ABB ACH580-01 Hardware Manual

—

ABB DRIVES FOR HVAC

ACH580-01 drives

(0.75 to 250 kW, 1 to 350 hp) Hardware manual

Related documents are listed on page 27.

Hardware manual

ACH580-01 drives (0.75 to 250 kW, 1 to 350 hp)

Table of contents

1. Safety instructions

4. Mechanical installation

6. Electrical installation – IEC

7. Electrical installation – North America

3AXD50000044839 Rev B

EFFECTIVE: 2018-12-20

IEC

NEC

Table of contents 5

1. Safety instructions

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Use of warnings and notes in this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

General safety in installation, start-up and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Electrical safety in installation, start-up and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Precautions before electrical work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Additional instructions and notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Additional instructions for permanent magnet motor drives . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Safety in installation, start-up and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

General safety in operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

2. Introduction to the manual

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Applicability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Target audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Purpose of the manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Contents of this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Categorization by frame (size) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Related documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Quick installation and commissioning flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Terms and abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Safety

3. Operation principle and hardware description

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Operation principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Overview of power and control connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

External control connection terminals, frames R1…R5 . . . . . . . . . . . . . . . . . . . . . . . . . . 44

External control connection terminals, frames R6…R9 . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Control panel door mounting kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Type designation label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Type designation key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

4. Mechanical installation

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Checking the installation site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Required tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Moving the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Unpacking and examining delivery, frames R1 and R2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

6 Table of contents

Frames R1 and R2 cable box (IP21, UL Type 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Unpacking and examining delivery, frame R3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Unpacking and examining delivery, frame R4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Unpacking and examining delivery, frame R5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Frame R5 cable box (IP21, UL Type 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Unpacking and examining delivery, frames R6…R9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Frame R6 cable box (IP21, UL Type 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Frame R7 cable box (IP21, UL Type 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Frame R8 cable box (IP21, UL Type 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Frame R9 cable box (IP21, UL Type 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Installing the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Installing the drive vertically, frames R1…R4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Install the cable box, frames R1…R2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Installing the drive vertically, frame R5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Installing the drive vertically, frames R6…R9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Installing the drive vertically side by side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Installing the drive horizontally, frames R1…R5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Flange mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

5. Guidelines for planning the electrical installation

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Limitation of liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Selecting the supply disconnecting device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

European Union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

North America . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Other regions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Checking the compatibility of the motor and drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Protecting the motor insulation and bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Requirements table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

Selecting the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

General guidelines, IEC and North America . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Power cable types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

Additional guidelines, North America . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

Conductor type, IEC and North America . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

Power cable shield, IEC and North America . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

Typical power cable sizes, IEC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

Typical power cable sizes, UL/NEC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

Armored cable / shielded power cable, IEC and North America . . . . . . . . . . . . . . . . . . . 99

Selecting the control cables, IEC and North America . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

Shielding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

Signals in separate cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

Signals allowed to be run in the same cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

Relay cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

Control panel cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

Drive composer PC tool cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

FPBA-01 PROFIBUS DP adapter module connectors . . . . . . . . . . . . . . . . . . . . . . . . . . 101

Routing the cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

General guidelines, IEC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

General guidelines, North America . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

Continuous motor cable shield or enclosure for equipment on the motor cable . . . . . . 104

Table of contents 7

Separate control cable ducts, IEC and North America . . . . . . . . . . . . . . . . . . . . . . . . . . 104

Implementing short-circuit and thermal overload protection . . . . . . . . . . . . . . . . . . . . . . . . . 105

Protecting the drive and input power cable in short-circuits . . . . . . . . . . . . . . . . . . . . . . 105

Protecting the motor and motor cable in short-circuits . . . . . . . . . . . . . . . . . . . . . . . . . . 105

Protecting the drive and the input power and motor cables against thermal overload . . 106

Protecting the motor against thermal overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

Protecting the drive against ground faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

Residual current device compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

Implementing the Emergency stop function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

Implementing the Safe torque off function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

