drive modules that run on wheels. Necessary tools The tools required for moving the unit to its final position, fastening it to the floor and wall and tightening the connections are listed below:...

  • Page 45: Moving And Unpacking The Drive

    Mechanical installation 41 Moving and unpacking the drive Move the drive in its original pallet, preferably in the original package to installation site as shown below to avoid damaging the cabinet surfaces and door devices. When you use a pallet truck, check its load capacity before you move the drive. Note: Transportation of the cabinet on its back is only allowed if it is packed for such transportation at the factory.

  • Page 46: Unpacking The Transport Package

    42 Mechanical installation Unpacking the transport package  Unpack the transport package as follows: 1. Undo the screws that hold the wooden elements of the transport crate together. 2. Remove the elements. 3. Remove the clamps with which the drive cabinet is mounted onto the transport pallet by undoing the fastening screws.

  • Page 47: Lifting The Cabinet

    Mechanical installation 43 Lifting the cabinet  Lift the drive cabinet using its lifting lugs. Maximum allowed lifting angle of IP42 (UL Type 1 Filtered) cabinets is 20°. Allowed minimum height of lifting slings of IP54 (UL Type 12) cabinets is 2 meters (6.5 ft). Max.

  • Page 48: Moving On Rollers

    44 Mechanical installation Moving on rollers Lay the cabinet on the rollers and move it carefully until close to its final location. Remove the rollers by lifting the unit with a crane, fork-lift, pallet truck or jack. Final placement Move the cabinet into its final position with an iron bar. Place a wooden piece at the bottom edge of the cabinet in order not to damage the cabinet frame with the iron bar.

  • Page 49: Installing The Ip54 Roof

    Mechanical installation 45 Installing the IP54 roof If the roof of an IP54 cabinet is delivered in a separate package, install the roof as follows. 1. Undo the mounting screws of the front top profile of the cabinet and remove it. Undo the back mounting screws of the roof from the cabinet top.

  • Page 50: Attaching The Cabinet To The Floor And Wall Or Roof

    46 Mechanical installation Attaching the cabinet to the floor and wall or roof General rules  • Install the drive cabinet in an upright vertical position with its back against a wall (a), or back-to-back with another cabinet (b). • Leave 400 mm (15.75 in) free space above the basic roof level of the cabinet for cooling.

  • Page 51: Attaching Methods

    Mechanical installation 47 Attaching methods  Attach the cabinet to the floor from the front and rear edge by using clamps delivered with the drive, or bolt the cabinet to the floor through the holes inside if they are accessible. Alternative 1 –...

  • Page 52: Miscellaneous

    Arc welding  ABB does not recommend attaching of the cabinet by arc welding. However, if arc welding is the only mounting option, proceed as follows: Connect the return conductor of the welding equipment to the cabinet frame at the bottom within 0.5 meters (1.5 ft) of the welding point.

  • Page 53: Guidelines For Planning The Electrical Installation

    ABB does not assume any liability whatsoever for any installation which breaches the local laws and/or other regulations. Furthermore, if the recommendations given by ABB are not followed, the drive may experience problems that the warranty does not cover.

  • Page 54: Protecting The Motor Insulation And Bearings

    Examining the compatibility of the motor and drive Use an asynchronous AC induction motor, permanent magnet synchronous motor, AC induction servomotor or ABB synchronous reluctance motor (SynRM motor) with the drive. Several induction motors can be connected to the drive at a time.

  • Page 55: Requirements Table

    Requirements table  The following table shows how to select the motor insulation system and when ABB requires optional drive du/dt and common mode filters and insulated N-end (non-drive end) motor bearings. If the installation does not fulfill these requirements or improper installation can shorten motor life or damage the motor bearings and voids the warranty.

  • Page 56: Additional Requirements For Abb Motors Of Types Other Than M2_, M3_, M4_, Hx_ And

    Additional requirements for ABB high-output and IP23 motors The rated output power of high output motors is higher than what is stated for the particular frame size in EN 50347 (2001). This table shows the requirements for ABB random-wound motor series (for example, M3AA, M3AP and M3BP).

  • Page 57: Additional Data For Calculating The Rise Time And The Peak Line-To-Line Voltage

    Guidelines for planning the electrical installation 53 Additional data for calculating the rise time and the peak line-to-line voltage If you need to calculate the actual peak voltage and voltage rise time considering the actual cable length, proceed as follows: •...

  • Page 58: Typical Power Cable Sizes

    Note: When continuous metal conduit is employed, shielded cable is not required. The conduit must have bonding at both ends. A four-conductor system is allowed for input cabling, but ABB recommend shielded symmetrical cable. Compared to a four-conductor system, the use of symmetrical shielded cable reduces electromagnetic emission of the whole drive system as well as the stress on motor insulation, bearing currents and wear.

