ABB ACS580-01-012A-4, ACS580-01-027A-4, ACS580-01-052A-4, ACS580-01-044A-4, ACS580-01-03A0-4 Quick Start Guide

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ABB GENERAL PURPOSE DRIVES

Quick installation and start-up guide

ACS580-01 drives (frames R1 to R9)

R1R4

R5

R6R9

List of related manuals in English

Drive manuals and guides Code (English)

ACS580 standard control program firmware manual 3AXD50000016097 ACS580-01 (0.75 to 250 kW, 1.0 to 350 hp) hardware

manual ACS-AP-X assistance control panels user’s manual 3AUA0000085685

Option manuals and guides

CDPI-01 communication adapter module user’s manual 3AXD50000009929 DPMP-01 mounting platform for control panels 3AUA0000100140 DPMP-02/03 mounting platform for control panels 3AUA0000136205 FCAN-01 CANopen adapter module user’s manual 3AFE68615500 FCNA-01 ControlNet adapter module user’s manual 3AUA0000141650 FDNA-01 DeviceNet

TM

adapter module user’s manual 3AFE68573360 FECA-01 EtherCAT adapter module user’s manual 3AUA0000068940 FENA-01/-11/-21 Ethernet adapter module user’s manual 3AUA0000095368 FEPL-02 Ethernet POWERLINK adapter module user’s

manual FPBA-01 PROFIBUS DP adapter module user’s manual 3AFE68573271 FSCA-01 RS485 adapter module user’s manual 3AUA0000109533 Flange mounting kit quick installation guide for

ACX580-01 frames R0 to R5 Flange mounting kit quick installation guide for

ACS580-01 frames R6 to R9 Flange mounting kit installation supplement 3AXD50000019100

3AXD50000018826

3AUA0000123527

3AXD50000036610

3AXD50000019099

Tool and maintenance manuals and guides

Drive composer PC tool user’s manual 3AUA0000094606 Converter module capacitor reforming instructions 3BFE64059629 NETA-21 remote monitoring tool user’s manual 3AUA0000969391 NETA-21 remote monitoring tool installation and start-up

3AUA0000096881

guide

You can find manuals and other product documents in PDF format on the Internet. See section Document library

on the Internet on the inside of the back cover. For manuals not available in the Document Library, contact your

local ABB representative.

The QR code below opens an online listing of the manuals applicable to the product.

ACS580-01 manuals

Table of contents

List of related manuals in English

Table of contents 3

Safety instructions

Use of warnings and notes in this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

General safety in installation, start-up and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Electrical safety in installation, start-up and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Precautions before electrical work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Additional instructions and notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Additional instructions for permanent magnet motor drives . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Safety in installation, start-up and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

General safety in operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Cybersecurity disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Ratings and fuses

I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

R1…R4 Quick installation guide

Obey the safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Check if capacitors need to be reformed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Select the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Ensure the cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Protect the drive and input power cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Install the drive on the wall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Check the insulation of the power cables and the motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Switch off the power and open the cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Install the cable box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Attach the warning sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Check the compatibility with IT (ungrounded) and corner-grounded TN systems . . . . . . . . . . 23

EMC filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Ground-to-phase varistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Disconnect EMC filter or ground-to-phase varistor, if needed . . . . . . . . . . . . . . . . . . . . . . 25

Wiring R1...R2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Wiring R3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Wiring R4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Default I/O connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Install optional modules, if any . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Reinstall cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

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4 Table of contents

R5 Quick installation guide

Obey the safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Check if capacitors need to be reformed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Select the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Ensure the cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Protect the drive and input power cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Install the drive on the wall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

R5

Check the insulation of the power cables and the motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Switch off the power and open the cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

R6-

Check the compatibility with IT (ungrounded) and corner-grounded TN systems . . . . . . . . . . 39

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EMC filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Ground-to-phase varistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Disconnect EMC filter or ground-to-phase varistor, if needed . . . . . . . . . . . . . . . . . . . . . . 41

Wiring R5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Default I/O connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Install optional modules, if any . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Reinstall cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

R6…R9 Quick installation guide

Obey the safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Check if capacitors need to be reformed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Select the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

