ABB ACS580-01 Hardware Manual

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ABB GENERAL PURPOSE DRIVES

ACS580-01 drives

(0.75 to 250 kW, 1.0 to 350 hp) Hardware manual

Related documents are listed on page 27.

Hardware manual

ACS580-01 drives (0.75 to 250 kW, 1.0 to 350 hp)

Table of contents

1. Safety instructions

4. Mechanical installation

6. Electrical installation – IEC

7. Electrical installation – North America

3AXD50000044794 Rev B

EFFECTIVE: 2019-03-13

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) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Unpacking and examining delivery, frame R3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Unpacking and examining delivery, frame R4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Unpacking and examining delivery, frame R5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Frame R5 cable box (IP21, UL Type 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Unpacking and examining delivery, frames R6…R9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Frame R6 cable box (IP21, UL Type 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Frame R7 cable box (IP21, UL Type 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Frame R8 cable box (IP21, UL Type 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Frame R9 cable box (IP21, UL Type 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Installing the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Installing the drive vertically, frames R1…R4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Install the cable box, frames R1…R2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Installing the drive vertically, frame R5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Installing the drive vertically, frames R6…R9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Installing the drive vertically side by side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Installing the drive horizontally, frames R1…R5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Flange mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

5. Guidelines for planning the electrical installation

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Limitation of liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Selecting the supply disconnecting device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

European Union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

North America . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

Other regions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

Checking the compatibility of the motor and drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Protecting the motor insulation and bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Requirements table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

Selecting the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

General guidelines, IEC and North America . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

Power cable types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

Additional guidelines, North America . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

Conductor type, IEC and North America . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

Power cable shield, IEC and North America . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

Typical power cable sizes, IEC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

Typical power cable sizes, UL/NEC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

Armored cable / shielded power cable, IEC and North America . . . . . . . . . . . . . . . . . . 101

Selecting the control cables, IEC and North America . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

Shielding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

Signals in separate cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

Signals allowed to be run in the same cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

Relay cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

Control panel cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

Drive composer PC tool cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

FPBA-01 PROFIBUS DP adapter module connectors . . . . . . . . . . . . . . . . . . . . . . . . . . 103

Routing the cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

General guidelines, IEC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

General guidelines, North America . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

Continuous motor cable shield or enclosure for equipment on the motor cable . . . . . . 106

Table of contents 7

Separate control cable ducts, IEC and North America . . . . . . . . . . . . . . . . . . . . . . . . . . 106

Implementing short-circuit and thermal overload protection . . . . . . . . . . . . . . . . . . . . . . . . . 107

Protecting the drive and input power cable in short-circuits . . . . . . . . . . . . . . . . . . . . . . 107

Protecting the motor and motor cable in short-circuits . . . . . . . . . . . . . . . . . . . . . . . . . . 107

Protecting the drive and the input power and motor cables against thermal overload . . 108

Protecting the motor against thermal overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

Protecting the motor against overload without thermal model or temperature sensors . 108

Implementing a ground fault detection function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

Residual current device compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

Implementing the Emergency stop function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

Implementing the Safe torque off function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

Implementing the ATEX-certified Safe motor disconnection function (option +Q971) . . . . . 109

Using a safety switch between the drive and the motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

Using a contactor between the drive and the motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

Implementing a bypass connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

Example bypass connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

Implementing the undervoltage control (power-loss ride-through) . . . . . . . . . . . . . . . . . . . . 112

Protecting the contacts of relay outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

Limiting relay output maximum voltages at high installation altitudes . . . . . . . . . . . . . . . . . . 113

Implementing a motor temperature sensor connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

6. Electrical installation – IEC

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

Required tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

Checking the insulation of the assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

Input power cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

Motor and motor cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

Brake resistor assembly for R1…R3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

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

delta and TT systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

EMC filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

Ground-to-phase varistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

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

delta and midpoint-grounded delta systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

Guidelines for installing the drive to a TT system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

Identifying different types of electrical power systems . . . . . . . . . . . . . . . . . . . . . . . . . . 123

Frames R1…R3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

Frames R4…R9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

Connecting the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

Connection procedure, frames R1…R4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

Connection procedure, frame R5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

Connection procedure, frames R6…R9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

DC connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

Connecting the control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

Default I/O connection diagram (ABB standard macro) . . . . . . . . . . . . . . . . . . . . . . . . . 147

Control cable connection procedure R1…R9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157

Installing option modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163

8 Table of contents

Mechanical installation of option modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163

Wiring the modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

Reinstalling grommets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166

Reinstalling covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

Reinstalling cover, frames R1…R4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

Reinstalling covers, frame R5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

Reinstalling side plates and covers, frames R6…R9 . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

Connecting a PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

7. Electrical installation – North America

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171

Required tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171

Checking the insulation of the assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

Input power cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

Motor and motor cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

Brake resistor assembly for R1…R3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

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

delta and TT systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174

EMC filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174

Ground-to-phase varistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174

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

grounded delta and midpoint-grounded delta systems . . . . . . . . . . . . . . . . . . . . . . . . . 175

Guidelines for installing the drive to a TT system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176

Identifying different types of electrical power systems . . . . . . . . . . . . . . . . . . . . . . . . . 177

Frames R1…R3, disconnecting EMC or varistor screws . . . . . . . . . . . . . . . . . . . . . . . . 178

Frames R4…R9, disconnecting EMC or varistor screws . . . . . . . . . . . . . . . . . . . . . . . . 180

Connecting the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182

Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182

Connection procedure, frames R1…R4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184

Connection procedure, frame R5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189

Connection procedure, frames R6…R9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194

DC connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199

Connecting the control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200

Default I/O connection diagram (ABB standard macro) . . . . . . . . . . . . . . . . . . . . . . . . . 201

Control cable connection procedure R1…R9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211

Installing option modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217

Mechanical installation of option modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217

Wiring the modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219

Reinstalling grommets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220

Reinstalling covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221

Reinstalling cover, frames R1…R4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221

Reinstalling covers, frame R5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222

Reinstalling side plates and covers, frames R6…R9 . . . . . . . . . . . . . . . . . . . . . . . . . . . 223

Installing UL Type 12 hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224

Connecting a PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225

Table of contents 9

8. Installation checklist

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227

Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227

9. Maintenance and hardware diagnostics

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229

Maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229

Description of symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230

Functional safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230

Recommended annual actions by the user . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230

Recommended maintenance actions by the user . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230

Heatsink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231

Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232

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

frames R1…R4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233

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

frames R5…R8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235

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

frame R9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236

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

frames R5…R9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237

Replacing the auxiliary cooling fan, IP55 (UL Type 12) frames R1…R2 . . . . . . . . . . . . 238

Replacing the auxiliary cooling fan, IP55 (UL Type 12) frame R3 . . . . . . . . . . . . . . . . . 239

Replacing the auxiliary cooling fan, IP55 (UL Type 12) frame R4 . . . . . . . . . . . . . . . . . 240

Replacing the second auxiliary cooling fan, IP55 (UL Type 12) frames R8…R9 . . . . . . 241

Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242

Reforming the capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242

Control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243

Cleaning the control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243

Replacing the battery in the control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243

LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244

Drive LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244

Control panel LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245

10. Technical data

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247

Electrical ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248

IEC ratings at UN = 230 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248

IEC ratings at UN = 400 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250

IEC ratings at UN = 480 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251

UL (NEC) ratings at UN = 208/230 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253

UL (NEC) ratings at UN = 460 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255

UL (NEC) ratings at UN = 575 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256

Conversion tables for IEC and North American type codes . . . . . . . . . . . . . . . . . . . . . . 257

Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258

Derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259

Ambient temperature derating, IP21 (UL Type 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261

10 Table of contents

Ambient temperature derating, IP55 (UL Type 12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262

Altitude derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265

Switching frequency derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266

Output frequency derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267

Fuses (IEC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268

gG fuses (IEC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268

uR and aR fuses (IEC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270

Circuit breakers (IEC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272

Fuses (UL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274

Dimensions, weights and free space requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276

Losses, cooling data and noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283

Cooling air flow, heat dissipation and noise for stand-alone drives . . . . . . . . . . . . . . . . 283

Cooling air flow and heat dissipation for flange mounting (option +C135) . . . . . . . . . . . 287

Terminal and lead-through data for the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288

IEC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288

UL (NEC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290

Terminal and lead-through data for the control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292

IEC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292

UL (NEC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293

Electrical power network specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294

Voltage (U1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294

Motor connection data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295

Brake resistor connection data for frames R1…R3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298

Control connection data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298

Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305

Degree of protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305

Ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305

Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307

Applicable standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308

CE marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309

Compliance with the European Low Voltage Directive . . . . . . . . . . . . . . . . . . . . . . . . . 309

Compliance with the European EMC Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309

Compliance with the European ROHS II Directive 2011/65/EU . . . . . . . . . . . . . . . . . . . 309

Compliance with the European WEEE Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309

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

June 2010 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309

Compliance with the IEC 61800-3:2017 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310

Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310

Category C1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310

Category C2 . . . . . . . . . . . . . . . . . . . . . . . . . .

