ABB ACH580-31 Hardware Manual

ABB drives for HVAC

Hardware manual

ACH580-31 drives

You can find manuals and other product documents in PDF format on the Internet. See section 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 codes below open an online listing of the manuals applicable to the product.

Hardware manual

ACH580-31 drives

able of contents

1. Safety instructions

4. Mechanical instal

6. Electrical i

stallation –

lati

IEC

7. Electrical installation – USA

3AXD50000037066 Rev C

EFFECTIVE: 2018-06-25

Update notice 1

Update notice

The notice concerns the ACH580-31 hardware manual given below.

Contents of the notice: Correction in type designation key table.

Code of this notice: 3AXD50000379842 Rev A. Valid: From 2018-12-17 until revision D of

the manual.

Manual code Revision Language

3AXD50000037066 C English EN

Type designation key

Changed:

CODE DESCRIPTION

Basic codes

ACH580 Product series

31 When no options are selected: Wall mounted, IP21 (UL Type 1), ACH-AP-H

control panel with a USB port, choke, internal EMC C3 filter, Safe torque off, function, coated boards, cable entry from bottom, multilingual quick installation and start-up guides

Table of contents 5

Table of contents

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 . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Safety in installation, start-up and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

General safety in operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Additional instruction for DC connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

2. Introduction to the manual

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Applicability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Target audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Purpose of the manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Categorization by frame (size) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Quick installation and commissioning flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Terms and abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Related documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

3. Operation principle and hardware description

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Operation principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

DC connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Overview of power and control connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Type designation label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Type designation key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

4. Mechanical installation

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Examining the installation site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Required tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Moving the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Unpacking and examining delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Installing the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Flange mounting (option +C135) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

6 Table of contents

Cabinet installation (option +P940) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

5. Guidelines for planning the electrical installation

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

Selecting the supply disconnecting device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

European Union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

North American Market . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Other regions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Checking the compatibility of the motor and drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Protecting the motor insulation and bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Requirements table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Additional requirements for ABB motors of types other than M2_, M3_, M4_, HX_ and

AM_ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Additional requirements for ABB high-output and IP23 motors . . . . . . . . . . . . . . . . . 58

Additional requirements for non-ABB high-output and IP23 motors . . . . . . . . . . . . . 58

Additional data for calculating the rise time and peak line-to-line voltage . . . . . . . . . 59

Additional note for sine filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Selecting the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

General rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Typical power cable sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

IEC ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

NEC ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Alternative power cable types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Recommended power cable types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Power cable types for limited use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Not allowed power cable types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Motor cable shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Additional US requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Conduit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Armored cable / shielded power cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Selecting the control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Shielding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Signals in separate cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Signals allowed to be run in the same cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Relay cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Control panel cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Drive composer PC tool cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Routing the cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

General rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Separate control cable ducts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Continuous motor cable shield or enclosure for equipment on the motor cable . . . . . . . 70

Implementing thermal overload and short-circuit protection . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Protecting the drive and input power cable in short-circuits . . . . . . . . . . . . . . . . . . . . . . . 71

Protecting the motor and motor cable in short-circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Protecting the drive and the input power and motor cables against thermal overload . . . 71

Protecting the motor against thermal overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Protecting the drive against ground faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Residual current device compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Implementing the Emergency stop function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Implementing the Safe torque off function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Table of contents 7

Implementing the ATEX-certified Safe motor disconnection function (option +Q971) . . . . . . 72

Implementing the undervoltage control (power-loss ride-through) . . . . . . . . . . . . . . . . . . . . . 72

Using a safety switch between the drive and the motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Using a contactor between the drive and the motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Protecting the contacts of relay outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Limiting relay output maximum voltages at high installation altitudes . . . . . . . . . . . . . . . . . . . 74

Implementing a motor temperature sensor connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Connection of motor temperature sensor to the drive via an option module . . . . . . . . . . . 76

Connection of motor temperature sensor to the drive via a relay . . . . . . . . . . . . . . . . . . . 76