FI

Ensure the cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Protect the drive and input power cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Install the drive on the wall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Check the insulation of the power cables and the motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Check the compatibility with IT (ungrounded) and corner-grounded TN systems . . . . . . . . . . 51

IT

EMC filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Ground-to-phase varistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Disconnect EMC filter or ground-to-phase varistor, if needed . . . . . . . . . . . . . . . . . . . . . . 53

Wiring R6…R9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Default I/O connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Install optional modules, if any . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Install side plates and covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

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Quick start-up guide

Before you start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

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Start-up with the First start assistant on an assistant control panel . . . . . . . . . . . . . . . . . . . . . 61

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Compliance with the European Machinery Directive 2006/42/EC

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Declaration of conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Table of contents 5

R1…R4 Figures

A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

B1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

B2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

B3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

C1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

C2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

E1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

E2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

G1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

G2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

I2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

J . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

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R5 Figures

A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

R6....R9 Figures

A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Further information

Product and service inquiries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Product training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Providing feedback on ABB Drives manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Document library on the Internet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

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Safety instructions

Safety instructions 7

These are 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.

General safety in installation, start-up and maintenance

These instructions are for all personnel that install the drive and do maintenance work on it.

WARNING! Obey these

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

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

• Handle the drive carefully.

• Frames R5…R9 lifting device. Use the lifting eyes of the drive.

• Frames R5…R9 over. The drive is heavy and its center of gravity is high. An overturning drive can cause physical injury.

: Lift the drive with a

: Do not tip the drive

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Electrostatic sensitive devices warning tells you about the risk of

electrostatic discharge which can

cause damage to the equipment.

8 Safety instructions

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• Beware of hot surfaces. Some parts,

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such as heatsinks of power semiconductors, remain hot for a

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while after disconnection of the electrical supply.

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• Keep the drive in its package prior to installation. Protect the installed drive

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against dust and burrs. Electrically conductive debris inside the drive

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may cause damage or malfunction.

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

• Do not cover the air inlet and outlet.

• Make sure that there is sufficient cooling. See section Ensure the

cooling on page 22, 38 or 50 for more

information.

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

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

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

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

• If you have connected safety circuits to the drive (for example, emergency stop and Safe torque off), validate them at 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]).

Safety instructions 9

• When the control location is not set to Local (text Hand is not shown on the top row of the panel and parameter

19.17 Off mode disable has value Off button disabled), the stop key on the control panel will not stop the drive.

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

Electrical safety in installation, start-up and maintenance

 Precautions before electrical

work

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

WARNING! Obey these

instructions. If you ignore them, injury or death, or damage to the equipment can occur. If you are not a qualified electrician, 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.

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

• Make sure that reconnection is not possible. Lock the disconnector to open position and attach a warning notice to the disconnector.

• Disconnect any external power sources from the control circuits before you do work on the control cables.

• 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 deenergized.

• Use a multimeter with an

impedance of at least 1 Mohm.

• Make sure that the voltage

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

• Make sure that the voltage

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

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

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

 Additional instructions and

notes

WARNING! Obey these

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

• If the drive will be connected on an IT system (ungrounded or highresistance-grounded [over 30 ohms]), make sure neither the EMC filter nor the ground-to-phase varistor are connected (metal screws

R1R4

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IT

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10 Safety instructions

should not be installed). Connections with metal screws in these systems can cause danger or damage. See section Check the compatibility with

IT (ungrounded) and cornergrounded TN systems on pages 23,

R1R4

R5

39 or 51.

Note: For other systems, connecting the internal EMC filter will reduce the conducted emission.

R6-

• If the drive will be connected on a

R9

corner-grounded TN system, make sure the EMC filter is not connected (metal screws should not be

FI

installed). Connections with metal screws in these systems can cause

FR

danger or damage. See section

Check the compatibility with IT (ungrounded) and corner-grounded

IT

TN systems on pages 23, 39 or 51.

NL

Note: For other systems, connecting

the internal EMC filter (using metal

PL

screws) will reduce the conducted emission.