Category C3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311

Category C4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312

UL marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313

UL checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313

China RoHS marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314

RCM marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314

WEEE marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314

EAC marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315

Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315

Cyber security disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311

Table of contents 11

11. Dimension drawings

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317

Frame R1, IP21 (UL Type 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318

Frame R1, IP55 (UL Type 12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319

Frame R1, IP55+F278 (UL Type 12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320

Frame R2, IP21 (UL Type 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321

Frame R2, IP55 (UL Type 12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322

Frame R2, IP55+F278 (UL Type 12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323

Frame R3, IP21 (UL Type 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324

Frame R3, IP55 (UL Type 12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325

Frame R3, IP55+E223 (UL Type 12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326

Frame R3, IP55+F278/F316 (UL Type 12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327

Frame R4, IP21 (UL Type 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328

Frame R4, IP55 (UL Type 12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329

Frame R4, IP55+E223 (UL Type 12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330

Frame R4, IP55+F278/F316 (UL Type 12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331

Frame R5, IP21 (UL Type 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332

Frame R5, IP55 (UL Type 12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333

Frame R5, IP55+E223 (UL Type 12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334

Frame R5, IP55+F278/F316 (UL Type 12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335

Frame R6, IP21 (UL Type 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336

Frame R6, IP55 (UL Type 12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337

Frame R7, IP21 (UL Type 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338

Frame R7, IP55 (UL Type 12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339

Frame R8, IP21 (UL Type 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340

Frame R8, IP55 (UL Type 12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341

Frame R9, IP21 (UL Type 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342

Frame R9, IP55 (UL Type 12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343

12. Resistor braking

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

Operation principle and hardware description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345

Resistor braking, frames R1…R3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346

Planning the braking system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346

Mechanical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350

Electrical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350

Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351

Resistor braking, frames R4…R9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352

Planning the braking system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352

Parameter settings for external braking chopper and resistor . . . . . . . . . . . . . . . . . . . . 352

13. Safe torque off function

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353

Compliance with the European Machinery Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354

Connection principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355

Single drive, internal +24 V DC power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355

Single drive, external +24 V DC power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358

12 Table of contents

Multiple ACS580-01 drives, internal +24 V DC power supply . . . . . . . . . . . . . . . . . . . . 359

Multiple ACS580-01 drives, external +24 V DC power supply . . . . . . . . . . . . . . . . . . . . 360

Activation switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361

Cable types and lengths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361

Grounding of protective shields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361

Operation principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361

Start-up including acceptance test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 362

Competence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 362

Acceptance test reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 362

Acceptance test procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363

Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 366

Competence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 366

Fault tracing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 366

Safety data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 368

Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 370

Declaration of conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 370

Certificate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 371

14. Optional I/O extension modules

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373

CHDI-01 115/230 V digital input extension module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373

Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373

Hardware description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373

Mechanical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 374

Electrical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 375

Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 377

Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 377

Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 378

CMOD-01 multifunction extension module (external 24 V AC/DC and digital I/O) . . . . . . . . 380

Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 380

Hardware description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 380

Mechanical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 381

Electrical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 382

Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 384

Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 385

Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 386

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

interface) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 389

Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 389

Hardware description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 389

Mechanical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 390

Electrical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 391

Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 393

Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 394

Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 395

CBAI-01 bipolar analog IO extension module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 397

Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 397

Hardware description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 397

Mechanical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 398

Table of contents 13

Electrical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 399

Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401

Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402

Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403

15. Common mode, du/dt and sine filters

Content of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405

Common mode filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405

When is a common mode filter needed? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405

du/dt filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405

When is a du/dt filter needed? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405

Common mode filter types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406

du/dt filter types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407

Description, installation and technical data of the FOCH filters . . . . . . . . . . . . . . . . . . . 407

Description, installation and technical data of the NOCH filters . . . . . . . . . . . . . . . . . . . 407

Sine filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408

Selecting a sine filter for the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408

Description, installation and technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409

Further information

Product and service inquiries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411

Product training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411

Providing feedback on ABB Drives manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411

Document library on the Internet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411

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 NING! 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 283 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 ACS580 standard control program firmware manual (3AXD50000016097 [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 ACS580 standard control program firmware manual (3AXD50000016097 [English]).

• When the control location is not set to Local (text Local is not shown on the top row of the panel and parameter 19.17 Local control disable has value 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 NING! 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 297.

• 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 121,

and Guidelines for installing the drive to a TT system on page 122.

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

varistor: TN-S, IT, corner-grounded delta and midpoint-grounded delta systems on page 175, and Guidelines for installing the drive to a TT system on

page 176.

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 121,

and Guidelines for installing the drive to a TT system on page 122.

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

varistor: TN-S, IT, corner-grounded delta and midpoint-grounded delta systems on page 175, and Guidelines for installing the drive to a TT system on

page 176.

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 NING! 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 91. 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 NING! 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 motor cannot be run into overspeed, e.g. driven by the load. 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 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 control location is not set to Local, the stop key on the control panel will not stop the drive.

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 ACS580-01 drives, including the new (2017) R1…R3 frames (see all applicable types in section Electrical ratings on page 248).

Note: The manual does not apply to R0…R3 frames with type codes ACS580-01: 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 ACS580-01 (0.75 to 250 kW, 1.0 to 350 hp) hardware manual (3AXD50000018826 [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 83) 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 117) 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 171) 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 227) contains a checklist for checking the mechanical and electrical installation of the drive before start-up.

• Maintenance and hardware diagnostics (page 229) contains preventive maintenance instructions and LED indicator descriptions.

• Technical data (page 247) 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 317) shows dimension drawings of the drive.

• Resistor braking (page 345) tells how to select the brake resistor.

• Safe torque off function (page 353) describes STO features, installation and technical data.

• Optional I/O extension modules (page 373) describes CMOD-01, CMOD-02, and CHDI-01 and CBAI-01 extension modules, their installation, start-up, diagnostics and technical data.

• Common mode, du/dt and sine filters (page 405) describes selection of external filters for the drive.

Introduction to the manual 27

• Further information (inside of the back cover, page 411) 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 ACS580-01 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 83

Technical data on page 247

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

page 59; R3 on page 62; R4 on page 64; R5 on page 66; R6…R9 on page 68

IEC:

Checking the compatibility with IT

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

page 120 North America:

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

page 174

installation: Routing the cables on page 104

Electrical installation: IEC:

Checking the insulation of the assembly

on page 118 North America:

assembly on page 172

Checking the compatibility

Checking the insulation of the

Connect the power cables. Electrical installation:

IEC:

Connecting the power cables on page

127

North America: on page 182

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

146

North America: on page 182

Check the installation. Installation checklist on page 227

Commission the drive. ACS580 standard control program firmware

manual (3AXD50000016097 [English])

Connecting the control cables

Introduction to the manual 31

Terms and abbreviations

Term/abbreviation Explanation

ACS-BP-S Basic control panel, basic operator keypad for communication with the

Assistant control panel

Brake chopper Conducts the surplus energy from the intermediate circuit of the drive to

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. CBAI-01 CBAI-01 bipolar analog IO extension module CCA-01 Configuration adapter CDPI-01 Communication adapter module 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 Mounting platform for ACS-AP control panel (flange mounting). CDP-01

DPMP-02 Mounting platform for ACS-AP control panel (surface mounting).

DPMP-EXT Door mounting kit for the panel. For one drive; contains both DPMP-02

Drive Frequency converter for controlling AC motors EMC Electromagnetic compatibility EFB Embedded fieldbus FBA Fieldbus adapter FCAN-01 Optional CANopen adapter module

drive. The ACS580 supports ACS-BP-S basic control panel. Assistant control panel (ACS-AP-x) is an advanced operator keypad for

communication with the drive. The ACS580 supports types ACS-AP-I and ACS-AP-S, as well as ACS-AP-W, which has a Bluetooth interface.

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)

communication adapter module is needed to connect the DMP0-01 to the drive. For up to 32 drives on a panel bus with a single panel on cabinet door, one DMP-02 with one CDPI-01 per each drive are used.

CDP-01 communication adapter module is needed to connect the DMP0-02 to the drive. For up to 32 drives on a panel bus with a single panel on cabinet door, one DMP-02 with one CDPI-01 per each drive are used.

and CDPI-01, which connects the DPMP-02 to the drive.

32 Introduction to the manual

Term/abbreviation Explanation

FCNA-01 ControlNet adapter module FDNA-01 Optional DeviceNet adapter module FECA-01 Optional EtherCAT adapter module FEIP-21 Optional two-port Ethernet/IP adapter module FENA-21 Optional two-port Ethernet adapter module for EtherNet/IP, Modbus

TCP and PROFINET IO protocols FEPL-02 Optional Ethernet POWERLINK adapter module FMBT-21 Optional two-port Modbus/TCP adapter module FPBA-01 Optional PROFIBUS DP adapter module FPNO-21 Optional PROFINET IO adapter module Frame (size) Refers to drive physical size, for example R1 and R2. The type

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

section Type designation key on page 49. FSCA-01 Optional EIA-485 adapter module 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. Macro Pre-defined default values of parameters in drive control program. Each

NEC 70 National Fire Protection Association (National Electric Code 70) 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

R1, R2, … Frame (size)

macro is intended for a specific application. See ACS580 firmware

manual (3AXD50000016097[English]).

), 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

, and the following

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.

Introduction to the manual 33

Term/abbreviation Explanation

Rectifier Converts alternating current and voltage to direct current and voltage. SIL Safety integrity level. See chapter Safe torque off function on page 353. STO Safe torque off. See chapter Safe torque off function on page 353.

34 Introduction to the manual

Operation principle and hardware description 35

Operation principle and hardware description

Contents of this chapter

This chapter briefly describes the operation principle, layout, type designation label and type designation information. It also shows a general diagram of power connections and control interfaces.

36 Operation principle and hardware description

L1 L2

T1/U T2/V

T3/W

R- UDC+

R+

1 2 3

UDC-

ACS580-01

Operation principle

The ACS580-01 is a drive for controlling asynchronous AC induction motors, permanent magnet motors and synchronous reluctance motors (SynRM).