6. Electrical installation – IEC

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Required tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Grounding the motor cable shield at the motor end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Checking the insulation of the assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Input power cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Motor and motor cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Brake resistor assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

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

ta, and TT systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

EMC filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Ground-to-phase varistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

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

and midpoint-grounded delta systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Guidelines for installing the drive to a TT system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

Identifying different types of electrical power systems . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

Disconnecting internal EMC filter and ground-to-phase varistor – frame R3 . . . . . . . . . . 86

Disconnecting internal EMC filter and ground-to-phase varistor – frame R6 . . . . . . . . . . 87

Disconnecting internal EMC filter and ground-to-phase varistor –frame R8 . . . . . . . . . . . 88

Connecting the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Connection procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

R8 power cable connection if you detach the motor cable connectors . . . . . . . . . . . . 98

Connecting the control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

Default I/O connection diagram (HVAC default configuration) . . . . . . . . . . . . . . . . . . . . 100

Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

PNP configuration for digital inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

NPN configuration for digital inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

Connection for obtaining 0…10 V from analog output 2 (AO2) . . . . . . . . . . . . . . . . 103

Connection examples of two-wire and three-wire sensors . . . . . . . . . . . . . . . . . . . . 104

DI5 as frequency input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

DI6 as PTC input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

AI1 and AI2 as Pt100, Pt1000, Ni1000, KTY83 and KTY84 sensor inputs (X1) . . . . 106

Safe torque off (X4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

Control cable connection procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

Installing option modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

Mechanical installation of option modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

Option slot 2 (I/O extension modules) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

8 Table of contents

Option slot 1 (fieldbus adapter modules) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

Wiring the optional modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

Reinstalling cover(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

Connecting a PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

Connecting a remote panel, or chaining one panel to several drives . . . . . . . . . . . . . . . . . . 114

7. Electrical installation – USA

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

Required tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

Checking the insulation of the assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

Input power cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

Motor and motor cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

Brake resistor assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

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

systems, and TT systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

Connecting the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

Connection procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

R8 motor cable connection if you detach the connectors . . . . . . . . . . . . . . . . . . . . 127

Connecting the control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

Default I/O connection diagram (HVAC default configuration) . . . . . . . . . . . . . . . . . . . . 129

Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

PNP configuration for digital inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

NPN configuration for digital inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

Connection for obtaining 0…10 V from analog output 2 (AO2) . . . . . . . . . . . . . . . . 132

Connection examples of two-wire and three-wire sensors . . . . . . . . . . . . . . . . . . . 133

DI5 as frequency input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

DI6 as PTC input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

AI1 and AI2 as Pt100, Pt1000, Ni1000, KTY83 and KTY84 sensor inputs (X1) . . . 135

Safe torque off (X4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

Control cable connection procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

Installing option modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

Reinstalling cover(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

Connecting a PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

Connecting a remote panel, or chaining one panel to several drives . . . . . . . . . . . . . . . . . . 141

8. Installation checklist

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

9. Start-up

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

Start-up procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

Table of contents 9

10. Maintenance and hardware diagnostics

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

Maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

Description of symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

Recommended annual maintenance actions by the user . . . . . . . . . . . . . . . . . . . . . . . . 148

Recommended maintenance actions by the user . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

Heatsink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

Replacing the main cooling fan, frame R3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

Replacing the main cooling fan, frame R6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

Replacing the main cooling fan, frame R8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

Replacing the auxiliary cooling fan, IP55 (UL Type 12) frame R3 . . . . . . . . . . . . . . . . . 153

Replacing the auxiliary cooling fan, frame R6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

Replacing the auxiliary cooling fan, frame R8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

Replacing the second auxiliary cooling fan IP55 (UL Type 12), frame R8 . . . . . . . . . . . 156

Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158

Reforming the capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158

Control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

Cleaning the control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

Replacing the battery in the control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160

Drive LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160

Control panel LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160

11. Technical data

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161

Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161

IEC ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162

UL (NEC) ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163

Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163

Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163

Derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164

Derating in case of several situations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164

Example: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164

Ambient temperature derating, IP21 (UL Type 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164