Implementing the ATEX-certified Safe motor disconnection function (option +Q971) . . . . . 107

Using a safety switch between the drive and the motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

Using a contactor between the drive and the motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

Implementing the undervoltage control (power-loss ride-through) . . . . . . . . . . . . . . . . . . . . 108

Protecting the contacts of relay outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

Limiting relay output maximum voltages at high installation altitudes . . . . . . . . . . . . . . . . . . 109

Implementing a motor temperature sensor connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

6. Electrical installation – IEC

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

Required tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

Checking the insulation of the assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

Input power cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

Motor and motor cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

Brake resistor assembly for R1…R3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

Checking the compatibility with IT (ungrounded), corner-grounded delta, midpoint-grounded

delta and TT systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

EMC filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

Ground-to-phase varistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

When to disconnect EMC filter or ground-to-phase varistor: TN-S, IT, corner-grounded

delta and midpoint-grounded delta systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

Guidelines for installing the drive to a TT system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

Identifying different types of electrical power systems . . . . . . . . . . . . . . . . . . . . . . . . . . 119

Frames R1…R3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

Frames R4…R9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

Connecting the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

Connection procedure, frames R1…R4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

Connection procedure, frame R5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

Connection procedure, frames R6…R9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

DC connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

Connecting the control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

Default I/O connection diagram (HVAC default configuration) . . . . . . . . . . . . . . . . . . . . 143

Control cable connection procedure R1…R9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

Installing option modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

Mechanical installation of option modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

Wiring the modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161

Reinstalling grommets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162

8 Table of contents

Reinstalling covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163

Reinstalling cover, frames R1…R4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163

Reinstalling covers, frame R5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164

Reinstalling side plates and covers, frames R6…R9 . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

Connecting a PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166

7. Electrical installation – North America

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

Required tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

Checking the insulation of the assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

Input power cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

Motor and motor cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

Brake resistor assembly for R1…R3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

Checking the compatibility with IT (ungrounded), corner-grounded delta, midpoint-grounded

delta and TT systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

EMC filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

Ground-to-phase varistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

When to connect EMC filter or disconnect ground-to-phase varistor: TN-S, IT, corner-

grounded delta and midpoint-grounded delta systems . . . . . . . . . . . . . . . . . . . . . . . . . 171

Guidelines for installing the drive to a TT system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

Identifying different types of electrical power systems . . . . . . . . . . . . . . . . . . . . . . . . . 173

Frames R1…R3, disconnecting EMC or varistor screws . . . . . . . . . . . . . . . . . . . . . . . . 174

Frames R4…R9, disconnecting EMC or varistor screws . . . . . . . . . . . . . . . . . . . . . . . . 176

Connecting the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178

Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178

Connection procedure, frames R1…R4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180

Connection procedure, frame R5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185

Connection procedure, frames R6…R9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190

DC connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195

Connecting the control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196

Default I/O connection diagram (HVAC default configuration) . . . . . . . . . . . . . . . . . . . . 197

Control cable connection procedure R1…R9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207

Installing option modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213

Mechanical installation of option modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213

Wiring the modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215

Reinstalling grommets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216

Reinstalling covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217

Reinstalling cover, frames R1…R4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217

Reinstalling covers, frame R5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218

Reinstalling side plates and covers, frames R6…R9 . . . . . . . . . . . . . . . . . . . . . . . . . . . 219

Installing UL Type 12 hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220

Connecting a PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221

8. Installation checklist

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223

Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223

Table of contents 9

9. Maintenance and hardware diagnostics

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225

Maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225

Description of symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226

Functional safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226

Recommended annual actions by the user . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226

Recommended maintenance actions by the user . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226