  • Page 59: Recommended Power Cable Types

    Guidelines for planning the electrical installation 55 Recommended power cable types Symmetrical shielded cable with three phase conductors and a concentric PE conductor as shield. The shield must meet the requirements of IEC 61439-1, see section Motor cable shield on page 53. Check with local / state / country electrical codes for allowance.

  • Page 60: Selecting The Control Cables

     All control cables must be shielded. Use a double-shielded twisted pair cable for analog signals. ABB recommends this type of cable for the pulse encoder signals also. Employ one individually shielded pair for each signal. Do not use common return for different analog signals.

  • Page 61: Separate Control Cable Ducts

    Guidelines for planning the electrical installation 57 The cable trays must have good electrical bonding to each other and to the grounding electrodes. Aluminum tray systems can be used to improve local equalizing of potential. A diagram of the cable routing is shown below. Motor cable Drive min 300 mm (12 in.)

  • Page 62: Implementing Thermal Overload And Short-Circuit Protection

    58 Guidelines for planning the electrical installation Implementing thermal overload and short-circuit protection Protecting the drive and input power cable in short-circuits  The drive is equipped with internal AC fuses (1) as standard. The fuses restrict drive damage and prevent damage to adjoining equipment in case of a short-circuit inside the drive.

  • Page 63: Protecting The Drive Against Ground Faults

    Guidelines for planning the electrical installation 59 Protecting the drive against ground faults The drive is equipped with an internal ground fault protective function to protect the drive against ground faults in the motor and motor cable in TN (grounded) networks. This is not a personnel safety or a fire protection feature.

  • Page 64: Implementing The Power-Loss Ride-Through Function

    Implementing a safety switch between the drive and the motor ABB recommends to install a safety switch between the permanent magnet synchronous motor and the drive output. The switch is needed to isolate the motor during any maintenance work on the drive.

  • Page 65: Using A Contactor Between The Drive And The Motor

    Guidelines for planning the electrical installation 61 Using a contactor between the drive and the motor Implementing the control of the output contactor depends on how you select the drive to operate. See also section Implementing a bypass connection on page 61. When you have selected to use •...

  • Page 66: Example Bypass Connection

    62 Guidelines for planning the electrical installation Example bypass connection  An example bypass connection is shown below. Drive main switch Drive main contactor on/off control Bypass circuit breaker Motor power supply selection (drive or direct-on- line) Drive main contactor Start when motor is connected direct-on-line Bypass contactor Stop when motor is connected direct-on-line...

  • Page 67: Switching The Motor Power Supply From Direct-On-Line To Drive

    Inductive loads (relays, contactors, motors) cause voltage transients when switched off. ABB highly recommends to equip inductive loads with noise attenuating circuits (varistors, RC filters [AC] or diodes [DC]) in order to minimize the EMC emission at switch-off. If not suppressed, the disturbances can connect capacitively or inductively to other conductors in the control cable and form a risk of malfunction in other parts of the system.

  • Page 68: Connecting A Motor Temperature Sensor To The Drive I/O

    64 Guidelines for planning the electrical installation Connecting a motor temperature sensor to the drive I/O WARNING! IEC 60664 requires double or reinforced insulation between live parts and the surface of accessible parts of electrical equipment which are either non- conductive or conductive but not connected to the protective earth.

  • Page 69: Electrical Installation

    Electrical installation 65 Electrical installation Contents of this chapter This chapter gives instructions on the wiring the drive. Warnings WARNING! If you are not a qualified electrician do not do the installation work described in this chapter. Obey the instructions in chapter Safety instructions.

  • Page 70: Motor And Motor Cable

    Protective Earth conductor using a measuring voltage of 1000 V DC. The insulation resistance of an ABB motor must exceed 100 Mohm (reference value at 25 °C or 77 °F). For the insulation resistance of other motors, consult the manufacturer’s instructions.

  • Page 71: Connecting The Power Cables

    Electrical installation 67 Connecting the power cables Connection diagram  ACS580-07 T1/ T2/ T3/ (PE) (PE) Use a separate grounding PE cable (1a) or a cable with a separate PE conductor (1b) if the conductivity of the shield does not meet the requirements for the PE conductor (see page 53). 360-degree grounding is recommended if shielded cable is used.

  • Page 72: Layout Of The Input And Motor Cable Connection Terminals (Frames R10 And R11)

    68 Electrical installation Layout of the input and motor cable connection terminals (frames  R10 and R11) Strain relief L1, L2, L3 Input power cable terminals U2, V2, W2 Motor cable terminals PE terminal Connection procedure (IEC)  1. Do the steps in section Precautions before electrical work on page before you start...
  • Page 73 12. Attach the conductive sleeves to the cable shields with cable ties. 13. Seal the slot between the cable and mineral wool sheet (if used) with sealing compound (eg, CSD-F, ABB brand name DXXT-11, code 35080082). 14. Tie up the unused conductive sleeves with cable ties.
  • Page 74 70 Electrical installation...