Ambient temperature derating, IP55 (UL Type 12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

Ambient temperature derating in table format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

Switching frequency derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

Altitude derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

Fuses (IEC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

aR fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

gG fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

Fuses (UL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171

Dimensions, weights and free space requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

Free space requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

Losses, cooling data and noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

Terminal and entry data for the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175

IEC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175

10 Table of contents

UL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175

UL listed cable lugs and tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176

Terminal and entry data for the control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176

IEC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176

US . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177

Electrical power network specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177

Voltage (U1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177

Motor connection data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178

CCU-24 control unit connection data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181

Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185

Degree of protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185

Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185

Applicable standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187

Ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188

CE marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189

Compliance with the European Low Voltage Directive . . . . . . . . . . . . . . . . . . . . . . . . . 189

Compliance with the European EMC Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189

Compliance with the European ROHS II Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190

Compliance with the European WEEE Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190

Compliance with the European Machinery Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190

Declaration of conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191

Compliance with the EN 61800-3:2004 + A1:2012 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192

Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192

Category C2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192

Category C3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193

Category C4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194

UL marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195

UL checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195

RCM marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196

China RoHS marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196

EAC marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196

Disclaimers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197

General disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197

Cybersecurity disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197

12. Dimension drawings

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199

R3, IP21 (UL Type 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200

R3 – Option +B056 (IP55, UL Type 12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201

R6, IP21 (UL Type 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202

R6 – Option +B056 (IP55, UL Type 12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203

R8, IP21 (UL Type 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204

R8 – Option +B056 (IP55, UL Type 12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205

13. The Safe torque off function

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207

Compliance with the European Machinery Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . 208

Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208

Table of contents 11

Connection with internal +24 V DC power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209

Connection with external +24 V DC power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210

Wiring examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210

Activation switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211

Cable types and lengths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211

Grounding of protective shields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212

Operation principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212

Start-up including acceptance test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212

Competence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212

Acceptance test reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212

Acceptance test procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212

Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215

Competence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216

Fault tracing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216

Safety data (SIL, PL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217

Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218

14. Resistor braking

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219

Operation principle and hardware description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219

Planning the braking system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219

Selecting the brake circuit components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219

Selecting a custom resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220

Selecting and routing the brake resistor cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220

Minimizing electromagnetic interference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221

Maximum cable length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221

EMC compliance of the complete installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221

Placing the brake resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221

Protecting the system against thermal overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222

Protecting the system in fault situations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222

Protecting the resistor cable against short-circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222

Mechanical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223

Electrical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223

Checking the insulation of the assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223

Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223

Connection procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223

Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223

Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224

Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224

Terminals and cable lead-through data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224

15. Common mode, du/dt and sine filters

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

Common mode filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225

When is a common mode filter needed? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225

du/dt filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225

When is a du/dt filter needed? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225

du/dt filter types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226

12 Table of contents

Description, installation and technical data of the NOCH filters . . . . . . . . . . . . . . . . . . . 227

Sine filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227

16. Optional I/O extension modules

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229

CHDI-01 115/230 V digital input extension module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229

Hardware description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229

Product overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229

Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230

Mechanical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230

Necessary tools and instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230

Unpacking and checking the delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230

Installing the module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230

Electrical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231

Necessary tools and instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231

Terminal designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231

General cabling instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232

Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232

Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233

Setting the parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233

Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233

Faults and warning messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233

LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233

Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234

CMOD-01 multifunction extension module (external 24 V AC/DC and digital I/O) . . . . . . . . 236

Hardware description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236

Product overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236

Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237

Mechanical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237

Necessary tools and instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237

Unpacking and checking the delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237

Installing the module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238

Electrical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238

Necessary tools and instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238

Terminal designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238

General cabling instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239

Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239

Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240

Setting the parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240

Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241

Faults and warning messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241

LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241

Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242

CMOD-02 multifunction extension module (external 24 V AC/DC and isolated PTC interface) . . 244

Hardware description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244

Product overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244

Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245

Table of contents 13

Mechanical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245

Necessary tools and instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245

Unpacking and checking the delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245

Installing the module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246

Electrical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246

Necessary tools and instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246

Terminal designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246

General cabling instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247

Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247

Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248

Setting the parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248

Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248

Faults and warning messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248

LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248

Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249

Further information

Product and service inquiries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251

Product training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251

Providing feedback on ABB Drives manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251

Document library on the Internet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251

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.