Heatsink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227

Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228

Replacing the main cooling fan, IP21 and IP55 (UL Type 1 and UL Type 12)

frames R1…R4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229

Replacing the main cooling fan, IP21 and IP55 (UL Type 1 and UL Type 12)

frames R5…R8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231

Replacing the main cooling fans, IP21 and IP55 (UL Type 1 and UL Type 12)

frame R9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232

Replacing the auxiliary cooling fan, IP21 and IP55 (UL Type 1 and UL Type 12)

frames R5…R9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233

Replacing the auxiliary cooling fan, IP55 (UL Type 12) frames R1…R2 . . . . . . . . . . . . 234

Replacing the auxiliary cooling fan, IP55 (UL Type 12) frame R3 . . . . . . . . . . . . . . . . . 235

Replacing the auxiliary cooling fan, IP55 (UL Type 12) frame R4 . . . . . . . . . . . . . . . . . 236

Replacing the second auxiliary cooling fan, IP55 (UL Type 12) frames R8…R9 . . . . . . 237

Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238

Reforming the capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238

Control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239

Cleaning the control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239

Replacing the battery in the control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239

LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240

Drive LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240

Control panel LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241

10. Technical data

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243

Electrical ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244

IEC ratings at UN = 230 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244

IEC ratings at UN = 400 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246

IEC ratings at UN = 480 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247

UL (NEC) ratings at UN = 208/230 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249

UL (NEC) ratings at UN = 460 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250

UL (NEC) ratings at UN = 575 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251

Conversion tables for IEC and North American type codes . . . . . . . . . . . . . . . . . . . . . . 252

Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253

Derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254

Ambient temperature derating, IP21 (UL Type 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256

Ambient temperature derating, IP55 (UL Type 12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257

Altitude derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258

Switching frequency derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260

Output frequency derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261

Fuses (IEC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262

gG fuses (IEC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262

10 Table of contents

uR and aR fuses (IEC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264

Circuit breakers (IEC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266

Fuses (UL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268

Dimensions, weights and free space requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270

Losses, cooling data and noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275

Cooling air flow, heat dissipation and noise for stand-alone drives . . . . . . . . . . . . . . . . 275

Cooling air flow and heat dissipation for flange mounting (option +C135) . . . . . . . . . . . 279

Terminal and lead-through data for the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280

IEC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280

UL (NEC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282

Terminal and lead-through data for the control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284

IEC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284

UL (NEC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285

Electrical power network specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286

Voltage (U1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286

Motor connection data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286

Brake resistor connection data for frames R1…R3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289

Control connection data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289

Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296

Degree of protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296

Ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296

Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298

Applicable standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298

CE marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300

Compliance with the European Low Voltage Directive . . . . . . . . . . . . . . . . . . . . . . . . . 300

Compliance with the European EMC Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300

Compliance with the European ROHS II Directive 2011/65/EU . . . . . . . . . . . . . . . . . . . 300

Compliance with the European WEEE Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300

Compliance with the European Machinery Directive 2006/42/EC 2nd Edition –

June 2010 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300

Compliance with the EN 61800-3:2004 + A1:2012 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301

Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301

Category C1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301

Category C2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302

Category C3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302

Category C4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303

UL marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304

UL checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304

China RoHS marking . . . . . . . . . . . . . . . . . . . . . .

RCM marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306

WEEE marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306

EAC marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306

Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306

Cyber security disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306

11. Dimension drawings

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309

Frame R1, IP21 (UL Type 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310

Frame R1, IP55 (UL Type 12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311

Frame R1, IP55+F278 (UL Type 12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312

Table of contents 11

Frame R2, IP21 (UL Type 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313

Frame R2, IP55 (UL Type 12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314

Frame R2, IP55+F278 (UL Type 12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315

Frame R3, IP21 (UL Type 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316

Frame R3, IP55 (UL Type 12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317

Frame R3, IP55+E223 (UL Type 12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318

Frame R3, IP55+F278/F316 (UL Type 12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319

Frame R4, IP21 (UL Type 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320

Frame R4, IP55 (UL Type 12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321

Frame R4, IP55+E223 (UL Type 12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322

Frame R4, IP55+F278/F316 (UL Type 12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323

Frame R5, IP21 (UL Type 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324

Frame R5, IP55 (UL Type 12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325

Frame R5, IP55+E223 (UL Type 12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326