PT

• Use all ELV (extra low voltage) circuits connected to the drive only

RU

within a zone of equipotential bonding, that is, within a zone where

SV

all simultaneously accessible conductive parts are electrically

TR

connected to prevent hazardous voltages appearing between them.

ZH

You can accomplish this by a proper factory grounding, that is, make sure that all simultaneously accessible conductive parts are grounded to the protective earth (PE) bus of the building.

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

Note:

• The motor cable terminals of the drive are at a dangerous voltage

when the input power is on, regardless of whether the motor is running or not.

• The DC 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.

WARNING! Obey these

instructions. If you ignore them, injury or death, or equipment malfunction can occur, and electromagnetic interference can increase.

• If you are not a qualified electrician, 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

Safety instructions 11

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 chapter Technical data in ACS580-01 (0.75 to 250 kW, 1.0 to

350 hp) hardware manual (3AXD50000018826 [English]). Obey

the local regulations.

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

• Standard IEC/EN 61800-5-1 (section

4.3.5.5.2.) requires that as the normal touch current of the drive is higher than 3.5 mA AC or 10 mA DC, you must use a fixed protective earth (PE) connection. In addition,

• install a second protective earth

conductor of the same crosssectional area as the original protective earthing conductor,

or

• install a protective earth

conductor with a cross-section of at least 7 AWG (10 mm

or

• install a device which

automatically disconnects the supply if the protective earth conductor breaks.

2

) Cu,

Additional instructions for permanent magnet motor drives

 Safety in installation, start-up

and maintenance

These are additional warnings concerning permanent magnet motor drives. The other safety instructions in this chapter are also valid.

WARNING! Obey these

instructions. If you ignore them, injury or death and damage to the equipment can occur.

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

• Use a multimeter with an

impedance of at least 1 Mohm.

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12 Safety instructions

• 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.

R1R4

R5

R6R9

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NL

PL

PT

• 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

FI

IT

(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 the motor is not run over the rated speed with dynamic/positive displacement loads.

General safety in operation

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These instructions are for all personnel that operate the drive.

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TR

ZH

WARNING! Obey these

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

• Do not control the motor with the line side disconnect at the drive power supply; instead, use the control panel start and stop keys or commands through the I/O terminals of the drive.

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

fault reset, unless you configure the drive for pulse start. See the firmware manual.

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

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

Cybersecurity disclaimer

This product is designed to be connected to and to communicate information and data via a network interface. It is Customer’s sole responsibility to provide and continuously ensure a secure connection between the product and Customer network or any other network (as the case may be). Customer shall establish and maintain any appropriate measures (such as but not limited to the installation of firewalls, application of authentication measures, encryption of data, installation of anti-virus programs, etc) to protect the product, the network, its system and the interface against any kind of security breaches, unauthorized access, interference, intrusion, leakage and/or theft of data or information. ABB and its affiliates are not liable for damages and/or losses related to such security breaches, any unauthorized access, interference, intrusion, leakage and/or theft of data or information.

Ratings and fuses

I

Type

ACS580-

01

3-phase UN = 240 V (208…240 V)

04A6-2 4.6 1 4.6 0.75 3.5 45 R1 06A6-2 6.6 1.5 6.6 1 4.6 55 R1 07A5-2 7.5 2 7.5 1.5 6.6 66 R1 10A6-2 10.6 3 10.6 2 7.5 84 R1 017A-2 16.7 5 16.7 3 10.6 106 R1 024A-2 24.2 7.5 24.2 5 16.7 133 R2 031A-2 30.8 10 30.8 7.5 24.2 174 R2 046A-2 46.2 15 46.2 10 30.8 228 R3 059A-2 59.4 20 59.4 15 46.2 322 R3 075A-2 74.8 25 74.8 20 59.4 430 R4 088A-2 88 30 88 25 74.8 525 R5 114A-2 114 40 114 30 88 619 R5 143A-2 143 50 143 40 114 835 R6 169A-2 169 60 169 50 143 1035 R7 211A-2 211 75 211 60 169 1251 R7 273A-2 273 100 273 75 211 1240 R8 343A-2 343 343 125 273 100 2547 R9 396A-2 396 396 150 343*** 125 3060 R9 * 130% overload only