WARNING! 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.

• Lift the drive with a lifting device. Use the lifting eyes of the drive.

• Do not tilt the drive. The drive is heavy and its center of gravity is high. It will

overturn easily.

• 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 from dust and metal shavings from drilling and grinding until you install it. Protect the installed drive against dust and metal shavings. Electrically conductive debris inside the drive can 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 Examining the installation

site on page 42 and Losses, cooling data and noise on page 173 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.

• 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

Safety instructions 17

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".

• The maximum number of drive power-ups is five in ten minutes. Too frequent power-ups can damage the charging circuit of the DC capacitors.

• Make sure that any safety circuits (for example, emergency stop and Safe torque off) are validated at start-up. For the Safe torque off, see chapter The Safe torque

off function page 207. For other safety functions, see their separate instructions.

Note:

• If you select an external source for the 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.

• Depending on the wiring and parametrization of the drive, the stop key on the control panel may not stop the drive.

• Only authorized persons are allowed to repair a malfunctioning drive.

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.

WARNING! 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 voltage between the drive DC terminals (UDC+ and UDC-) and the grounding terminal (PE) is close to 0 V.

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 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 When to disconnect EMC filter or

ground-to-phase varistor: TN-S, IT, corner-grounded delta, and midpointgrounded delta systems on page 83 and Guidelines for installing the drive to a TT system on page 84.

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

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

considerably reduced. See section EMC compatibility and motor cable length on page 179.

• 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 When to disconnect EMC

filter or ground-to-phase varistor: TN-S, IT, corner-grounded delta, and midpointgrounded delta systems on page 83 and Guidelines for installing the drive to a TT system on page 84.

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

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.

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 terminals (UDC+, UDC-) 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.

20 Safety instructions

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.

WARNING! 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 61. 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.

Note:

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

• Standard IEC/EN 61800-5-1 (section 4.3.5.5.2.) requires 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 mm2Al,

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

earth conductor breaks.

Safety instructions 21

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 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, like hydraulic crawling drives, can rotate the motor directly or through any mechanical connection like felt, nip, rope, etc.

• 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:

• Make sure that the operator cannot run the motor over the rated speed. Motor overspeed causes overvoltage that can damage or destroy the capacitors in the intermediate circuit of the drive.

22 Safety instructions

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 control the motor with the disconnector at the drive power supply; instead, use the control panel start and stop 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.

Note: When the drive is not in the Hand mode, the Off key on the control panel will not stop the drive.

Additional instruction for DC connection

WARNING! Do not connect the drive DC link to a common DC system. The

drive will get damaged.

Introduction to the manual 23

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 ACH580-31 drives.

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 US instructions for installations in the United States are given.

Purpose of the manual

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

Categorization by frame (size)

The drive is manufactured in frames. Some instructions and other information which only concern certain frames are marked with the symbol of the frame, for example R3. The frame is marked on the type designation label attached to the drive, see section Type designation label on page 37.

24 Introduction to the manual

Quick installation and commissioning flowchart

Task See

Identify the frame of your drive: R3, R6 or R8. See the type designation label of the drive.

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

required cooling air flow.

Unpack and check the drive. Unpacking and examining delivery on page

If the drive will be connected to an IT (ungrounded) system or corner-grounded delta system, check that the internal EMC filter and ground-to-phase varistor are not connected.

Install the drive on a wall. Mechanical installation on page 41

Route the cables. Routing the cables on page 69

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

Connect the power cables. Connecting the power cables on page 89

Connect the control cables. Connecting the control cables on page 99

Guidelines for planning the electrical installation on page 53

Technical data on page 161

46,

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

page 82

Checking the insulation of the assembly on

page 80

Check the installation. Installation checklist on page 143

Commission the drive. Firmware manual

Quick start-up guide for the drive

Terms and abbreviations

Term/abbreviation Explanation

ACH-AP-H Control panel with Hand-Off-Auto functionality. The dedicated assistant

control panel for the ACQ580 is ACH-AP-H (Hand-Off-Auto panel).