  • Page 75: Grounding The Motor Cable Shield At The Motor End

    Electrical installation 71 Grounding the motor cable shield at the motor end  Always ground the motor cable shield at the motor end. For minimum radio frequency interference, ground the motor cable shield 360 degrees at the lead-through of the motor terminal box See also Continuous motor cable shield or enclosure for equipment on the motor cable...

  • Page 76: Grounding The Outer Shields Of The Control Cables At The Cabinet Lead-Through

    72 Electrical installation Grounding the outer shields of the control cables at the cabinet lead-through Applicability This section applies to drives without solid cable conduit plate (no options +H351, +H353, +H358). Procedure Ground the outer shields of all control cables 360 degrees at the EMI conductive cushions as follows: 1.
  • Page 77 Electrical installation 73 Stripped cable Conductive surface of the shield exposed Stripped part covered with copper foil Cable shield Copper foil Shielded twisted pair Grounding wire Note for top entry of cables: When each cable has its own rubber grommet, sufficient IP and EMC protection can be achieved.

  • Page 78: Routing The Control Cables Inside The Cabinet (Frames R10 And R11)

    74 Electrical installation Routing the control cables inside the cabinet (frames R10 and R11) Connecting the control unit cables Note: Keep any signal wire pairs twisted as close to the terminals as possible. Twisting the wire with its return wire reduces disturbances caused by inductive coupling. Note: Leave slack to the control wires to make it possible to lift the control unit mounting plate a little when the drive module is replaced.

  • Page 79: Connecting The Emergency Stop Push Buttons (Options +Q951)

    Electrical installation 75 Drives with additional I/O terminal block (option +L504): Ground the pair-cable shields and all grounding wires to the grounding clamp next to the terminal block as shown below. Leave the other ends of the control cable shields unconnected or ground them indirectly via a high-frequency capacitor with a few nanofarads, eg, 3.3 nF / 630 V.

  • Page 80: Setting The Voltage Range Of The Auxiliary Control Voltage Transformer (T21)

    76 Electrical installation Setting the voltage range of the auxiliary control voltage transformer (T21) Connect the power supply wires of the auxiliary control voltage transformer according to the power network voltage. Connecting a PC A PC (with eg. the Drive composer PC tool) can be connected to the drive as follows: 1.

  • Page 81: Installing Option Modules

    Electrical installation 77 Installing option modules WARNING! Obey the instructions in chapter Safety instructions. If you ignore them, injury or death, or damage to the equipment can occur. 1. Stop the drive and do the steps in section Precautions before electrical work on page before you start the work.
  • Page 82 78 Electrical installation...

  • Page 83: Control Unit

    Control unit 79 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-12)

  • Page 84: Layout

    80 Control unit Layout The layout of the external control connection terminals on the drive module control unit are shown below. SLOT 1 SLOT 1 Option slot 1 (fieldbus adapter modules) ANALOG IN/OUT 1…3 Analog input 1 Current/Voltage selection switch for analog input 1 1…3, AI1 4…6...

  • Page 85: Default I/O Connection Diagram

    Control unit 81 Default I/O connection diagram The default I/O connections of the ABB Standard macro are shown below. Analog input 1 1…10 kohm Signal cable shield (screen) Output frequency/speed reference 1: 0…10 V AGND Analog input circuit common Current/Voltage selection for analog input 1...
  • Page 86 82 Control unit Notes: 1. Current [0(4)…20 mA, R = 100 ohm] or voltage [0(2)…10 V, R > 200 kohm] input selected with switch AI1. Change of setting requires changing the corresponding parameter. 2. Current [0(4)…20 mA, R = 100 ohm] or voltage [ 0(2)…10 V, R >...

  • Page 87: Switches

    Control unit 83 Switches Switch Description Position Determines whether analog input AI1 is used as a voltage or Voltage (U) (default) current input. Current (I) Determines whether analog input AI2 is used as a voltage or Voltage (U) current input. Current (I) (default) Determines whether analog output AO1 is used as a current Current (I) (default)

  • Page 88: Npn Configuration For Digital Inputs (Digital In)

    84 Control unit NPN configuration for digital inputs (DIGITAL IN) Internal and external +24 V power supply connections for NPN configuration are shown in the figure below. Internal +24 V power supply External +24 V power supply NPN connection (sink) NPN connection (sink) +24V +24V...

  • Page 89: In/Out)

    Control unit 85 Connection examples of two-wire and three-wire sensors to analog input 2 (ANALOG IN/OUT) Hand/Auto, Hand/PID, and PID macros use analog input AI2. Note: The maximum capability of the auxiliary voltage output (24 V DC [250 mA]) must not be exceeded.