** 125% overload only

*** Maximum current with 40% overload, allowed for one minute every ten minutes

Input

rating

I

1N

A A hp A hp W

Output ratings Maximum

Nominal use Heavy duty use

I

P

Ld

I

Ld

P

Hd

dissipation

heat

Frame

Ratings and fuses 13

size

R1R4

R5

R6R9

EN

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ES

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IT

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14 Ratings and fuses

Type

ACS580-

01

R1R4

3-phase UN = 480 V (440…480 V)

R5

02A1-4 2.1 2.1 1 1.6 0.75 45 R1

Input

rating

I

1N

Output ratings Maximum

Nominal use Heavy duty use

I

P

Ld

I

Ld

P

Hd

dissipation

A A hp A hp W

heat

03A0-4 3 3 1.5 2.1 1 55 R1 03A5-4 3.5 3.5 2 3 1.5 66 R1

R6-

04A8-4 4.8 4.8 3 3.4 2 84 R1

R9

06A0-4 6 6 3 4 3 106 R1 07A6-4 7.6 7.6 5 4.8 3 133 R1 012A-4 12 12 7.5 7.6 5 174 R1 014A-4 14 14 10 11 7.5 228 R2 023A-4 23 23 15 14 10 322 R2

EN

027A-4 27 27 20 21 15 430 R3 034A-4 34 34 25 27 20 525 R3

DA

044A-4 44 44 30 34 25 619 R3 052A-4 52 52 40 40 30 835 R4 065A-4 65 65 50 52 40 1024 R4

DE

077A-4 77 77 60 65 50 1240 R5 078A-4 77 77 60 65 50 1240 R5

ES

096A-4 96 96 75 77 60 1510 R5 124A-4 124 124 100 96 75 1476 R6

FI

156A-4 156 156 125 124 100 1976 R7 180A-4 180 180 150 156 125 2346 R7 240A-4 240 240 200 180 150 3336 R8

FR

260A-4 260 260 200 240* 150 3936 R8 302A-4 302 302 250 260 200 4836 R9

IT

* 130% overload only

** 125% overload only

NL

*** Maximum current with 40% overload, allowed for one minute every ten minutes

PL

Frame

size

PT

RU

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ZH

Ratings and fuses 15

Type

ACS580-

01

Input

rating

I

1N

Output ratings Maximum

Nominal use Heavy duty use

I

P

Ld

I

Ld

P

Hd

heat

dissipation

Frame

size

A A hp A hp W

361A-4 361 361 300 302 250 4836 R9 414A-4 414 414 350 361** 300 6036 R9

3-phase UN = 600 V (500…575 V)

02A7-6 2.7 2.7 2 2.4 1.5 66 R2 03A9-6 3.9 3.9 3 2.7 2 84 R2 06A1-6 6.1 6.1 5 3.9 3 133 R2 09A0-6 9 9 7.5 6.1 5 174 R2 011A-6 11 11 10 9 7.5 228 R2 017A-6 17 17 15 11 10 322 R2 022A-6 22 22 20 17 15 430 R3 027A-6 27 27 25 22 20 525 R3 032A-6 32 32 30 27 25 619 R3 041A-6 41 41 40 32 30 835 R5 052A-6 52 52 50 41 40 1024 R5 062A-6 62 62 60 52 50 1240 R5 077A-6 77 77 75 62 60 1510 R5 099A-6 99 99 100 77 75 2061 R7 125A-6 125 125 125 99 100 2466 R7 144A-6 144 144 150 125 125 3006 R8 192A-6 180 192 200 144 150 4086 R9 242A-6 242 242 250 192 200 4896 R9 271A-6 271 271 250 210 200 4896 R9

* 130% overload only

** 125% overload only

*** Maximum current with 40% overload, allowed for one minute every ten minutes

R1R4

R5

R6R9

EN

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16 Ratings and fuses

II

NEC

type

ACS580

R1-

3-phase UN = 240 V (208…240 V)

R4

04A6-2 4.6 600 KTK-R-15 or JJS-15 CC or T R1 06A6-2 6.6 600 KTK-R-15 or JJS-15 CC or T R1