Introduction to the manual 25

Term/abbreviation Explanation

ACX-AP-x Assistant control panel, advanced operator keypad for communication

with the drive. The ACH580 offers limited support of ACS-AP-I and ACS-AP-W. The

Start, Stop, Loc/Rem buttons on these panels act as Hand, Auto and Off buttons, respectively, when used with the ACH580. You can use parameters and Primary settings menus with ACS-AP-I and parameters and I/O with ACS-AP-W.

BACnet™ BACnet™ is a registered trademark of American Society of Heating,

Brake chopper An external brake chopper conducts the surplus energy from the

Brake resistor Dissipates the drive surplus braking energy conducted by the brake

Control board Circuit board in which the control program runs. Capacitor bank See DC link capacitors. CDPI-01 Communication adapter module CCA-01 Configuration adapter CHDI-01 Optional 115/230 V digital input extension module CMOD-01 Optional multifunction extension module (external 24 V AC/DC and

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

CPTC-02 Optional multifunction extension module (external 24 V and ATEX

DC link DC circuit between rectifier and inverter DC link capacitors Energy storage which stabilizes the intermediate circuit DC voltage DPMP-01 Control panel mounting platform (flush) DPMP-02 Control panel mounting platform (surface) Drive Frequency converter for controlling AC motors EMC Electromagnetic compatibility EFB Embedded fieldbus FBIP-21 Optional BACnet/IP adapter module FCAN-01 Optional CANopen adapter module FCNA-01 ControlNet adapter module FDNA-01 Optional DeviceNet adapter module FECA-01 Optional EtherCAT adapter module

Refrigerating and Air-Conditioning Engineers (ASHRAE).

intermediate circuit of the drive to the brake resistor when necessary. The chopper operates when the DC link voltage exceeds a certain maximum limit. The voltage rise is typically caused by deceleration (braking) of a high inertia motor.

chopper to heat. Essential part of the brake circuit. See Brake chopper.

digital I/O extension)

isolated PTC interface)

certified PTC interface)

26 Introduction to the manual

Term/abbreviation Explanation

FENA-21 Optional Ethernet adapter module for EtherNet/IP, Modbus TCP and

FEPL-02 Optional Ethernet POWERLINK adapter module FLON-01 L FPBA-01 Optional PROFIBUS DP adapter module Frame (size) Refers to drive physical size, for example R3. The type designation

I/O Input/Output IGBT Insulated gate bipolar transistor Intermediate circuit See DC link. Inverter Converts direct current and voltage to alternating current and voltage.

ONWORKS®LONWORKS® (local operating network) is a networking platform

NETA-21 Remote monitoring tool Network control With fieldbus protocols based on the Common Industrial Protocol

Parameter User-adjustable operation instruction to the drive, or signal measured or

PLC Programmable logic controller PROFIBUS,

PROFIBUS DP, PROFINET IO

PTC Positive temperature coefficient (PTC) refers to materials that

R3, R6, R8 Frame (size) Rectifier Converts alternating current and voltage to direct current and voltage. STO Safe torque off. See chapter The Safe torque off function on page 207.

PROFINET IO protocols

ONWORKS® adapter module

label attached to the drive shows the frame of the drive, see section

Type designation key on page 38.

specifically created to address the needs of control applications.

), such as DeviceNet and Ethernet/IP, denotes the control of the

(CIP drive using the Net Ctrl and Net Ref objects of the ODVA AC/DC Drive Profile. For more information, see www.odva.org manuals:

• FDNA-01 DeviceNet adapter module user’s manual (3AFE68573360 [English]), and

• FENA-01/-11/-21 Ethernet adapter module user’s manual (3AUA0000093568 [English]).

calculated by the drive

Registered trademarks of PI - PROFIBUS & PROFINET International

experience an increase in electrical resistance when their temperature is raised.

, and the following