  • Page 90: Ai1 And Ai2 As Pt100, Pt1000, Ni1000, Kty83 And Kty84 Sensor Inputs (Analog In/Out)

    86 Control unit AI1 and AI2 as Pt100, Pt1000, Ni1000, KTY83 and KTY84 sensor inputs (ANALOG IN/OUT) One, two or three Pt100 sensors; one, two or three Pt1000 sensors; or one Ni1000, KTY83 or KTY84 sensor for motor temperature measurement can be connected between an analog input and output as shown below.

  • Page 91: Technical Data

    Control unit 87 Technical data External power supply Maximum power: 36 W, 1.50 A at 24 V AC/DC ±10% as standard Term. 40, 41 Terminal size: 0.14…2.5 mm +24 V DC output Total load capacity of this outputs is 6.0 W (250 mA / 24 V) minus the power (Term.
  • Page 92 88 Control unit Isolation areas Panel port SLOT 1 Fieldbus module 1…3 4…6 Power unit connection 7…8 10…12 24 V 13…15 16…18 SLOT 3 Embedded fieldbus module 34…38 40, 41 Ext. 24 V 19…21 SLOT 2 22…24 extension module 25…27 Symbol Description Reinforced insulation (IEC/EN 61800-5-1:2007)

  • Page 93: Installation Checklist

    Installation checklist 89 Installation checklist Contents of this chapter This chapter contains an installation checklist which you must complete before you start up the drive. Warnings WARNING! Obey the instructions in chapter Safety instructions. If you ignore them, injury or death, or damage to the equipment can occur. Checklist Do the steps in section Precautions before electrical work...
  • Page 94 90 Installation checklist Check that … There is an adequately sized protective earth (ground) conductor between the drive and the switchboard, and the conductor has been connected to appropriate terminal. Proper grounding has also been measured according to the regulations. There is an adequately sized protective earth (ground) conductor between the motor and the drive, and the conductor has been connected to appropriate terminal.

  • Page 95: Start-Up

    Start-up 91 Start-up Contents of this chapter This chapter contains the start-up procedure of the drive. The default device designations (if any) are given in brackets after the name, for example “main switch-disconnector (Q1)”. The same device designations are also used in the circuit diagrams, typically. Start-up procedure Action Safety...

  • Page 96: Start-Up With The First Start Assistant On An Assistant Panel

    92 Start-up Action Setting up the drive parameters, and performing the first start Setup the drive control program. See section Start-up with the First start assistant on an assistant panel on page 92. Drives with main contactor (Q2, option +F250): Close the main contactor by turning the operating switch on the cabinet door from OFF into ON position.
  • Page 97 Start-up 93 Hints on using the assistant control panel The two commands at the bottom of the display (Options and Menu in the figure on the right), show the functions of the two softkeys located below the display. The commands assigned to the softkeys vary depending on the context.
  • Page 98 Refer to the motor nameplate for the following nominal value settings of the motor. Enter the values exactly as shown on the motor nameplate. Example of a nameplate of an induction (asynchronous) motor ABB Motors motor M2AA 200 MLA 4 IEC 200 M/L 55 Ins.cl.
  • Page 99 Start-up 95 Check the direction of the motor. If it is forward, select Yes, motor is spinning forward and press (Next) to continue. If the direction is not forward, select No, fix direction and press (Next) to continue. If you want to make a backup of the settings made so far, select Backup and press (Next).
  • Page 100 96 Start-up 2 – Additional settings: Start, stop and reference values If you do not wish to use a macro, define the settings for start, stop and reference: Select Start, stop, reference and press (Select) Adjust the parameters according to your needs. Select a parameter and, depending on the parameter type, press (Edit) or press...

  • Page 101: Fault Tracing

    Fault tracing 97 Fault tracing Contents of this chapter This chapter describes the fault tracing possibilities of the drive. Warning and fault messages See the firmware manual for the descriptions, causes and remedies of the drive control program warning and fault messages.
  • Page 102 98 Fault tracing...

  • Page 103: Maintenance

    (www.abb.com/drivesservices).For more information, consult your local ABB Service representative ( www.abb.com/searchchannels). The maintenance and component replacement intervals are based on the assumption that the equipment is operated within the specified ratings and ambient conditions. ABB recommends annual drive inspections to ensure the highest reliability and optimum performance.

  • Page 104: Descriptions Of Symbols

    100 Maintenance Descriptions of symbols  Action Description Visual inspection and maintenance action if needed Performance of on/off-site work (commissioning, tests, measurements or other work) Replacement of component Recommended annual maintenance actions by the user.  Action Target IP42 air inlet and outlet meshes on the cabinet doors IP54 air filters on the cabinet doors Quality of supply voltage Spare parts...

  • Page 105: Cleaning The Air Inlet (Door) Meshes (Ip42 / Ul Type 1 Filtered)

    Maintenance 101 Cleaning the air inlet (door) meshes (IP42 / UL Type 1 Filtered) WARNING! Use a vacuum cleaner with an antistatic hose and nozzle. Using a normal vacuum cleaner creates static discharges which can damage circuit boards. Check the dustiness of the air inlet meshes. If the dust cannot be removed by vacuum cleaning from outside through the grating holes with a small nozzle, proceed as follows: 1.