The figure below shows the simplified main circuit diagram of the drive.

1 Rectifier. Converts alternating current and voltage to direct current and voltage. 2 DC link. DC circuit between rectifier and inverter. 3 Inverter. Converts direct current and voltage to alternating current and voltage. 4 Built-in brake chopper (R-, R+) in frames R1…R3. Conducts the surplus energy from

the intermediate DC 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. The user obtains and installs the brake resistor when needed.

5 DC connection (UDC+, UDC-), for an external brake chopper in frames R4…R9.

Layout

1 Mounting points (4 pieces) 2 Cover: upper part (2a), lower part (2b) 3 Cover screw 4 Cable/conduit box 5 Control panel 6 Control panel connection 7 Cold configuration connection for CCA-01 7 Power OK and Fault LEDs. See section

LEDs on page 244.

8 I/O connections. See section External

control connection terminals, frames R1…R5 on page 44.

9 Varistor grounding screw (VAR).

See Frames R1…R3 on page 124 (IEC) or Frames R1…R3, disconnecting EMC

or varistor screws (North America) on

page 178.

R1 IP21 / UL Type 1

10 EMC filter grounding screw (EMC (DC)).

See Frames R1…R3 on page 124 (IE C or

Frames R1…R3, disconnecting EMC or varistor screws (North America) on page

178.

11 Place for storing the removed VAR screw 12 Place for storing the removed EMC screw 13 Input power connection (L1, L2, L3),

motor connection (T1/U, T2/V, T3/W) and

brake connection (R-, R+) 14 PE connection (power line) 15 Grounding connection (motor) 16 Additional grounding connection 17 Stripping length (8 mm) checker 18 Cable entry 19 Main cooling fan 20 Cable tie mounts for /I/O cables 21 Auxiliary cooling fan connector

Frames R1…R2

The layout of a frame R1 drive is presented below. The main structure of frame R2 is similar to R1. IP55 / UL Type 12 frames are also slightly different from IP21 / UL Type 1 frames, for example, IP21 / UL Type 1 front cover has two parts while IP55 / UL Type 12 front cover only has one part.

Operation principle and hardware description 37

38 Operation principle and hardware description

R1 IP55 / UL Type 12

1 Mounting points (4 pieces), top points are

under the hood, which is installed last. 2 Front cover 3 Cover screws (2 pieces) 4 Control panel behind the transparent

window 5 Hood, UL Type 12 only. Hood types vary

by the frame size, see page 278.

This is an example of IP55 / UL Type 12 frames. They have one-piece front cover, which has a transparent window to leave the control panel visible. UL Type 12 frames have a hood, whose construction depends on the frame size.

Frame R3

BRAKE RES

INPUT

MOTOR

R-

R+

UDC+

T1/U

T2/V

T3/W

1 Mounting points (4 pieces) 2Cover 3 Cover screw 4 Control panel 5 Control panel connection 6 Cold configuration connection for CCA-01 7 Power OK and Fault LEDs. See section

LEDs on page 244.

8 I/O connections. See section External

control connection terminals, frames

R1…R5 on page 44.

9 Varistor grounding screw (VAR).

See Frames R1…R3 on page 124 (IEC)

or Frames R1…R3, disconnecting EMC

or varistor screws (North America) on

page 178. 10 EMC filter grounding screw (EMC (DC)).

See Frames R1…R3 on page 124 (IEC)

or Frames R1…R3, disconnecting EMC

or varistor screws (North America) on

page 178.

11 Input power connection (L1, L2, L3),

motor connection (T1/U, T2/V, T3/W) and

brake connection (R-, R+) 12 PE connection (power line) 13 Grounding connection (motor) 14 Additional grounding connection 15 Cable entry 16 Main cooling fan 17 Cable tie mounts for I/O cables 18 Auxiliary cooling fan. For

IP55/UL Type 12 drives only. 19 Auxiliary cooling fan connector 20 Place for storing the removed EMC screw 21 Place for storing the removed VAR screw

5 6

R3 IP21 / UL Type 1

20 21

Operation principle and hardware description 39

40 Operation principle and hardware description

1 Mounting points (4 pieces) 2Cover 3 Cover screw 4 Control panel 5 Control panel connection 6 Cold configuration connection for CCA-01 7 Power OK and Fault LEDs. See section

LEDs on page 244.

8 I/O connections. See section External

control connection terminals, frames R1…R5 on page 44.

9 Varistor grounding screw (VAR).

See Frames R4…R9 on page 125 (IEC) or Frames R4…R9, disconnecting EMC

or varistor screws (North America) on

page 180.

10 Two EMC filter grounding screws, 10a:

EMC (DC) and 10b: EMC (AC).

See Frames R4…R9 on page 125 (IEC)

or Frames R4…R9, disconnecting EMC

or varistor screws (North America) on

page 180. 11 Input power connection (L1, L2, L3),

motor connection (T1/U, T2/V, T3/W) and

DC connection (UDC+, UDC-) 12 PE connection (power line) 13 Grounding connection (motor) 14 Cable entry 15 Main cooling fan 16 Cable tie mounts for I/O cables 17 Auxiliary cooling fan. For

IP55/UL Type 12 drives only. 18 Auxiliary cooling fan connector 19 Additional grounding connection

5 6

R4 IP21 / UL Type 1

10b

10a

Frame R4

Frame R5

1 Mounting points (6 pieces: 2 at the top, 2

at the bottom of the main part of the

frame, 2 at the top of the cable box) 2Cover 3 Cable/conduit box 4 Cover screws (2 pieces) 5 Control panel 6 Control panel connection 7 Cold configuration connection for CCA-01 8 Power OK and Fault LEDs. See section

LEDs on page 244.

9 I/O connections. See section External

control connection terminals, frames

R1…R5 on page 44.

10 Varistor grounding screw (VAR).

See Frames R4…R9 on page 125 (IEC)

or Frames R4…R9, disconnecting EMC

or varistor screws (North America) on

page 180.

11 Two EMC filter grounding screws, 11a:

EMC (DC) and 11b: EMC (AC). See Frames R4…R9 on page 125 (IEC)

or Frames R4…R9, disconnecting EMC

or varistor screws (North America) on

page 180.

12 Input power connection (L1, L2, L3),

motor connection (T1/U, T2/V, T3/W) and DC connection (UDC+, UDC-) under the

shroud 13 PE connection (power line) 14 Grounding connection (motor) 15 Cable box plate 16 Cable entry 17 Main cooling fan 18 Cable tie mounts for I/O cables 19 Auxiliary cooling fan connector

R5 IP21 / UL Type 1

6 7 8

11b

11a

Operation principle and hardware description 41

42 Operation principle and hardware description

1 Mounting points (6 pieces: 2 at the top, 2

at the bottom of the main part of the

frame, 2 at the top of the cable box) 2 Cover 3 Cable/conduit box 4Heatsink 5 Lifting holes (6 pieces) 6 Control panel 7 Control panel connection 8 Cold configuration connection for CCA-01 9 Power OK and Fault LEDs. See section

LEDs on page 244.

10 I/O connections. See section External

control connection terminals, frames

R6…R9 on page 45.

11 Cable tie mounts for I/O cables 12 Clamps for I/O cable mechanical support 13 Varistor grounding screw (VAR), under

the control panel platform.

See Frames R4…R9 on page 125 (IEC) or Frames R4…R9, disconnecting EMC

or varistor screws (North America) on

page 180.

14 Two EMC filter grounding screws, 14a:

EMC (DC) under the control panel platform and 14b: EMC (AC) at the left, above the shroud.

See Frames R4…R9 on page 125 (IEC) or Frames R4…R9, disconnecting EMC

or varistor screws (North America) on

page 180.

15 Shroud. Under the shroud: Input power

connection (L1, L2, L3), motor connection (T1/U, T2/V, T3/W) and DC connection

(UDC+, UDC-). 16 PE connection (power line) 17 Grounding connection (motor), under the

shroud (15). 18 Cable entry 19 Main cooling fan 20 Auxiliary cooling fan

R6 IP21 / UL Type 1

7 8 9

14a

14b

Frames R6…R9

The layout of a frame R6 drive is presented below. The constructions of frames R6…R9 differ to some extent.

Operation principle and hardware description 43

Slot 2

T1/U

T2/V

T3/W

3 ~

R-

UDC+ R+

UDC-

Slot 1

..........

Panel port

Overview of power and control connections

The logical diagram below shows the power connections and control interfaces of the drive.

1 Option slot 1 for optional fieldbus adapter modules 2 Option slot 2 for optional I/O extension modules 3 Panel port. 4du/dt or common mode filter (optional), see page 405.

Not in all frame sizes.

44 Operation principle and hardware description

Description

X1 Analog inputs and outputs X2 Aux. voltage output X3 Programmable digital inputs X4 Safe torque off connection X5 Embedded fieldbus X6 Relay output 3 X7 Relay output 2

X8 Relay output 1 X10 Auxiliary fan connection (IP55) X13 Option slot 1 (fieldbus adapter

modules)

X14 Option slot 2 (I/O extension

modules)

S4, S5 Termination switch (S4), bias

resistor switch (S5), see section

Switches on page 150 (IEC) or Switches on page 150 (North

America)

1 Panel port (control panel

connection)

2 Cold configuration connection. This

connector is used with the CCA-01 configuration adapter.

3 Power OK and Fault LEDs. See

section LEDs on page 244.

X13

X14

X10

R1…R5

 External control connection terminals, frames R1…R5

The layout of the external control connection terminals of the R1 frame is shown below. Layout of the external control connection terminals is identical in frames R1…R5 but the location of the control board with the terminals is different in frames R3…R5.