R5

07A5-2 7.6 600 KTK-R-15 or JJS-15 CC or T R1 10A6-2 10.6 600 KTK-R-15 or JJS-15 CC or T R1

R6-

017A-2 16.7 600 KTK-R-30 or JJS-30 CC or T R1

R9

024A-2 24.2 600 JJS-40 T R2 031A-2 30.8 600 JJS-40 T R2 046A-2 46.2 600 JJS-80 T R3 059A-2 59.4 600 JJS-80 T R3

EN

075A-2 74.8 600 JJS-100 T R4 088A-2 88 600 JJS-150 T R5

DA

114A-2 114 600 JJS-150 T R5 143A-2 143 600 JJS-200 T R6 169A-2 169 600 JJS-250 T R7

DE

211A-2 211 600 JJS-300 T R7 273A-2 273 600 JJS-400 T R8

ES

343A-2 343 600 JJS-500 T R9 396A-2 396 600 JJS-600 T R9

FI

1) ABB does not require Bussmann brand fuses. Fuses which meet the appropriate UL class type, current rating, and are rated at 600V, 200 kA may be used.

FR

I

Voltage rating Bussmann type

N

A V

UL

1)

UL class Frame size

IT

NL

PL

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Ratings and fuses 17

NEC

type

ACS580

3-phase UN = 480 V (440…480 V)

02A1-4 03A0-4 03A5-4 04A8-4 06A0-4 07A6-4 012A-4 014A-4 023A-4 027A-4 034A-4 044A-4 052A-4 065A-4 077A-4 100 600 JJS-100 T R4 078A-4 110 600 JJS-110 T R5 096A-4 150 600 JJS-150 T R5 124A-4 200 600 JJS-200 T R6 156A-4 225 600 JJS-225 T R7 180A-4 300 600 JJS-300 T R7 240A-4 350 600 JJS-350 T R8 260A-4 400 600 JJS-400 T R8 302A-4 500 600 JJS-500 T R9 361A-4 500 600 JJS-500 T R9 414A-4 600 600 JJS-600 T R9

1) ABB does not require Bussmann brand fuses. Fuses which meet the appropriate UL class type, current rating, and are rated at 600V, 200 kA may be used.

I

Voltage rating Bussmann type

N

A V

15 15 15 15 15 15 15 30 30 40 50 60 80 90

600 600 600 600 600 600 600 600 600 600 600 600 600 600

UL

JJS-15 JJS-15 JJS-15 JJS-15 JJS-15 JJS-15 JJS-15 JJS-30 JJS-30 JJS-40 JJS-50 JJS-60 JJS-80 JJS-90

1)

UL class Frame size

T R1 T R1 T R1 T R1 T R1 T R1 T R1 T R2 T R2 T R3 T R3 T R3 T R4 T R4

R1R4

R5

R6R9

EN

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ES

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IT

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18 Ratings and fuses

NEC

type

ACS580

3-phase UN = 600 V (500…575 V)

02A7-6 2.7 600 KTK-R-15 or JJS-15 CC or T R2

R1-

03A9-6 3.9 600 KTK-R-15 or JJS-15 CC or T R2

R4

06A1-6 6.1 600 KTK-R-15 or JJS-15 CC or T R2

R5

09A0-6 9 600 KTK-R-15 or JJS-15 CC or T R2 011A-6 11 600 KTK-R-15 or JJS-15 CC or T R2

R6-

017A-6 17 600 KTK-R-30 or JJS-30 CC or T R2

R9

022A-6 22 600 JJS-40 T R3 027A-6 27 600 JJS-40 T R3 032A-6 32 600 JJS-40 T R3 041A-6 41 600 JJS-100 T R5 052A-6 52 600 JJS-100 T R5

EN

062A-6 62 600 JJS-100 T R5 077A-6 77 600 JJS-100 T R5

DA

099A-6 99 600 JJS-150 T R7 125A-6 125 600 JJS-200 T R7

DE

144A-6 144 600 JJS-250 T R8 192A-6 180 600 JJS-300 T R9

ES

242A-6 242 600 JJS-400 T R9 271A-6 271 600 JJS-400 T R9

FI

1) ABB does not require Bussmann brand fuses. Fuses which meet the appropriate UL class type, current rating, and are rated at 600V, 200 kA may be used.