  • Page 106: Replacing The Air Filters (Ip54 / Ul Type 12)

    102 Maintenance Replacing the air filters (IP54 / UL Type 12) Check the air filters and replace if necessary (see page for the correct filter types). Inlet (door) filters (IP54 / UL Type 12)  1. Remove the fasteners at the top of the grating. 2.

  • Page 107: Heatsink

    See the firmware manual for the actual signal which indicates the running time of the cooling fan. Reset the running time signal after a fan replacement. Replacement fans are available from ABB. Do not use other than ABB specified spare parts.

  • Page 108: Replacing The Cabinet Fan

    104 Maintenance Replacing the cabinet fan  WARNING! Obey the instructions in chapter Safety instructions. If you ignore them, injury or death, or damage to the equipment can occur. 1. Stop the drive and do the steps in section Precautions before electrical work on page before you start the work.

  • Page 109: Replacing The Drive Module Main Fans

    Maintenance 105 Replacing the drive module main fans  WARNING! Obey the instructions in chapter Safety instructions. If you ignore them, injury or death, or damage to the equipment can occur. 1. Stop the drive and do the steps in section Precautions before electrical work on page before you start the work.

  • Page 110: Replacing The Circuit Board Compartment Cooling Fan

    106 Maintenance Replacing the circuit board compartment cooling fan  WARNING! Obey the instructions in chapter Safety instructions. If you ignore them, injury or death, or damage to the equipment can occur. 1. Stop the drive and do the steps in section Precautions before electrical work on page before you start the work.

  • Page 111: Replacing The Ip54 (Ul Type 12) Roof Fan

    Maintenance 107 Replacing the IP54 (UL type 12) roof fan  WARNING! Obey the instructions in chapter Safety instructions. If you ignore them, injury or death, or damage to the equipment can occur. 1. Stop the drive and do the steps in section Precautions before electrical work on page before you start the work.

  • Page 112: Replacing The Drive Module

    108 Maintenance Replacing the drive module This replacing procedure requires: two persons, installation ramp, a set of screw drivers and a torque wrench with an extension bar. The drawings show frame R11. The details in frame R10 are slightly different. WARNING! Obey the instructions in chapter Safety instructions.
  • Page 113 Maintenance 109 11. Undo the screws that attach the drive module to the cabinet at the top and behind the front support legs. 12. Attach the extraction ramp to the cabinet base with two screws. 13. Attach the drive module lifting lugs to the cabinet lifting lug with chains. 14.
  • Page 114 110 Maintenance R10 and R11...
  • Page 115 Maintenance 111 R10 and R11...
  • Page 116 112 Maintenance R10 and R11...
  • Page 117 Maintenance 113 R10 and R11...
  • Page 118 114 Maintenance R10 and R11 R10 and R11...

  • Page 119: Capacitors

    Capacitor failure is usually followed by damage to the unit and an input cable fuse failure, or a fault trip. Contact ABB if capacitor failure is suspected. Replacements are available from ABB. Do not use other than ABB specified spare parts.

  • Page 120: Replacing The Battery In The Assistant Control Panel

    116 Maintenance Replacing the battery in the assistant control panel  A battery is only used in assistant control panels that have the clock function. The battery keeps the clock operating during power interruptions. The expected life for the battery is greater than ten years. Note: The battery is NOT required for any control panel or drive functions, except the clock.

  • Page 121: Technical Data

    Technical data 117 Technical data Contents of this chapter This chapter contains the technical specifications of the drive, for example, the ratings, sizes and technical requirements, provisions for fulfilling the requirements for CE and other markings. Ratings The nominal ratings for the drives with 50 Hz and 60 Hz supply are given below. The symbols are described below the table.

  • Page 122: Definitions

    Note 2: To achieve the rated motor power given in the table, the rated current of the drive must be higher than or equal to the rated motor current. The DriveSize dimensioning tool available from ABB is recommended for selecting the drive, motor and gear combination.

  • Page 123: Altitude Derating

    Technical data 119 Altitude derating  At altitudes from 1000 to 2000 m (3300 to 6561 ft) above sea level, the derating is 1% for every 100 m (328 ft). If ambient temperature is below +40 °C (+104 .°F), the derating can be reduced by 1.5% for every 1 °C reduction in temperature.

  • Page 124: Dimensions And Weights

    120 Technical data Fuses (IEC) The drive is equipped with aR fuses listed below. Drive type Input Ultrarapid (aR) fuses (one fuse per phase) ACS580-07- current Manufacturer Type Type with Size option +F289 = 400 V 0495A-4 465000 Bussmann 170M6412 170M6412 0575A-4 670000...