Operation principle and hardware description 45

Description

X1 Analog inputs and outputs X2 Aux. voltage output X3 Digital inputs X4 Safe torque off connection X5 Connection to embedded EIA-

485 fieldbus adapter module X6 Relay output 3 X7 Relay output 2 X8 Relay output 1

X10 External +24 V AC/DC input

connection

X12 Panel connection X13 Option slot 1 (fieldbus adapter

modules)

X14 Option slot 2 (I/O extension

modules)

X16 Auxiliary fan 1 connection X17 Auxiliary fan 2 connection

S4, S5 Termination switch (S4), bias

resistor switch (S5), see section

Switches on page 150 (IEC) or

Switches on page 150 (North

America)

1 Panel port (control panel

connection)

2 Cold configuration connection.

This connector is used with the

CCA-01 configuration adapter.

3 Power OK and Fault LEDs. See

section LEDs on page 244.

R6…R9

X13

X10

S4, S5

X17X16

X14

X1:1…3

X1:4…6

X1:7…9

X3:1…3

X3:4…6

X12

 External control connection terminals, frames R6…R9

The layout of the external control connection terminals of frames R6…R9 is shown below.

WARNING! Do not connect the +24 V AC cable to the control board ground when the

control board is powered using an external 24 V AC supply.

46 Operation principle and hardware description

Control panel

To remove the control panel, press the retaining clip at the top (1a) and pull it forward from the top edge (1b).

To reinstall the control panel, put the bottom of the container in position (1a), press the retaining clip at the top (1b) and push the control panel in at the top edge (1c).

For the use of the control panel, see ACS580 standard control program firmware

manual (3AXD50000016097 [English]) and ACX-AP-X assistant control panels user’s manual (3AUA0000085685 [English]).

Operation principle and hardware description 47

 Control panel door mounting kits

Door mounting kits for the control panel are available.

For more information, see DPMP-01 mounting platform for control panels (3AUA0000100140 [English]), DPMP-02/03 mounting platform for control panels (3AUA0000136205 [English]) or DPMP-06/07 mounting platform for control panels (3AXD50000289561 [English]).

Type designation label

The type designation label includes IEC and UL (NEC) ratings, appropriate markings and the type designation and serial number, which allow identification of each drive. The type designation label is located on the left side of the drive, see section

Locations of the labels on the drive. An example label is shown below.

No. Description

1 Type designation, see section Type designation key on page 49. 2 Name and address of the manufacturer 3 Frame (size) 4 Type of the drive, for example, with Air cooling or Liquid cooling, and so on. 5 Degree of protection 6 IEC: Icc (Rated conditional short-circuit current) = 100 kA,

UL (NEC): SCCR (Short circuit current rating) = 100 kA

7 Nominal ratings in the supply voltage range, see section Electrical ratings on page 248,

section Electrical power network specification on page 294 and section Motor connection

data on page 295.

See page 294 for further information on input voltage range. 8 Valid markings 9 S/N: Serial number of format MYYWWXXXX, where

YY:

WW:

XXXXX:

Manufacturing plant 16, 17, 18, … for 2016, 2017, 2018, … 01, 02, 03, … for week 1, week 2, week 3, … Digits making the serial number unique

48 Operation principle and hardware description

Locations of the labels on the drive

Note: Pn is not shown in UL (NEC) drive labels.

Operation principle and hardware description 49

ACS580-01-12A7-4+L501+K457+...

1 2 3 4

Type designation key

The type designation contains information on the specifications and configuration of the drive. You find the type designation on the type designation label attached to the drive. The first digits from the left express the basic configuration, for example, ACS580-01-12A7-4. The optional selections are given after that, separated by plus signs, for example, +L501. The main selections are described below. Not all selections are available for all types.

CODE DESCRIPTION

Basic codes

ACS580 Product series

01 When no options are selected: Wall mounted, IP21 (UL Type 1), assistant

Size

xxxx Refer to the rating table, page 248

Voltage rating

4 2 = 200…240 V

Option codes (plus codes)

Control panel and panel options

J400 ACS-AP-S Assistant control panel (as standard) J404 ACS-BP-S Basic control panel J424 CDUM-01 Blank control panel cover (no control panel) J425 ACS-AP-I Assistant control panel J429 ACS-AP-W Assistant control panel with a Bluetooth interface

I/O (one slot available for I/O options)

L500 CBAI-01 Bipolar analog IO extension L501 CMOD-01 External 24 V AC/DC and digital I/O extension (2×RO and 1×DO) L512 CHDI-01 115/230 V Digital input extension (6×DI and 2×RO) L523 CMOD-02 External 24 V AC/DC and isolated PTC interface L537 CPTC-02 ATEX certified PTC interface and external 24 V. Requires option

control panel with a USB port, choke, EMC C2 filter (internal EMC filter), safe torque off, braking chopper in frames R1, R2, R3, coated boards, cable lead through entry from the bottom, cable box or the conduit plate with cable entries, quick installation and start-up guide (multilingual).

4 = 380…480 V 6 = 575…600 V

See page 294 for further information.

Q971. Europe only.

50 Operation principle and hardware description

CODE DESCRIPTION

Safety

Q971 ATEX certified safe disconnection function, EX II (2) GD. Available only with

option L357. Europe only.

Fieldbus adapters

K451 FDNA-01 DeviceNet™ K454 FPBA-01 PROFIBUS DP K457 FCAN-01 CANopen K458 FSCA-01 Modbus/RTU K462 FCNA-01 ControlNet™ K469 FECA-01 EtherCAT K470 FEPL-02 Ethernet POWERLINK K475 FENA-21 Two-port Ethernet (EtherNet/IP™, Modbus/TCP, PROFINET) K490 FEIP-21 Two-port EtherNet/IP K491 FMBT-21 Two-port Modbus/TCP K492 FPNO-21 Two-port PROFINET IO

Embedded fieldbus

CEIA-01 Embedded Modbus RTU adapter, EIA-485 (as standard)

Construction

B056 IP55 (UL type 12). Factory option, retro-fit not possible. C135 Flange mounting kit. Flange mounting kit is ordered separately North

America, not with a plus code.

E223 EMC filter, category C1 for earthed network. For frame sizes R1

F278 Main switch. For frame sizes R1

F316 Main switch and EMC filter, category C1 for earthed network. For frame sizes

H358 Cable conduit plate, blank.

Requires option B056. IEC only.

…R5. Requires option B056. IEC only. Valid

for APAN region.

…R5. Requires option B056. IEC only.

…R5.

Operation principle and hardware description 51

CODE DESCRIPTION

Full set of printed manuals in selected language. Note: The delivered manual set may include manuals in English if the translation is not

available. Note: These options are not available in North America. You can find manuals in PDF

format on the Internet. See section Document library on the Internet on the inside of the back cover.

R700 English R701 German R702 Italian R703 Dutch R704 Danish R705 Swedish R706 Finnish R707 French R708 Spanish R709 Portuguese (Brazil) R711 Russian R712 Chinese R713 Polish R714 Turkish

3AXD10000081909

52 Operation principle and hardware description

Mechanical installation 53

Mechanical installation

Contents of this chapter

This chapter tells how to check the installation site, unpack, check the delivery and install the drive mechanically.

Safety

WARNING! Frames R5…R9: 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. An overturning drive can cause physical injury.

54 Mechanical installation

Frame size R4 R9 Hood height (in) 2.83 9.06 Hood height (mm) 72 230

Checking the installation site

The drive must be installed on the wall or an enclosure. There are three alternative ways to install it:

•V

ertical

Note: Do not install the drive upside down.

Frame size

Above (a)

mm in mm in mm in mm in mm in mm in

IP21 (UL Type 1) IP55 (UL Type 12)

Below (b)2)Beside

R1 150 5.91 86 3.39 150 5.91 137 5.39 116 4.57 150 5.91 R2 150 5.91 86 3.39 150 5.91 137 5.39 116 4.57 150 5.91 R3 200 7.87 53 2.09 150 5.91 200 7.87 53 2.09 150 5.91 R4 53 2.09 200 7.87 150 5.91 53 2.09 200 7.87 150 5.91 R5 100 3.94 200 7.87 150 5.91 100 3.94 200 7.87 150 5.91 R6 155 6.10 300 11.81 150 5.91 155 6.10 300 11.81 150 5.91 R7 155 6.10 300 11.81 150 5.91 155 6.10 300 11.81 150 5.91 R8 155 6.10 300 11.81 150 5.91 155 6.10 300 11.81 150 5.91 R9 200 7.87 300 11.81 150 5.91 200 7.87 300 11.81 150 5.91

Free space above is measured from the frame, not from the hood used in UL Type 12 frames. Note: The height of the hood for frames R4 and R9 exceeds the requirement of free space above for

these frames

Vertical installation - Free space

3AXD00000586715.xls L

(c)

Free space below is always measured from the drive frame, not from the cable box

Mechanical installation 55

Free space between the drive and other objects, e.g. wall. Note: The recommended free space above and below the drive is for installations where the drive is mounted on a wall indoors. For ABB cabinet-built drives, which are thermally tested and approved for a specified temperature range, free space could vary from this recommendation.

56 Mechanical installation

Frame size

Vertical installation side by side - Free space,

IP21 (UL Type 2) and IP55 (UL Type 12)

Above (a)

Below (b)

Between (c)

mm in mm in mm in

R1 200 7.87 200 7.87 0 0 R2 200 7.87 200 7.87 0 0 R3 200 7.87 200 7.87 0 0 R4 200 7.87 200 7.87 0 0 R5 200 7.87 200 7.87 0 0 R6 2007.8730011.81 0 0 R7 2007.8730011.81 0 0 R8 2007.8730011.81 0 0 R9 2007.8730011.81 0 0

3AXD00000586715.xls L

Free space above is measured from the frame, not from the hood used in UL Type 12 frames.