Frame R5, IP55+F278/F316 (UL Type 12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327

Frame R6, IP21 (UL Type 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328

Frame R6, IP55 (UL Type 12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329

Frame R7, IP21 (UL Type 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330

Frame R7, IP55 (UL Type 12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331

Frame R8, IP21 (UL Type 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332

Frame R8, IP55 (UL Type 12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333

Frame R9, IP21 (UL Type 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334

Frame R9, IP55 (UL Type 12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335

12. Resistor braking

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337

Operation principle and hardware description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337

Resistor braking, frames R1…R3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338

Planning the braking system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338

Mechanical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342

Electrical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342

Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343

Resistor braking, frames R4…R9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344

Planning the braking system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344

13. Safe torque off function

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345

Compliance with the European Machinery Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346

Connection principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347

Connection with internal +24 V DC power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347

Connection with internal +24 V DC power supply, single-channel . . . . . . . . . . . . . . . . . 348

Connection with external +24 V DC power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349

Wiring examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349

Activation switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350

Cable types and lengths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350

Grounding of protective shields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351

Operation principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351

Start-up including acceptance test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351

12 Table of contents

Competence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352

Acceptance test reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352

Acceptance test procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353

Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356

Competence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356

Fault tracing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356

Safety data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358

Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 360

Declaration of conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 360

Certificate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361

14. Optional I/O extension modules

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363

CHDI-01 115/230 V digital input extension module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363

Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363

Hardware description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363

Mechanical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364

Electrical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365

Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367

Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367

Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 368

CMOD-01 multifunction extension module (external 24 V AC/DC and digital I/O) . . . . . . . . 370

Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 370

Hardware description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 370

Mechanical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 371

Electrical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 372

Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 374

Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 375

Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 376

CMOD-02 multifunction extension module (external 24 V AC/DC and isolated PTC

interface) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 379

Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 379

Hardware description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 379

Mechanical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 380

Electrical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 381

Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 383

Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 384

Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 385

15. Common mode, du/dt and sine filters

Content of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 389

Common mode filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 389

When is a common mode filter needed? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 389

du/dt filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 389

When is a du/dt filter needed? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 389

Common mode filter types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 390

du/dt filter types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 391

Description, installation and technical data of the FOCH filters . . . . . . . . . . . . . . . . . . . 391

Table of contents 13

Description, installation and technical data of the NOCH filters . . . . . . . . . . . . . . . . . . . 391

Sine filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 392

Selecting a sine filter for the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 392

Description, installation and technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 393

Further information

Product and service inquiries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 395

Product training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 395

Providing feedback on ABB Drives manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 395

Document library on the Internet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 395

14 Table of contents

Safety instructions 15

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 and notes in this manual

Warnings tell you about conditions which can cause injury or death, or damage to the equipment. They also tell you how to prevent the danger. Notes draw attention to a particular condition or fact, or give information on a subject.

The manual uses these warning symbols:

Electricity warning tells about hazards from electricity which can cause injury or death, or damage to the equipment.

General warning tells about conditions, other than those caused by electricity, which can cause injury or death, or damage to the equipment.

Electrostatic sensitive devices warning tells you about the risk of electrostatic discharge which can cause damage to the equipment.

16 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 it.

WAR NIN G! Obey these instructions. If you ignore them, injury or death, or damage to the equipment can occur.

• Use safety shoes with a metal toe cap to avoid foot injury. Wear protective gloves and long sleeves. Some parts have sharp edges.

• Handle the drive carefully.

•Frames R

drive.

•Frames R5…R9: Do not tilt the drive. The drive is heavy and its center of

gravity is high. An overturning drive can cause physical injury.

5…R9: Lift the drive with a lifting device. Use the lifting eyes of the

• Beware of hot surfaces. Some parts, such as heatsinks of power semiconductors, remain hot for a while after disconnection of the electrical supply.

• Keep the drive in its package or protect it otherwise from dust and burr from drilling and grinding until you install it.

• Protect also the installed drive against dust and burr. Electrically conductive debris inside the drive may cause damage or malfunction.