  • Page 125: Losses, Cooling Data And Noise

    Technical data 121 Door opening: 800 mm (31.50 in.) Losses, cooling data and noise Drive type Frame Air flow Heat dissipation Noise dB(A) /min = 400 V ACS580-07-0495A-4 2950 1837 6102 ACS580-07-0575A-4 2950 1837 6909 ACS580-07-0640A-4 2950 1837 8622 ACS580-07-0715A-4...
  • Page 126 122 Technical data Input and motor cable terminal dimensions of frame R10 Bottom entry and exit:...
  • Page 127 Technical data 123 Input and motor cable terminal dimensions of frame R11 Bottom entry and exit:...

  • Page 128: Terminal Data For The Control Cables

    124 Technical data Input and motor cable terminal dimensions of frames R10 and R11 Top entry and exit (option +H351+H353): Terminal data for the control cables See chapter Control unit on page 79.

  • Page 129: Electrical Power Network Specification

    Technical data 125 Electrical power network specification Voltage (U ACS580-07-xxxxx-4 drives: 380…480 VAC 3-phase +10%. This is indicated in the type designation label as typical input voltage levels 3 400/480 V AC. Network type TN (grounded) and IT (ungrounded) systems Short-circuit withstand Maximum allowable prospective short-circuit current is 65 kA when the input strength (IEC 61439-1)

  • Page 130: Ambient Conditions

    Installation site altitude 0 to 2000 m (6561 ft) above sea level. For altitudes over 2000 m, contact ABB. Output derated above 1000 m (3281 ft). See section Output derating Air temperature -0 to +50 °C (32 to...

  • Page 131: Auxiliary Circuit Power Consumption

    288 mm x 521 mm (ABB code: 64640194) 688 mm x 521 mm (ABB code 64748017) Outlet (roof): airTex G150 2 pcs: 398 mm x 312 mm (ABB code: 64722166) Fire safety of materials Insulating materials and non-metallic items mostly self-extinctive...

  • Page 132: Ce Marking

    128 Technical data Applicable standards The drive complies with the standards below. The compliance with the European Low Voltage Directive is verified according to standard EN 61800-5-1. European electrical safety requirements product standards EN 61800-5-1:2007 Adjustable speed electrical power drive systems. Part 5-1: Safety requirements –...

  • Page 133: Declaration Of Conformity (Safe Torque Off)

    Technical data 129 Declaration of Conformity (Safe torque off) See also chapter Safe torque off function on page and section Implementing the emergency stop function on page 59.
  • Page 134 130 Technical data...

  • Page 135: Compliance With The En 61800-3:2004

    Technical data 131 Compliance with the EN 61800-3:2004 Definitions  EMC stands for Electromagnetic Compatibility. It is the ability of electrical/electronic equipment to operate without problems within an electromagnetic environment. Likewise, the equipment must not disturb or interfere with any other product or system within its locality.

  • Page 136: Cyber Security Disclaimer

    ABB and its affiliates are not liable for damages and/or losses related to such security breaches, any unauthorized access, interference, intrusion, leakage and/or theft of data or information.

  • Page 137: Dimension Drawings

    Dimension drawings 133 Dimension drawings Example dimension drawings are shown below.
  • Page 138 134 Dimension drawings Frames R10 and R11 (IP42)
  • Page 139 Dimension drawings 135 Frames R10 and R11 (IP54 – option +B055)
  • Page 140 136 Dimension drawings...

  • Page 141: Safe Torque Off Function

    Safe torque off function 137 Safe torque off function Contents of this chapter This chapter describes the Safe torque off function of the drive and gives instructions for its use. Description The Safe torque off function can be used, for example, to construct safety or supervision circuits that stop the drive in case of danger (such as an emergency stop circuit).

  • Page 142: Compliance With The European Machinery Directive

    138 Safe torque off function Standard Name IEC 61508-1:2010 Functional safety of electrical/electronic/programmable electronic safety- related systems – Part 1: General requirements IEC 61508-2:2010 Functional safety of electrical/electronic/programmable electronic safety- related systems – Part 2: Requirements for electrical/electronic/programmable electronic safety-related systems IEC 61511:2003 Functional safety –...

  • Page 143: Grounding Of Protective Shields

    Safe torque off function 139 Maximum cable lengths: • 300 m (984 ft) between activation switch (K) and drive control unit • 60 m (200 ft) between multiple drives • 60 m (200 ft) between external power supply and first drive. Note that the voltage at the INx terminals of each drive must be at least 13 V DC to be interpreted as “1”.

  • Page 144: Single Drive (External +24 V Dc Power Supply)

    140 Safe torque off function Single drive (external +24 V DC power supply)  24 V DC Drive Control unit OUT1 + 24 V DC OUT2 + 24 V DC SGND UDC+ T1/U, Control logic T2/V, T3/W UDC-...