Note: The height of the hood for frames R4 and R9 exceeds the requirement of free space above for these frames.

Free space below is always measured from the drive frame, not from the cable box.

Free space between the drives. Note: The recommended free space above and below the drive is for installations where the drive is mounted on a wall indoors. For ABB cabinet-built drives, which are thermally tested and approved for a specified temperature range, free space could vary from this recommendation. Note for IP21 (UL Type 1) frames R1…R2: The cover fastening clips can be removed to make the front cover opening easier. Note for IP55 (UL Type 12) frames R1…R2: Auxiliary fan maintenance cannot be performed without removing every second drive from installation to get access to the fan.

Frame size R4 R9 Hood height (in) 2.83 9.06 Hood height (mm) 72 230

c= 0

•Vertical side by side

Mechanical installation 57

Frame size

Horizontal installation - Free space

IP21 (IP20) IP55 (UL Type 12)

Above (a) Below (b)

mm in mm in mm in mm in

R1 150 5.91 86 3.39 137 5.39 116 4.57 R2 150 5.91 86 3.39 137 5.39 116 4.57 R3 200 7.87 53 2.09 200 7.87 53 2.09 R4 30 1.18 200 7.87 30 1.18 200 7.87 R5 30 1.18 200 7.87 30 1.18 200 7.87

Frame size

Side up (c) Side down (d) Side up (c) Side down (d)

mm in mm in mm in mm in

R1 30 1.18 200 7.87 30 1.18 200 7.87 R2 30 1.18 200 7.87 30 1.18 200 7.87 R3 30 1.18 200 7.87 30 1.18 200 7.87 R4 30 1.18 200 7.87 30 1.18 200 7.87 R5 30 1.18 200 7.87 30 1.18 200 7.87

3AXD00000586715.xls L

Free space below is always measured from the drive frame, not from the cable box.

•Horizontal, IP20 and IP55, R1…R5 only

Note 1: You can install IP21 / UL Type 1 drives horizontally but the installation meets IP20 requirements only.

Note 2: IP55/Type 12 drive mounted horizontally meet IP21/Type 1 ratings. Note 3: In the horizontal mounting, the drive is not protected from dripping water. Note 4: The vibration specification in section Ambient conditions on page 305

may not be fulfilled.

58 Mechanical installation

Check the installation site according to the requirements below:

• The installation site is sufficiently ventilated or cooled to remove the heat away from the drive. See section Losses, cooling data and noise on page 283.

• The operation conditions of the drive meet the specifications given in section

Ambient conditions on page 305.

• The wall is as close to vertical as possible, of non-flammable material and strong enough to carry the weight of the drive, see section Dimensions, weights and free

space requirements on page 276.

• The floor/material below the installation is non-flammable.

• There is enough free space above and below the drive to enable cooling air flow, service and maintenance, See the required free space tables for each of the different mounting alignments on page 54 (or page 276).

Required tools

To install the drive mechanically, you need the following tools:

• drill with suitable bits

• screwdriver set (Torx, flat and/or Phillips, as appropriate)

• socket set (metric and SAE)

• tape measure, if you will not be using the provided mounting template.

Moving the drive

Frames R5…R9: Move the transport package by pallet truck to the installation site.

Mechanical installation 59

6 Plastic bag 7 Straps 8Tray 9 Control panel selected in the order (in a

separate package) in the option box. North America: Control panel factory

installed.

10 Possible options in separate packages, if

they have been ordered with a plus code, such as for example +K490 (FEIP21 Two-port EtherNet/IP adapter module) in the option box.

North America: Options may be ordered as factory installed.

Note: Hood included with option +B056 (IP55/UL Type 12) in North America

1 Cable box package.

Note: The cable box is mounted to the

IP55 drive module frame at the factory. 2Drive 3 Option tray 4 In the option tray

• Europe: Multilingual quick installation and start-up guide (always), and Hardware and firmware manuals (if ordered with a plus code)

• North America: Multilingual quick installation and start-up guide

• Multilingual residual voltage warning stickers

5 Cardboard box. Mounting template in the

cardboard box.

10 10

Unpacking and examining delivery, frames R1 and R2

The figure below shows the layout of the transport package. Examine that all items are present and there are no signs of damage. Read the data on the type designation label of the drive to make sure that the drive is of the correct type. See section Type

designation label on page 47.

60 Mechanical installation

To unpack:

• Cut the straps (7).

• Remove the upper tray (8a) and option tray (3).

• Remove the cardboard box (5).

• Remove the plastic bag (6).

• Lift the drive (2).

WAR NING! R1…R2, IP21: Do not lift the drive by holding it from the cover. The drive can fall and become damaged or damage the surroundings.

Recycle the package material according to local regulations.

Mechanical installation 61

3AXD50000103577

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

This illustration shows the contents of the cable box package. The package also includes an assembly drawing which shows how to install the cable box to the drive module frame.

Follow the installation instructions in section Installing the drive vertically, frames

R1…R4 on page 74.

62 Mechanical installation

5 Plastic bag 6Straps 7Tray 8 Control panel selected in the order (in a

separate package) in the option box. North America: Control panel factory

installed.

9 Possible options in separate packages, if

they have been ordered with a plus code, such as for example +K490 (FEIP21 Two-port EtherNet/IP adapter module) in the option box.

North America: Options may be ordered as factory installed.

Note: Hood included with option +B056 (IP55/UL Type 12) in North America

1Drive 2 Option tray 3 In the option tray

• Europe: Multilingual quick installation and start-up guide (always), and Hardware and firmware manuals (if ordered with a plus code)

• North America: Multilingual quick installation and start-up guide

• Multilingual residual voltage warning stickers

• Mounting template

4 Cardboard box.

9 9

1 5

Unpacking and examining delivery, frame R3

designation label on page 47.

Mechanical installation 63

To unpack:

• Cut the straps (6).

• Remove the upper tray (7a) and option tray (2).

• Remove the cardboard box (4).

• Remove the plastic bag (5).

• Lift the drive (2).

Recycle the package material according to local regulations.

64 Mechanical installation

• Possible options in separate packages, if they have been ordered with a plus code, such as for example +K490 (FEIP-21 Two-port EtherNet/IP adapter module) in the option box.

North America: Options may be ordered as factory installed.

4 Cardboard box 5 Inner box with edge boards and

cushions. Mounting template in the inner

box. 6Plastic bag Note: Hood included with option +B056

(IP55/UL Type 12) in North America

1Drive 2 Option tray 3 In the option tray

• Europe: Multilingual quick installation and start-up guide (always), and Hardware and firmware manuals (if ordered with a plus code)

• North America: Multilingual quick installation and start-up guide

• Multilingual residual voltage warning stickers

• Control panel selected in the order (in a separate package) in the option box.

North America: Control panel factory installed.

A B

Unpacking and examining delivery, frame R4

designation label on page 47.

Mechanical installation 65

To unpack:

• Cut the straps.

• Open box (4) and remove top cushions and option tray (2).

• Lift out the inner box (5).

• Open the inner box (5), lift the drive (1) and remove plastic bag (7).

Recycle the package material according to local regulations.

66 Mechanical installation

5 Stopper 6 Cover protecting film 7 Straps 8Pallet 9 Control panel selected in the order (in a

separate package) in the option box. North America: Control panel factory

installed.

10 Possible options in separate packages, if

they have been ordered with a plus code, such as for example +K490 (FEIP21 Two-port EtherNet/IP adapter module) in the option box.

North America: Options may be ordered as factory installed.

Note: Hood included with option +B056 (IP55/UL Type 12) in North America

1 Cable box package.

Note: The cable box is mounted to the

IP55 drive module frame at the factory. 2Drive 3 In the option box

• Europe: Multilingual quick installation and start-up guide (always), and Hardware and firmware manuals (if ordered with a plus code)

• North America: Multilingual quick installation and start-up guide

• Multilingual residual voltage warning stickers

4 Cardboard box. Mounting template in the

cardboard box.

109

Unpacking and examining delivery, frame R5

designation label on page 47.

Mechanical installation 67

3AXD10000497342

To unpack:

• Cut the straps (7).

• Remove the cardboard box (4) and option box (3).

• Remove the cover protecting film (6).

• Lift the drive (2).

Recycle the package material according to local regulations.

 Frame R5 cable box (IP21, UL Type 1)

This illustration shows the contents of the cable box package. The package also includes an assembly drawing which shows how to install the cable box to the drive module frame.

68 Mechanical installation

1 Cable box. Power and control cable

grounding shelves in a plastic bag, assembly drawing. Note: The cable box is mounted to the

IP55 drive module frame at the factory. 2 Drive with factory installed options. 3 Cardboard box 4Straps 5 VCI bag for protecting against corrosion 6Pallet 7 Stopper 8 Option tray 9 In the option tray

• Europe: Multilingual quick installation and start-up guide (always), and Hardware and firmware manuals (if ordered with a plus code)

• North America: Multilingual quick installation and start-up guide

• Multilingual residual voltage warning stickers

10 Control panel selected in the order (in a

separate package) in the option tray. North America: Control panel factory

installed.

11 Possible options in separate packages, if

they have been ordered with a plus code, such as for example +K490 (FEIP-21 Two-port EtherNet/IP adapter module) in the option tray.

North America: Options may be ordered as factory installed.

12 Mounting template on top of the option

tray

Note: Hood included with option +B056 (IP55/UL Type 12) in North America

8 9 10 11

Unpacking and examining delivery, frames R6…R9

designation label on page 47.