• Vacuum clean the area below the drive before the start-up to prevent the drive cooling fan from drawing the dust inside the drive.

• Do not cover the air inlet and outlet when the drive runs.

• Make sure that there is sufficient cooling. See sections Checking the installation

site on page 54 and Losses, cooling data and noise on page 275 for more

information.

• Before you connect voltage to the drive, make sure that the drive covers are on. Keep the covers on during the operation.

• Before you adjust the drive operation limits, make sure that the motor and all driven equipment can operate throughout the set operation limits.

Safety instructions 17

• Before you activate the automatic fault reset or automatic restart functions of the drive control program, make sure that no dangerous situations can occur. These functions reset the drive automatically and continue operation after a fault or supply break. If these functions are activated, the installation must be clearly marked as defined in IEC/EN 61800-5-1, subclause 6.5.3, for example, “THIS MACHINE STARTS AUTOMATICALLY”.

• If you have connected safety circuits to the drive (for example, emergency stop and Safe torque off), validate them at the start up. For the validation of the Safe torque off, see ACH580 HVAC control program firmware manual (3AXD50000027537 [English]). For the validation of other safety circuits, see the instructions provided with them.

Note:

• If you select an external source for start command and it is on, and the start command is level-triggered, the drive will start immediately after fault reset. See parameters 20.02 Ext1 start trigger type and 20.07 Ext2 start trigger type in ACH580 HVAC control program firmware manual (3AXD50000027537 [English]).

• When the control location is not set to Local (text Hand is not shown on the top row of the panel and parameter 19.19 Off mode disable has value Off button disabled), the stop key on the control panel will not stop the drive.

• Frames R1…R5

: Do not attempt to repair a malfunctioning drive; contact your

local representative for replacement or repair by authorized persons. Frames R6…R9: Can be repaired by authorized persons.

18 Safety instructions

Electrical safety in installation, start-up and maintenance

 Precautions before electrical work

These warnings are for all personnel who do work on the drive, motor cable or motor.

WAR NIN G! Obey these instructions. If you ignore them, injury or death, or

damage to the equipment can occur. If you are not a qualified electrical professional, do not do electrical installation or maintenance work. Go through these steps before you begin any installation or maintenance work.

1. Clearly identify the work location.

2. Disconnect all possible voltage sources. Lock and tag.

• Open the main disconnector at the power supply of the drive.

• Make sure that reconnection is not possible.

• Disconnect any external power sources from the control circuits.

• After you disconnect the drive, always wait for 5 minutes to let the intermediate circuit capacitors discharge before you continue.

3. Protect any other energized parts in the work location against contact.

4. Take special precautions when close to bare conductors.

5. Measure that the installation is de-energized.

• Use a multimeter with an impedance of at least 1 Mohm.

• Make sure that the voltage between the drive input power terminals (L1, L2, L3) and the grounding terminal (PE) is close to 0 V.

• Make sure that the drive DC voltage is close to 0 V. Frames R1…R3

grounding terminal (PE) with one multimeter. As there is no UDC- terminal, measure the voltage between the drive T1/U terminal and grounding terminal (PE) with another multimeter. Make sure that the voltage difference between the multimeters is close to 0 V.

Frames R4…R9 and UDC-) and the grounding terminal (PE) and make sure that it is close to 0V.

: Measure the voltage between the drive UDC+ terminal and

: Measure the voltage between the drive DC terminals (UDC+

6. Install temporary grounding as required by the local regulations.

7. Ask for a permit to work from the person in control of the electrical installation work

Safety instructions 19

 Additional instructions and notes

WARNING! Obey these instructions. If you ignore them, injury or death, or damage to the equipment can occur.

• A drive with the internal EMC filter connected can be installed to a symmetrically grounded TN-S system. If you install the drive to another system, check if you must disconnect the EMC filter. See sections

•IEC:

•North America:

drive. Note: When the internal EMC filter is disconnected, the EMC compatibility of the

drive is considerably reduced. See section EMC compatibility and motor cable

length on page 288.