I

Voltage rating Bussmann type

N

A V

UL

1)

UL class Frame size

FR

IT

NL

PL

PT

RU

SV

TR

ZH

—

ABB GENERAL PURPOSE DRIVES

Quick installation guide

ACS580-01 drives (frames R1 to R4)

R1R4

R5

[Page intentionally left blank]

R1…R4 Quick installation guide 21

R1…R4 Quick installation guide

This guide briefly describes how to install the drive. For complete information on installation, see ACS580-01 (0.75 to 250 kW, 1.0 to 350 hp) hardware manual

(3AXD50000018826 [English]). For start-up instructions, see chapter Quick start-up

guide on page 61.

To read a manual, go to www.abb.com/drives/documents number.

Obey the safety instructions

WARNING! Obey these instructions. If you ignore them, injury or death, or

damage to the equipment can occur:

and search for the document

R1R4

R5

R6R9

• If you are not a qualified electrician, do not do electrical installation work.

• Do not work on the drive, motor cable or motor when main power is applied. If the drive is already connected to the input power, wait for 5 minutes after disconnecting the input power.

• Do not work on the control cables when power is applied to the drive or to the external control circuits.

• Make sure that debris from borings and grindings does not enter the drive when installing.

• Make sure that the floor below the drive and the wall where the drive is installed are non-flammable.

Check if capacitors need to be reformed

If the drive has not been powered (either in storage or unused) for over one year, you must reform the capacitors.

You can determine the manufacturing time from the serial number, which you find on the type designation label attached to the drive. The serial number is of format MYYWWRXXXX. YY and WW tell the manufacturing year and week as follows:

YY: 16, 17, 18, … for 2016, 2017, 2018, WW: 01, 02, 03, … for week 1, week 2, week 3,

For information on reforming the capacitors, see Converter module capacitor reforming instructions (3BFE64059629 [English]), available on the Internet at

www.abb.com/drives/documents

.

…

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22 R1…R4 Quick installation guide

Select the power cables

Size the power cables according to local regulations to carry the nominal current given on the type designation label of your drive.

R1-

Ensure the cooling

R4

See table I on page 13 for the losses.The allowed operating temperature range of the

R5

drive is -15 to +50 °C (+5 to +122 °F). No condensation or frost is allowed. For more information on the ambient temperature and derating, see chapter Technical data in

R6-

ACS580-01 (0.75 to 250 kW, 1.0 to 350 hp) hardware manual (3AXD50000018826

R9

[English]).

Protect the drive and input power cable

See table II on page 16 for the fuses.

If you use gG fuses, make sure that the operating time of the fuse is below 0.5

DA

seconds. Follow the local regulations.

DE

Install the drive on the wall

ES

See figure R1…R4 Figures A on page 73.

FI

Check the insulation of the power cables and the motor

FR

Check the insulation of the input cable according to local regulations before connecting it to the drive.

IT

See figure B1 on page 73.

NL

1. Check the insulation of the motor cable and motor when the cable is disconnected

PL

PT

RU

SV

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

Note: Moisture inside the motor casing will reduce the insulation resistance. If moisture is suspected, dry the motor and repeat the measurement.

TR

ZH

R1…R4 Quick installation guide 23

Switch off the power and open the cover

See figure B1 on page 73.

2. Switch off the power from the drive.

3. Remove the front cover: Loosen the retaining screw, if any, with a screwdriver (3a) and lift the cover from the bottom outwards (3b) and then up (3c).

Install the cable box

Only for frames IP21, R1….R2 and IP55, R1….R2.

See figures B1 and B2 on page 73.

4. IP21, R1….R2: cable box.

Remove the screw (4a) and lift the cover off (4b) from the separate

R1R4

R5

R6R9

5. IP21, R1….R2:

6. IP21, R1….R2: tighten the screws (6b).

Attach the cable box cover to the front cover.

Install the cable box to the frame. Position the cable box (6a) and

Attach the warning sticker

See figure B2 on page 73.