Mechanical installation 69

To unpack:

• Cut the straps (4).

• Remove the cardboard box (3) and option tray (8).

• Remove the VCI bag (5).

• Attach lifting hooks to the lifting eyes of the drive (see the figure on page 53). Lift the drive with a hoist.

Recycle the package material according to local regulations.

70 Mechanical installation

 Frame R6 cable box (IP21, UL Type 1)

The figure below shows the contents of the cable box package. The package also includes an assembly drawing which shows how to install the cable box to the drive frame.

Mechanical installation 71

 Frame R7 cable box (IP21, UL Type 1)

The figure below shows the contents of the cable box package. The package also includes an assembly drawing which shows how to install cable box to the drive frame.

72 Mechanical installation

 Frame R8 cable box (IP21, UL Type 1)

The figure below shows the contents of the cable box package. The package also includes an assembly drawing which shows how to install the cable box to the drive frame.

Mechanical installation 73

 Frame R9 cable box (IP21, UL Type 1)

The figure below shows the contents of the cable box package. The package also includes an assembly drawing which shows how to install the cable box to the drive frame.

74 Mechanical installation

1 2

×4

R1…R2: M5 (#10) R3…R4: M6 (¼ in)

×4

Installing the drive

 Installing the drive vertically, frames R1…R4

The figures show frame R3 as an example.

Select fasteners and their application to meet local requirements appropriate to wall surface materials, drive weight and application.

1. Mark the hole locations using the mounting template included in the package. Do not leave the mounting template under the drive. The drive dimensions and hole locations are also shown in the drawings in chapter Dimension drawings on page

317.

2. Drill the mounting holes.

3. Insert anchors or plugs into the holes and start the bolts into the anchors or plugs.

a 98 3.86 98 3.86 160 6.30 160 6.30 b 317 12.48 417 16.42 473 18.62 619 24.37

Weight

IP21 (UL Type 1)

Weight

IP55 (UL Type 12)

R1 R2 R3 R4

mm in mm in mm in mm in

kg lb kg lb kg lb kg lb

4.6 10.1 6.6 14.6 11.8 26.0 19.0 41.9

kg lb kg lb kg lb kg lb

4.8 10.6 6.8 15.0 13.0 28.7 20.0 44.1

Mechanical installation 75

×4

4. Position the drive onto the lower bolts (4a) on the wall to support the weight of the drive. Rotate drive to the wall and place drive over the upper bolts (4b).

WARNING! R1…R2, IP21:

Do not lift the drive by holding it from the cover. The

drive can fall and become damaged or damage the surroundings.

5. Tighten the bolts in the wall securely.

76 Mechanical installation

6 7 8

 Install the cable box, frames R1…R2

6. Remove the screw (6a) and lift the cover off (6b) from the separate cable box.

7. Attach the cable box cover to the front cover.

8. Install the cable box to the frame. Position the cable box (8a) and tighten the screws (8b).

Note: Install the hood to UL Type 12 drives after you have installed the drive electrically and reinstalled covers, see page 224.

Mechanical installation 77

R5 IP21 (UL Type 1)

R5 IP55 (UL Type 12)

mm in mm in

a 612 24.09 612 24.09 b 581 22.87 581 22.87

c 1606.301606.30 d > 2007.872007.87 e > 1003.941003.94

R5 IP21 (UL Type 1)

R5 IP55 (UL Type 12)

kg lb kg lb

28.3 62.4 29.0 64.0

×2

×6

R5: M6 (¼ in)

 Installing the drive vertically, frame R5

Select fasteners and their application to meet local requirements appropriate to wall surface materials, drive weight and application.

317.

2. Drill the mounting holes.

3. Insert fixing anchors or plugs into the holes. Start the two upper bolts and the two lowest bolts into the anchors or plugs.

78 Mechanical installation

4 5

3×M5 (#10)

IP21 (UL Type 1)

4. Remove the front cover: Remove the fastening screws (4a) with a T20 Torx screwdriver and lift the cover from the bottom upwards (4b) and then to the top side (4c).

5. Attach the cable box to the drive frame.

6. Tighten the box nuts.

7. Slide the box cover from the bottom (7a) and tighten the retaining screws (7b).

8. Put the tabs at the top of the front cover in their counterparts on the housing and then press at the bottom (8a) and tighten the retaining screws (8b).

Mechanical installation 79

×2

IP21 (UL Type 1), IP55 (UL Type 12)

9. Position the drive onto the lower bolts (9a) on the wall to support the weight of the drive. Rotate drive to the wall and place drive over the upper bolts (9b). Lift the drive with another person or with a lifting device as it is heavy. Tighten the bolts in the wall securely (9c).

10. Tighten the two remaining bolts securely.

Note: Install the hood on UL Type 12 drives after you have installed the drive electrically and reinstalled covers, see page 224.

80 Mechanical installation

R6 R7 R8 R9

mm in mm in mm in mm in

a 571 22.5 623 24.5 701 27.6 718 28.3 b 531 20.9 583 23.0 658 25.9 658 25.9 c 213 8.4 245 9.7 263 10.3 345 13.6 d 300 11.8 300 11.8 300 11.8 300 11.8 e 155 6.1 155 6.1 155 6.1 200 7.9

IP21,

UL Type 1

kg lb kg lb kg lb kg lb

42.4 93.5 54 119.1 69 152.2 97 213.9

IP55,

UL Type 12

kg lb kg lb kg lb kg lb

43.0 94.8 56 123.5 77 169.8 103 227.1

× 4

× 2 × 2

×6

R6…R9: M8 (5/16) in

 Installing the drive vertically, frames R6…R9

Select fasteners and their application to meet local requirements appropriate to wall surface materials, drive weight and application.

1. Mark the hole locations for the six mounting holes using the mounting template included in the package. Do not leave the mounting template under the drive.

The drive dimensions and hole locations are also shown in the drawings in chapter Dimension drawings on page 317.

Note: You can use only two bolts instead of four to attach the lower part of the drive.

2. Drill the mounting holes.

3. Insert fixing anchors or plugs into the holes and start the bolts into the anchors or plugs.

4. Position the drive onto the bolts on the wall. Lift the drive with a lifting device as it is heavy.

5. Tighten the top two bolts in the wall securely.

Mechanical installation 81

M8 (5/16) in) ×6

IP21 (UL Type 1)

6. Remove the front cover: Remove the fastening screws (a) with a T20 Torx screwdriver, move the cover to the top side (b) and then up (c).

7. Attach the cable box to the drive frame.

8. Tighten the box bolts: three at the top (8a) and two at the bottom (8b). Also tighten the bottom bolts started in step 3 (8c).

IP55 (UL Type 12)

9. Remove the front cover: Remove the fastening screws (a) with a T20 Torx screwdriver, move the cover to the top side (b) and then up (c).

Note: Install the hood for UL Type 12 drives after you have installed the drive electrically and reinstalled covers, see page 224.

 Installing the drive vertically side by side

Install the drive following the steps in the appropriate section Installing the drive

vertically, frames R1…R4 (page 74), Installing the drive vertically, frame R5 (page 77)

or Installing the drive vertically, frames R6…R9 (page 80).

82 Mechanical installation

 Installing the drive horizontally, frames R

Install the drive following the steps in the appropriate section Installing the drive

vertically, frames R1…R4 (page 74) or Installing the drive vertically, frame R5 (page

77). The drive can be installed either the left or right side up.

…R5

Flange mounting

Instructions for flange mounting are delivered with the flange mounting kit: Flange mounting kit quick installation guide for ACX580-01 frames R1 to R3 (3AXD50000119172 [English]), Flange mounting kit quick installation guide for ACX580-01 frames R4 to R5 (3AXD50000287093 [English]) or Flange mounting kit quick installation guide for ACS880-01 and ACX580-01 frames R6 to R9 (3AXD50000019099 [English]). For more information on flange mounting, see Flange mounting kit installation supplement (3AXD50000019100 [English]).

Guidelines for planning the electrical installation 83

Guidelines for planning the electrical installation

Contents of this chapter

This chapter contains instructions for planning the electrical installation of the drive, for example, for checking the compatibility of the motor and drive, selecting cables, protections and cable routing.

Limitation of liability

The installation must always be designed and made according to applicable local laws and regulations. The manufacturer does not assume any liability whatsoever for any installation which breaches the local laws and/or other regulations. Furthermore, if the recommendations given by the manufacturer are not followed, the drive may experience problems that the warranty does not cover.

Selecting the supply disconnecting device

Install a hand-operated input disconnecting device between the AC power source and the drive. The disconnecting device must be of a type that can be locked to the open position for installation and maintenance work.

84 Guidelines for planning the electrical installation

 European Union

To meet the European Union Directives, according to standard EN 60204-1, Safety of Machinery, the disconnecting device must be one of the following types:

• switch-disconnector of utilization category AC-23B (EN 60947-3)

• disconnector that has an auxiliary contact that in all cases causes switching devices to break the load circuit before the opening of the main contacts of the disconnector (EN 60947-3)

• circuit breaker suitable for isolation in accordance with EN 60947-2.

 North America

Installations must meet the requirements of UL (UL 508C) and/or CSA (C22.2 No. 14) and be compliant with NFPA 70 (NEC) Code (CE) along with state and local codes for your location and application.

National Fire Protection Association 70 (National Electric Code).

and/or Canadian Electrical

 Other regions

The disconnecting device must conform to the applicable local safety regulations.

Guidelines for planning the electrical installation 85

Checking the compatibility of the motor and drive

Use an asynchronous AC induction motor, permanent magnet motor or synchronous reluctance motor (SynRM) with the drive. Several induction motors can be operated at a time when using scalar mode. Operation of permanent magnet motors is limited to one connection to the drive at a time.