• A drive with the ground-to-phase varistor connected can be installed to a symmetrically grounded TN-S system. If you install the drive to another system, check if you must disconnect the varistor. See sections

•IEC:

•North America:

varistor circuit can be damaged.

• Use all ELV (extra low voltage) circuits connected to the drive only within a zone of equipotential bonding, that is, within a zone where all simultaneously accessible conductive parts are electrically connected to prevent hazardous voltages appearing between them. You can accomplish this by a proper factory grounding, that is, make sure that all simultaneously accessible conductive parts are grounded to the protective earth (PE) bus of the building.

• Do not do insulation or voltage withstand tests on the drive or drive modules.

When to disconnect EMC filter or ground-to-phase varistor: TN-S, IT,

corner-grounded delta and midpoint-grounded delta systems on page 117,

and Guidelines for installing the drive to a TT system on page 118.

When to connect EMC filter or disconnect ground-to-phase

varistor: TN-S, IT, corner-grounded delta and midpoint-grounded delta systems on page 171, and Guidelines for installing the drive to a TT system on

page 172.

WARNING! Do not install a drive with the EMC filter connected to a system that the filter is not suitable for. This can cause danger, or damage the

When to disconnect EMC filter or ground-to-phase varistor: TN-S, IT,

corner-grounded delta and midpoint-grounded delta systems on page 117,

and Guidelines for installing the drive to a TT system on page 118.

When to connect EMC filter or disconnect ground-to-phase

varistor: TN-S, IT, corner-grounded delta and midpoint-grounded delta systems on page 171, and Guidelines for installing the drive to a TT system on

page 172.

WARNING! Do not install a drive with the ground-to-phase varistor connected to a system that the varistor is not suitable for. If you do, the

20 Safety instructions

Note:

• The motor cable terminals of the drive are at a dangerous voltage when the input power is on, regardless of whether the motor is running or not.

• The DC and brake resistor terminals (UDC+, UDC-, R+ and R-) are at a dangerous voltage.

• External wiring can supply dangerous voltages to the terminals of relay outputs (RO1, RO2 and RO3).

• The Safe torque off function does not remove the voltage from the main and auxiliary circuits. The function is not effective against deliberate sabotage or misuse.

WARNING! Use a grounding wrist band when you handle the printed circuit boards. Do not touch the boards unnecessarily. The boards contain components sensitive to electrostatic discharge.

 Grounding

These instructions are for all personnel who are responsible for the electrical installation, including the grounding of the drive.

WAR NIN G! Obey these instructions. If you ignore them, injury or death, or equipment malfunction can occur, and electromagnetic interference can

increase.

• If you are not a qualified electrical professional, do not do grounding work.

• Always ground the drive, the motor and adjoining equipment to the protective earth (PE) bus of the power supply. This is necessary for the personnel safety. Proper grounding also reduces electromagnetic emission and interference.

• In a multiple-drive installation, connect each drive separately to the protective earth (PE) bus of the power supply.

• Make sure that the conductivity of the protective earth (PE) conductors is sufficient. See section Selecting the power cables on page 89. Obey the local regulations.

• Connect the power cable shields to the protective earth (PE) terminals of the drive.

• Make a 360° grounding of the power and control cable shields at the cable entries to suppress electromagnetic disturbances.

Safety instructions 21

Note:

• You can use power cable shields as grounding conductors only when their conductivity is sufficient.

• Standards IEC/EN 61800-5-1 (section 4.3.5.5.2.) and UL 68100-5-1 require that as the normal touch current of the drive is higher than 3.5 mA AC or 10 mA DC, you must use a fixed protective earth (PE) connection. In addition,

• install a second protective earth conductor of the same cross-sectional area

as the original protective earthing conductor,

• install a protective earth conductor with a cross-section of at least 10 mm

or 16 mm

Al (when aluminum cables are allowed),

• install a device which automatically disconnects the supply if the protective

earth conductor breaks.

22 Safety instructions

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.