  • Page 145: Multiple Drives (Internal Power Supply)

    Safe torque off function 141 Multiple drives (internal power supply)  ACS580-07 Control unit OUT1 + 24 V DC OUT2 + 24 V DC SGND ACS580-07 Control unit OUT1 + 24 V DC OUT2 + 24 V DC SGND ACS580-07 Control unit OUT1 + 24 V DC...

  • Page 146: Multiple Drives (External Power Supply)

    142 Safe torque off function Multiple drives (external power supply)  24 V DC – ACS580-07 Control unit OUT1 + 24 V DC OUT2 + 24 V DC SGND ACS580-07 Control unit OUT1 + 24 V DC OUT2 + 24 V DC SGND ACS580-07 Control unit...

  • Page 147: Operation Principle

    Safe torque off function 143 Operation principle 1. The Safe torque off activates (the activation switch is opened, or safety relay contacts open). 2. STO inputs on the drive control unit de-energize. 3. The control unit cuts off the control voltage from the drive IGBTs. 4.

  • Page 148: Use

    144 Safe torque off function Action Close the disconnector and switch the power on. Test the operation of the STO function when the motor is stopped. • Give a stop command for the drive (if running) and wait until the motor shaft is at a standstill. Make sure that the drive operates as follows: •...

  • Page 149: Maintenance

    If any wiring or component change is needed after start up, or the parameters are restored, follow the test given in section Acceptance test procedure page 143. Use only ABB approved spare parts. Record all maintenance and proof test activities in the machine logbook. Competence ...

  • Page 150: Safety Data (Sil, Pl)

    Any failures of the Safe torque off function must be reported to ABB. Safety data (SIL, PL) The safety data for the Safe torque off function is given below.

  • Page 151: Abbreviations

    Safe torque off function 147 Abbreviations  Abbr. Reference Description Cat. EN ISO 13849-1 Classification of the safety-related parts of a control system in respect of their resistance to faults and their subsequent behavior in the fault condition, and which is achieved by the structural arrangement of the parts, fault detection and/or by their reliability.
  • Page 152 148 Safe torque off function...

  • Page 153: Optional I/O Extension Modules

    Optional I/O extension modules 149 Optional I/O extension modules Contents of this chapter This chapter describes how to install and start up the optional CHDI-01, CMOD-01 and CMOD-01 IO extension modules. The chapter also contains their diagnostics and technical data. CHDI-01 115/230 V digital input extension module Safety instructions ...

  • Page 154: Layout

    150 Optional I/O extension modules Layout Item Description Additional information Grounding screw Hole for mounting screw 3-pin terminal blocks for relay outputs Page 3-pin terminal block for 115/230 V inputs Page Diagnostic LED Page Mechanical installation  Necessary tools and instructions •...

  • Page 155: Electrical Installation

    Optional I/O extension modules 151 Electrical installation  Warnings WARNING! Obey the instructions in chapter Safety instructions on page 13. If you ignore them, injury or death, or damage to the equipment can occur. If you are not a qualified electrician, do not do electrical work. Make sure that the drive is disconnected from the input power during installation.

  • Page 156: Start-Up

    152 Optional I/O extension modules Relay output connection example RO4C RO4A 24 V DC RO4B CHDI-01 Digital input connection example 230 V AC source HDI7 HDI8 NEUTRAL CHDI-01 Start-up  Setting the parameters 1. Power up the drive. 2. If no warning is shown, •...

  • Page 157: Leds

    Optional I/O extension modules 153 LEDs The extension module has one diagnostic LED. Color Description Green The extension module is powered up. Technical data  Dimension drawing: The dimensions are in millimeters and [inches]. Installation: Into an option slot on the drive control unit Degree of protection: IP20 Ambient conditions: See the drive technical data.
  • Page 158 154 Optional I/O extension modules Isolation areas: CHDI-01 Plugged to drive SLOT2 Symbol Description Reinforced insulation (IEC 61800-5-1:2007) Functional insulation (IEC 61800-5-1:2007) Relay outputs (50…52, 53…55): • Wire size max. 1.5 mm • Minimum contact rating: 12 V / 10 mA •...

  • Page 159: Cmod-01 Multifunction Extension Module (External 24 V Ac/Dc And Digital I/O)

    Optional I/O extension modules 155 CMOD-01 multifunction extension module (external 24 V AC/DC and digital I/O) Safety instructions  WARNING! Obey the safety instructions for the drive. If you ignore the safety instructions, injury or death can occur. Hardware description ...

  • Page 160: Layout

    156 Optional I/O extension modules Layout Item Description Additional information Grounding screw Hole for mounting screw 3-pin terminal blocks for relay outputs Page 3-pin terminal block for transistor output Page 2-pin terminal block for external power supply Page Diagnostic LED Page Mechanical installation ...