Check that the motor and the drive are compatible according to the rating table in section Electrical ratings on page 248. The table lists the typical motor power for each drive type.

Ensure that the motor withstands the maximum peak voltage in the motor terminals. See the Requirements table on page 86. For basics of protecting the motor insulation and bearings in drive systems, refer to section Protecting the motor insulation and

bearings below.

Note:

• Consult the motor manufacturer before using a motor whose nominal voltage differs from the AC line voltage connected to the drive input.

• The voltage peaks at the motor terminals are relative to the supply voltage of the drive, not the drive output voltage.

• If the motor and drive are not of the same size, consider the following operation limits of the drive control program:

• motor nominal voltage range 1/6 ... 2 · U

• motor nominal current range 1/6 ... 2 · IN (IEC), or 1/6 ... 2 · I

America), of the drive in vector control and 0 ... 2 · I control mode is selected by a drive parameter.

(North

in scalar control. The

 Protecting the motor insulation and bearings

In North America a du/dt filter is typically not used unless the application has very long cable lengths or when they have problems occurring.

The drive employs modern IGBT inverter technology. Regardless of frequency, the drive output comprises pulses of approximately the drive DC voltage with a very short rise time. The pulse voltage can almost double at the motor terminals, depending on the attenuation and reflection properties of the motor cable and the terminals. This can cause additional stress on the motor and motor cable insulation.

Modern variable speed drives with their fast rising voltage pulses and high switching frequencies can generate current pulses that flow through the motor bearings. This can gradually erode the bearing races and rolling elements.

Optional du/dt filters protect motor insulation system and reduce bearing currents. Optional common mode filters mainly reduce bearing currents. Insulated N-end (nondrive end) bearings protect the motor bearings.

86 Guidelines for planning the electrical installation

 Requirements table

The following table shows how to select the motor insulation system and when an optional drive du/dt and common mode filters and insulated N-end (non-drive end) motor bearings are required. Ignoring the requirements or improper installation may shorten motor life or damage the motor bearings and voids the warranty.

Motor

type

Nominal AC supply

voltage

Motor

insulation

system

Requirement for

ABB du/dt and common mode filters,

insulated N-end motor bearings

< 100 kW

and frame size

< IEC 315

100 kW < PN < 350 kW

IEC 315 <

frame size <

IEC 400

< 134 hp

and frame size

< NEMA 500

134 hp < PN < 469 hp

NEMA 500 <

size <

NEMA 580

ABB motors

Randomwound

< 500 V Standard - + N

M2_,M3_ and M4_

Formwound

380 V < U

< 690 V Standard n.a. + N + CMF

HX_ and AM_

Old* formwound

380 V < U

< 690 V Check with

the motor manufacturer.

+ du/dt

with voltages over 500 V + N +

CMF

HX_ and modular

Randomwound HX_ and

0 V < U

< 500 V Enameled

wire with fiber glass taping

+ N + CMF

AM_ ** * manufactured before 1.1.1998 ** For motors manufactured before 1.1.1998, contact your local ABB representative.

frame

Guidelines for planning the electrical installation 87

Motor

type

Nominal AC supply

voltage

Motor

insulation

system

Requirement for

ABB du/dt and common mode filters,

insulated N-end motor bearings

< 100 kW

and frame size

< IEC 315

100 kW <

IEC 315 <

PN < 350 kW

frame size <

IEC 400

< 134 hp

and frame size

< NEMA 500

134 hp < PN < 469 hp

NEMA 500 <

size <

frame

NEMA 580

Non-ABB motors

Randomwound and formwound

< 420 V Standard:

420 V < U

< 500 V Standard:

= 1300 V

-+ N or CMF

+ du/dt

+ du/dt + (N or CMF)

or Reinforced:

= 1600 V,

0.2

-+ N or CMF

microsecond rise time

The abbreviations used in the table are defined below.

Abbr. Definition

du/dt CMF Common mode filter. Depending on the drive type, CMF is available from ABB as

N N-end bearing: insulated motor non-drive end bearing n.a. Motors of this power range are not available as standard units. Consult the motor

Nominal AC line voltage Peak line-to-line voltage at motor terminals which the motor insulation must

withstand Motor nominal power du/dt filter at the output of the drive. Available from ABB as an optional add-on kit.

an optional add-on kit.

manufacturer.

Additional requirements for the braking applications

When the motor brakes the machinery, the intermediate circuit DC voltage of the drive increases, the effect being similar to increasing the motor supply voltage by up to 20 percent. Consider this voltage increase when specifying the motor insulation requirements if the motor will be braking a large part of its operation time.

Example: Motor insulation requirement for a 400 V AC line voltage application must be selected as if the drive were supplied with 480 V.

88 Guidelines for planning the electrical installation

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

If you need to calculate the actual peak voltage and voltage rise time considering the actual cable length, proceed as follows:

• Peak line-to line voltage: Read the relative Û diagram below and multiply it by the nominal supply voltage (U

• Voltage rise time: Read the relative values Û

value from the appropriate

LL/UN

and (du/dt)/UN from the

LL/UN

appropriate diagram on page 89. Multiply the values by the nominal supply voltage (U

) and substitute into equation t = 0.8 · ÛLL/(du/dt).

Guidelines for planning the electrical installation 89

ÛLL/U

l (m)

du/dt

------ ----- --(1/ s)

1.0

2.0

5.0

4.0

3.0

1.5

2.5

3.5

4.5

100 200 300

0.0

0.5

1.0

1.5

2.0

2.5

3.0

l (m)

du/dt

--------- ----(1/s)

ÛLL/U

5.5

ADrive with du/dt filter B Drive without du/dt filter

l Motor cable length

ÛLL/U

(du/dt)/U

Note: ÛLL and du/dt values are approximately 20% higher with resistor braking.

Relative peak line-to-line voltage

Relative du/dt value

90 Guidelines for planning the electrical installation

Additional note for sine filters

Sine filters protect the motor insulation system. Therefore, a du/dt filter can be replaced with a sine filter. The peak phase-to-phase voltage with the sine filter is approximately 1.5 · U

Guidelines for planning the electrical installation 91

Selecting the power cables

 General guidelines, IEC and North America

Select the input power and motor cables according to local regulations:

• Current: Select a cable capable of carrying the drive nominal current. See section Electrical ratings (page 248) for the rated currents.

• Temperature: For IEC, select a cable rated for at least 70 °C (90 °C for IP55 [UL Type 12]) maximum permissible temperature of conductor in continuous use. For North America, power cables must be rated for 90 derating.

• Voltage: 600 V AC cable is accepted for up to 500 V AC. 1000 V AC cable is required above 500 V AC.

• Conductivity: The conductivity of the PE conductor must be sufficient, see the table on page 92.

To comply with the EMC requirements of the CE mark, use one of the approved cable types in section Preferred power cable types, IEC and North America on page 93.

Symmetrical shielded cable reduces electromagnetic emission of the whole drive system as well as the stress on motor insulation, bearing currents and wear.

Metal conduit reduces electromagnetic emission of the whole drive system.

The protective conductor must always have an adequate conductivity. Unless local wiring regulations state otherwise, the cross-sectional area of the

protective conductor must agree with the conditions that require automatic disconnection of the supply required in 411.3.2. of IEC 60364-4-41:2005 and be capable of withstanding the prospective fault current during the disconnection time of the protective device.

The cross-sectional area of the protective conductor can either be selected from the table below or calculated according to 543.1 of IEC 60364-5-54.

°C (194 °F) or higher with

92 Guidelines for planning the electrical installation

This table shows the minimum cross-sectional area related to the phase conductor size according to IEC 61800-5-1 when the phase conductor and the protective conductor are made of the same metal. If this is not so, the cross-sectional area of the protective earthing conductor shall be determined in a manner which produces a conductance equivalent to that which results from the application of this table.

Cross-sectional area of the phase

conductors

)

S (mm

16 S

S <

35 16

16 < S <

35 < S S/2

Minimum cross-sectional area of the corresponding protective conductor

Sp (mm2)

Note: See the IEC/EN 61800-5-1 requirement on grounding in the Note on page 21.

Guidelines for planning the electrical installation 93

 Power cable types

Preferred power cable types, IEC and North America

Recommended cable types are presented here. Check with local / state / country electrical codes for allowance.

Cable type Use as input power

Use as motor cabling

cabling

Ye s Yes

Symmetrical shielded (or armored)

cable with three phase conductors

and concentric PE conductor as

shield (or armor)

Ye s Yes

Symmetrical shielded (or armored)

cable with three phase conductors

and symmetrically constructed PE

conductor and a shield (or armor)

Ye s Yes

Symmetrical shielded (or armored)

cable with three phase conductors

and a shield (or armor), and

separate PE conductor/cable

A separate PE conductor is required if the conductivity of the shield (or armor) is not sufficient

for the PE use. For IEC 61800-5-1 requirements, see page 92.

94 Guidelines for planning the electrical installation

PVC

EMT

Alternate power cable types

Cable type Use as input power

Four-conductor cabling in PVC

conduit or jacket (three phase

conductors and PE)

Four-conductor cabling in metal

conduit (three phase conductors and

PE), eg, EMT, or four-conductor

armored cable

Well-shielded (Al/Cu shield or armor)

four-conductor cable (three phase

conductors and a PE)

cabling

Yes with phase conductor

smaller than 10 mm

(8 AWG).

Yes Yes with phase conductor

Yes Yes with motors up to

Use as motor cabling

Yes with phase conductor

smaller than 10 mm

(8 AWG), or motors up to

30 kW (40 hp).