WAR NIN G! Obey these instructions. If you ignore them, injury or death and damage to the equipment can occur.

• Do not work on a drive when a rotating permanent magnet motor is connected to it. A rotating permanent magnet motor energizes the drive including its input power terminals.

Before installation, start-up and maintenance work on the drive:

• Stop the motor.

• Disconnect the motor from the drive with a safety switch or by other means.

• If you cannot disconnect the motor, make sure that the motor cannot rotate during work. Make sure that no other system can rotate the motor directly or through any mechanical connection.

• Measure that the installation is de-energized.

• Use a multimeter with an impedance of at least 1 Mohm.

• Make sure that the voltage between the drive output terminals (T1/U, T2/V,

T3/W) and the grounding (PE) busbar is close to 0 V.

• Make sure that the voltage between the drive input power terminals (L1, L2,

L3) and the grounding (PE) busbar is close to 0 V.

• Make sure that the voltage between the drive DC terminals (UDC+, UDC-) and

the grounding (PE) terminal is close to 0 V.

• Install temporary grounding to the drive output terminals (T1/U, T2/V, T3/W). Connect the output terminals together as well as to the PE.

Start-up and operation:

• Motor overspeed causes overvoltage that can damage or destroy the capacitors in the intermediate circuit of the drive.

Safety instructions 23

General safety in operation

These instructions are for all personnel that operate the drive.

WARNING! Obey these instructions. If you ignore them, injury or death, or damage to the equipment can occur.

• Do not power up the drive more than five times in ten minutes. Too frequent power-ups can damage the charging circuit of the DC capacitors. If you need to start or stop the drive, use the control panel Hand, Off and Auto keys or commands through the I/O terminals of the drive.

• Give a stop command to the drive before you reset a fault. If you have an external source for the start command and the start is on, the drive will start immediately after the fault reset, unless you configure the drive for pulse start. See the firmware manual.

• Before you activate automatic fault reset functions of the drive control program, make sure that no dangerous situations can occur. These functions reset the drive automatically and continue operation after a fault.

24 Safety instructions

Introduction to the manual 25

Introduction to the manual

Contents of this chapter

The chapter describes applicability, target audience and purpose of this manual. It describes the contents of this manual and refers to a list of related manuals for more information. The chapter also contains a flowchart of steps for checking the delivery, installing and commissioning the drive. The flowchart refers to chapters/sections in this manual.

Applicability

The manual applies to the ACH580-01 drives, including the new (2017) R1…R3 frames (see all applicable types in section Electrical ratings on page 244).

Note: The manual does not apply to R0…R3 frames with type codes ACH580-01: 02A6-4, 03A3-4, 04A0-4, 05A6-4, 07A2-4, 09A-4, 12A6-4, 017A-4, 025A-4, 032A-4, 038A-4, 045A-4. For these types, see ACH580-01 (0.75 to 250 kW, 1 to 350 hp) hardware manual (3AUA0000076331[English]).

Target audience

The reader is expected to know the fundamentals of electricity, wiring, electrical components and electrical schematic symbols.

The manual is written for readers worldwide. Both SI and imperial units are shown. Special instructions for installations in North America are given.

Purpose of the manual

This manual provides information needed for planning the installation, installing, and servicing the drive.

26 Introduction to the manual

Contents of this manual

The manual consists of the following chapters:

• Safety instructions (page 15) gives safety instructions you must obey when installing, commissioning, operating and servicing the drive.

• Introduction to the manual (this chapter, page 25) describes applicability, target audience, purpose and contents of this manual. It also contains a quick installation and commissioning flowchart. At the end, it lists terms and abbreviations.

• Operation principle and hardware description (page 35) describes the operation principle, layout, power connections and control interfaces, type designation label and type designation information in short.

• Mechanical installation (page 53) describes how to check the installation site, unpack, check the delivery and install the drive mechanically.

• Guidelines for planning the electrical installation (page 81) describes how to plan the electrical installation of the drive, for example, how to check the compatibility of the motor and the drive and select cables, protections and cable routing.