  • Page 161: Electrical Installation

    Optional I/O extension modules 157 Electrical installation  Warnings WARNING! Obey the instructions in chapter Safety instructions on page 13. If you ignore them, injury or death, or damage to the equipment can occur. If you are not a qualified electrician, do not do electrical work. Make sure that the drive is disconnected from the input power during installation.
  • Page 162 158 Optional I/O extension modules Relay output connection example RO4C RO4A 24 V DC RO4B CMOD-01 Digital output connection example DO1 SRC 24 V DC DO1 OUT DO1 SGND CMOD-01 Frequency output connection example DO1 SRC DO1 OUT DO1 SGND CMOD-01 An externally supplied frequency indicator which provides, for example: •...

  • Page 163: Start-Up

    Optional I/O extension modules 159 Start-up  Setting the parameters 1. Power up the drive. 2. If no warning is shown, • make sure that the value of both parameter 15.02 Detected extension module and parameter 15.01Extension module type is CMOD-01. If warning A7AB Extension I/O configuration failure is shown, •...

  • Page 164: Leds

    160 Optional I/O extension modules LEDs The extension module has one diagnostic LED. Color Description Green The extension module is powered up. Technical data  Dimension drawing: The dimensions are in millimeters and [inches]. Installation: Into an option slot on the drive control unit Degree of protection: IP20 Ambient conditions: See the drive technical data.
  • Page 165 Optional I/O extension modules 161 Isolation areas: CMOD-01 Plugged to 24 V drive SLOT2 Symbol Description Reinforced insulation (IEC 61800-5-1:2007) Functional insulation (IEC 61800-5-1:2007) Relay outputs (50…52, 53…55): • Wire size max. 1.5 mm • Minimum contact rating: 12 V / 10 mA •...

  • Page 166: Cmod-02 Multifunction Extension Module (External 24 V Ac/Dc And Isolated Ptc Interface)

    162 Optional I/O extension modules CMOD-02 multifunction extension module (external 24 V AC/DC and isolated PTC interface) Safety instructions  WARNING! Obey the safety instructions for the drive. If you ignore the safety instructions, injury or death can occur. Hardware description ...

  • Page 167: Layout

    Optional I/O extension modules 163 Layout Item Description Additional information Grounding screw Hole for mounting screw 2-pin terminal block for motor thermistor connection Page 2-pin terminal block for relay output Page 2-pin terminal block for external power supply Page Diagnostic LED Page Mechanical installation ...

  • Page 168: Electrical Installation

    164 Optional I/O extension modules Electrical installation  Warnings WARNING! Obey the instructions in chapter Safety instructions on page 13. If you ignore them, injury or death, or damage to the equipment can occur. If you are not a qualified electrician, do not do electrical work. Make sure that the drive is disconnected from the input power during installation.

  • Page 169: Start-Up

    Optional I/O extension modules 165 Motor thermistor connection example PTC IN PTC IN CMOD-02 1) One or 3…6 PTC thermistors connected in series. The PTC input is reinforced/double insulated. If the motor part of the PTC sensor and wiring are reinforced/double insulated, voltages on the PTC wiring are within SELV limits. If the motor PTC circuit is not reinforced/double insulated (ie, it is basic insulated), it is mandatory to use reinforced/double insulated wiring between the motor PTC and CMOD- 02 PTC terminal.

  • Page 170: Diagnostics

    166 Optional I/O extension modules If warning A7AB Extension I/O configuration failure is shown, • make sure that the value of parameter 15.02 Detected extension module is CMOD-02. • set parameter 15.01 Extension module type to CMOD-02. You can now see the parameters of the extension module in parameter group 15 I/O extension module.
  • Page 171 Optional I/O extension modules 167 Ambient conditions: See the drive technical data. Package: Cardboard Isolation areas: CMOD-02 Plugged 24 V to drive SLOT2 Symbol Description Reinforced insulation (IEC 61800-5-1:2007) Motor thermistor connection (60…61): • Wire size max. 1.5 mm • Supported standards: DIN 44081 and DIN 44082 •...

  • Page 172: Cptc-02 Atex-Certified Thermistor Protection Module, (External 24 V Ac/Dc And Isolated Ptc Interface)

    168 Optional I/O extension modules CPTC-02 ATEX-certified thermistor protection module, (external 24 V AC/DC and isolated PTC interface) See CPTC-02 ATEX-certified thermistor protection module, Ex II (2) GD (+L537+Q971) user's manual (3AXD50000030058 [English]).

  • Page 173: Further Information

    Product and service inquiries Address any inquiries about the product to your local ABB representative, quoting the type designation and serial number of the unit in question. A listing of ABB sales, support and service contacts can be found by navigating to www.abb.com/searchchannels.
  • Page 174 Contact us www.abb.com/drives www.abb.com/drivespartners 3AXD50000032622 Rev A (EN) 2016-03-16...

This manual is also suitable for:

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