Note: Shielded or armored

cable, or cabling in metal

conduit is always

recommended to minimize

radio frequency

interference

smaller than 10 mm

(8 AWG) or motors up to

30 kW (40 hp).

100 kW (135 hp). A

potential equalization

between the frames of

motor and driven

equipment is required.

Guidelines for planning the electrical installation 95

L3L2

L1L3

L2L1

Cable type Use as input power

A single-core cable system: three

phase conductors and PE conductor

on cable tray

Preferable cable arrangement to

avoid voltage or current unbalance

between the phases

Not allowed power cable types

Cable type Use as input power

cabling

Ye s

WARNING! If you

use unshielded high-power input power cables in an IT network, make sure that the nonconductive outer sheath

(jacket) of the cables have

good contact with a

properly grounded

conductive surface, for

example, install the cables

on a properly grounded

cable tray. Otherwise voltage may become

present on the non-

conductive outer sheath of

the cables, and there is

even a risk of an electric

shock.

cabling

No No

Use as motor cabling

Symmetrical shielded cable with

individual shields for each phase

conductor

 Additional guidelines, North America

Follow these additional guidelines for North America with the general guidelines in section General guidelines, IEC and North America on page 91.

ABB recommends the use of conduit for power wiring to the drive and between the drive and the motor(s). Due to the variety of application needs, metallic and nonmetallic conduit can be used. ABB prefers the use of metallic conduit. Where permitted, non-metallic conduit may be used.

The following tables show examples of various materials and methods for wiring the drive in the intended application. See NEC 70 along with state and local codes for the appropriate materials for your application.

96 Guidelines for planning the electrical installation

In all applications, ABB prefers the use of VFD cable between drive and motor(s).

Conduit - Metallic

1, 3)

Notes

Electrical metallic tubing: Type EMT • Symmetrical shielded VFD cable is preferred. Rigid metal conduit: Type RMC Liquid-tight flexible metal electrical

conduit: Type LFMC

Conduit - Non-metallic

2,3)

Liquid-tight flexible nonmetallic conduit: Type LFNC

Wireways

Metallic

• Use separate conduit run for each motor.

• Do not run power feed wiring and motor wiring in the same conduit.

Notes

• Symmetrical shielded VFD cable is preferred.

• Use separate conduit run for each motor.

• Do not run power feed wiring and motor wiring in the same conduit.

Notes

• Symmetrical shielded VFD cable is preferred.

• Use output conductors require separation from motor feed and other low voltage conductors.

• Do not run outputs of multiple drives in parallel. Bundle each cable together and use separator where possible.

Free air

Enclosures, air handlers, etc.

• Symmetrical shielded VFD cable is preferred.

Notes

• Allowed internally in enclosures when in accordance with UL.

Metallic conduit may be used as an additional ground path, provided this path is a solid path capable of handling ground currents.

Non-metallic conduit use underground is allowed; however, these installations inherently

have an increased chance for nuisance problems due to the potential for water/moisture in the conduit. Water/moisture in the conduit increases the likelihood of VFD faults or warnings. Proper installation is required to ensure there is no intrusion of water/moisture.

See 70 (NEC), UL, and local codes for your application.

See routing instructions in section General guidelines, North America on page 105.

Guidelines for planning the electrical installation 97

1 3 4 52

 Conductor type, IEC and North America

The following table includes various conductor types that can be connected to the drive. For optimal drive performance, VFD cable is preferred. When not available, see the following standards in the footnotes below.

Conductor type

Copper Allowed All frames Aluminum (UL installations) Not allowed All frames Aluminum (IEC installations) Not allowed Frames R1…R4

Allowed Frames R5…R8 (for U

230 V only)

The selection of cable sizing/type is based on 70 (NEC) Table 310.15 (B) (16), formerly table

310.16, for copper wires is based on 75 °C (167 °F), and wire insulation at 30 °C (86 °F) ambient temperature. Not more than three current-carrying conductors in raceway or cable or earth (directly buried). For other ambient temperatures addition derating may be required.

See 310.15(B)(2)(a) for the ampacity correction factors where the ambient temperature is other than 30°C (86°F).

See to 310.15(B)(3)(a) for more than three current-carrying conductors. For other conditions, size the cables according to local safety regulations, appropriate input

voltage and the load current of the drive. See also page 297 for the accepted cable sizes of the drive

Select cable size/type is based on CSA 22.1 latest acceptable revision for your area.

Notes

1, 2)

 Power cable shield, IEC and North America

If the cable shield is used as the sole PE conductor, make sure that the conductivity agrees with the PE conductor requirements. See section General guidelines, IEC and

North America on page 91, or IEC 61800-5-1.

To effectively suppress radiated and conducted radio-frequency emissions, the cable shield conductivity must be at least 1/10 of the phase conductor conductivity. The requirements are easily met with a copper or aluminum shield. The minimum requirement of the motor cable shield of the drive is shown below. It consists of a concentric layer of copper wires with an open helix of copper tape or copper wire. The better and tighter the shield, the lower the emission level and bearing currents.

1 Insulation jacket

98 Guidelines for planning the electrical installation

2 Helix of copper tape or copper wire 3 Copper wire screen 4 Inner insulation 5 Cable core

Guidelines for planning the electrical installation 99

 Typical power cable sizes, IEC

The table below gives copper cable types with concentric copper shield for the drives with nominal current. The value separated by the plus sign means the diameter of the PE conductor.

See page 288 for the cable lead-through sizes allowed for the selected drive frame size.

IEC

type

ACS580-01-

3-phase UN = 230 V

04A7-2 R1 3×1.5 + 1.5 06A7-2 R1 3×1.5 + 1.5 07A6-2 R1 3×1.5 + 1.5 12A0-2 R1 3×1.5 + 1.5 018A-2 R1 3×2.5 + 2.5 025A-2 R2 3×4.0 + 4.0 032A-2 R2 3×6.0 + 6.0 047A-2 R3 3×10 + 10 060A-2 R3 3×10 + 10 089A-2 R5 3×35 + 16 3×50 + 25 115A-2 R5 3×50 + 25 3×70 + 35 144A-2 R6 3×70 + 35 3×120 + 70 171A-2 R7 3×95 + 50 3×150 + 70 213A-2 R7 3×120 + 70 3×240 + 120 276A-2 R8 2×(3×70 + 35) 2×(3×95 + 50)

3-phase UN = 400 V

02A7-4 R1 3×1.5 + 1.5 03A4-4 R1 3×1.5 + 1.5 04A1-4 R1 3×1.5 + 1.5 05A7-4 R1 3×1.5 + 1.5 07A3-4 R1 3×1.5 + 1.5 09A5-4 R1 3×2.5 + 2.5 12A7-4 R1 3×2.5 + 2.5 018A-4 R2 3×2.5 + 2.5 026A-4 R2 3×6 + 6 033A-4 R3 3×10 + 10 039A-4 R3 3×10 + 10 046A-4 R3 3×10 + 10 062A-4 R4 3×25 + 16 073A-4 R4 3×35 + 16 088A-4 R5 3×50 + 25 106A-4 R5 3×70 + 35 145A-4 R6 3×95 + 50 169A-4 R7 3×120 + 70 206A-4 R7 3×150 + 70 246A-4 R8 2×(3×70+35) 293A-4 R8 2×(3×95+50) -

Frame

size

Cu cable type

AI cable type

1,2)

100 Guidelines for planning the electrical installation

IEC

type

ACS580-01-

Frame

size

Cu cable type

AI cable type

1,2)

363A-4 R9 2×(3×120+70) 430A-4 R9 2×(3×150+70) -

The cable sizing is based on max. 6 cables laid on a cable ladder side by side, ambient

temperature 30 °C, PVC insulation, surface temperature 70 °C (EN 60204-1 and IEC 603645-52/2001). For other conditions, size the cables according to local safety regulations, appropriate input voltage and the load current of the drive. See also page 288 for the accepted cable sizes of the drive.

Aluminum cables can be used with UN = 230 V frames R1…R4, only.

3AXD00000586715.xls L

See also section Terminal and lead-through data for the power cables on page 288.

ABB ACS580-01 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

Terms and abbreviations

Operation principle and hardware description

Contents of this chapter

Operation principle

Layout

Frames R1…R2

Frame R3

Frame R4

Frame R5

Frames R6…R9

Overview of power and control connections

 External control connection terminals, frames R6…R9

Control panel

 Control panel door mounting kits

Type designation label

Type designation key

Mechanical installation

Contents of this chapter

Safety

Checking the installation site

Required tools

Moving the drive

Unpacking and examining delivery, frames R1 and R2

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

Unpacking and examining delivery, frame R3

Unpacking and examining delivery, frame R4

Unpacking and examining delivery, frame R5

 Frame R5 cable box (IP21, UL Type 1)

Unpacking and examining delivery, frames R6…R9

 Frame R6 cable box (IP21, UL Type 1)

 Frame R7 cable box (IP21, UL Type 1)

 Frame R8 cable box (IP21, UL Type 1)

 Frame R9 cable box (IP21, UL Type 1)

Installing the drive

IP21 (UL Type 1)

IP21 (UL Type 1), IP55 (UL Type 12)

IP21 (UL Type 1)

IP55 (UL Type 12)

 Installing the drive vertically side by side

Flange mounting

Guidelines for planning the electrical installation

Contents of this chapter

Limitation of liability

Selecting the supply disconnecting device

 European Union

 North America

 Other regions

Checking the compatibility of the motor and drive

 Protecting the motor insulation and bearings

 Requirements table

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

Additional note for sine filters

Selecting the power cables

 General guidelines, IEC and North America

 Power cable types