• Electrical installation – IEC (page 113) describes how to check the insulation of the assembly and the compatibility with other than symmetrically grounded TN-S systems. It then shows how to connect the power and control cables, install optional modules and connect a PC.

• Electrical installation – North America (page 167) describes how to check the insulation of the assembly and the compatibility with other than symmetrically grounded TN-S systems. It then shows how to connect the power and control cables, install optional modules and connect a PC.

• Installation checklist (page 223) contains a checklist for checking the mechanical and electrical installation of the drive before start-up.

• Maintenance and hardware diagnostics (page 225) contains preventive maintenance instructions and LED indicator descriptions.

• Technical data (page 243) contains technical specifications of the drive, eg, ratings, sizes and technical requirements as well as provisions for fulfilling the requirements for CE, UL and other marks.

• Dimension drawings (page 309) shows dimension drawings of the drive.

• Resistor braking (page 337) tells how to select the brake resistor.

• Safe torque off function (page 345) describes STO features, installation and technical data.

• Optional I/O extension modules (page 363) describes CMOD-01, CMOD-02, and CHDI-01 extension modules, their installation, start-up, diagnostics and technical data.

• Common mode, du/dt and sine filters (page 389) describes selection of external filters for the drive.

Introduction to the manual 27

• Further information (inside of the back cover, page 395) tells how to make product and service inquiries, get information on product training, provide feedback on manuals and find documents on the Internet.

Categorization by frame (size)

The ACH580-01 is manufactured in frames (frame sizes) R1…R9. Some instructions and other information that only concern certain frames are marked with the symbol of the frame (R1…R9). The frame is marked on the type designation label attached to the drive, see section Type designation label on page 47.

Quick installation and commissioning flowchart

Tas k Se e

Identify the frame of your drive: R1…R9. Operation principle and hardware description:

Type designation key on page 49

Plan the installation: select the cables, etc. Check the ambient conditions, ratings and

required cooling air flow.

Unpack and check the drive. Check that all necessary optional modules

and equipment are present and correct.

If the drive will be connected to another system than symmetrically grounded TN-S system: Check if you must disconnect the EMC filter or ground-to-phase varistor.

Install the drive on a wall. Mechanical installation on page 53

Route the cables. Guidelines for planning the electrical

Check the insulation of the input cable and the motor and the motor cable.

Guidelines for planning the electrical installation on page 81

Technical data on page 243

Mechanical installation: Unpacking and examining delivery, frames R1 and R2 on

page 59; R3 on page 61; R4 on page 63; R5 on page 65; R6…R9 on page 67

IEC:

Checking the compatibility with IT

(ungrounded), corner-grounded delta, midpoint-grounded delta and TT systems on

page 11 6 North America:

with IT (ungrounded), corner-grounded delta, midpoint-grounded delta and TT systems on

page 170

installation: Routing the cables on page 102

Electrical installation: IEC:

Checking the insulation of the assembly

on page 114 North America:

assembly on page 168

Checking the compatibility

Checking the insulation of the

Connect the power cables. Electrical installation:

IEC:

Connecting the power cables on page

123

North America: on page 178

Connecting the power cables

30 Introduction to the manual

Tas k Se e

Connect the control cables. Electrical installation:

IEC:

Connecting the control cables on page

142

North America: on page 178

Check the installation. Installation checklist on page 223

Commission the drive. ACH580 HVAC control program firmware

manual (3AXD50000027537 [English])

Connecting the control cables

+ 366 hidden pages

ABB ACH580-01 Hardware Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Table of contents

Safety instructions

Contents of this chapter

Use of warnings and notes in this manual

General safety in installation, start-up and maintenance

Electrical safety in installation, start-up and maintenance

 Precautions before electrical work

 Additional instructions and notes

 Grounding

Additional instructions for permanent magnet motor drives

 Safety in installation, start-up and maintenance

General safety in operation

Introduction to the manual

Contents of this chapter

Applicability

Target audience

Purpose of the manual

Contents of this manual

Categorization by frame (size)

Related documents

Quick installation and commissioning flowchart