7. Attach the residual voltage warning sticker in the local language.

Check the compatibility with IT (ungrounded) and cornergrounded TN systems

 EMC filter

The internal EMC filter is not suitable for use on an IT (ungrounded) system or on a corner-grounded TN system. Disconnect the EMC filter before connecting the drive to the supply network. Check the table on page 24.

WARNING! Do not install the drive with the internal EMC filter connected on an

IT system (an ungrounded power system or a high-resistance-grounded [over 30 ohms] power system), otherwise the system will be connected to ground potential through the EMC filter capacitors of the drive. This can cause danger, or damage the drive.

Do not install the drive with the internal EMC filter connected on a corner-grounded TN system, otherwise the drive will be damaged.

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

considerably reduced.

24 R1…R4 Quick installation guide

 Ground-to-phase varistor

The ground-to-phase varistor is not suitable for use on an IT (ungrounded) system. Disconnect the ground-to-phase varistor before connecting the drive to the supply network. Check the table on page 24.

R1R4

R5

R6R9

DA

DE

ES

FI

FR

IT

NL

PL

PT

RU

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WARNING! Do not install the drive with the ground-to-phase varistor

connected on an IT system (an ungrounded power system or a highresistance-grounded [over 30 ohms] power system), otherwise the varistor circuit can be damaged.

Check the table below to determine which screws may be metal for your system. For instructions on how to do this, see page 25.

Frame

sizes

R1…R3 VAR

R4 EMC

1) 2) 3)

EMC filter

(EMC)

Ground-

to-phase

5)

varistor (VAR)

5)

1 metal screw

(connects VAR and

AC EMC circuit)

EMC

- Disconnect

1 plastic

screw

- Disconnect 1 metal, 1 plastic

screw

- VAR 1 metal

screw

L1

L2

L3

N

PE

Symmetrically

grounded TN

systems

(TN-S systems)

Do not

disconnect:

Metal screws can be used.

Corner grounded

TN systems

1)

Disconnect

Remove metal

screw.

Maintain plastic

screw.

Maintain plastic screw. Remove

metal screw.

Do not disconnect

Maintain metal

screw.

L1

L2 L3 PE

4)

2)

(ungrounded or high-resistance

[>30 ohms])

:

Remove metal

:

Maintain plastic

:

Maintain plastic screw. Remove

4)

:

Remove metal

IT systems

grounded

Disconnect:

screw.

Disconnect:

screw.

Disconnect:

metal screw.

Disconnect:

screw.

3)

L1

L2

L3

ZH

4)

R4 frames were evaluated for use on corner grounded networks by UL standards. R4 frames are not to be used on IEC installations of corner grounded networks.

5)

EMC and VAR columns show the screw material when the drive is shipped.

Note: For statements containing “Maintain plastic screw.”: Metal screw must not be used, plastic screw may be maintained or removed from the AC EMC circuit.

Drive

Drive Drive

R1…R4 Quick installation guide 25

 Disconnect EMC filter or ground-to-phase varistor, if needed

To disconnect the internal EMC filter or ground-to-phase varistor, if needed, do as follows:

1. Switch off the power from the drive.

2. Open the front cover, if not already opened, see figure B1 on page 73.

1…R3: To disconnect the internal EMC filter, remove the EMC screw (3a) and

3. R place it in the storage place (3b). R4:

To disconnect the internal EMC filter, remove the two EMC screws.

1…R3: To disconnect the ground-to-phase varistor, remove the varistor screw

4. R (4a) and place it in the storage place (4b). R4:

To disconnect the ground-to-phase varistor, remove the varistor screw.

R1…R2 R3

4a

3a

3b4b

R4

3b

3a

4a

4b

R1R4

R5

R6R9

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3

PT

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3

ZH

4

26 R1…R4 Quick installation guide

Wiring R1...R2

Note: These are instructions for conduit wiring. For cable wiring, see the ACS580

Hardware manual, publication number 3AXD50000018826.

Note: In US deliveries, options are already installed at the factory. If installing on site,

R1-

option slot 1 modules (fieldbus adapter) may be installed by mounting the module on

R4

the control board and tightening the mounting screw, which is also the grounding

R5

screw. Option slot 2 modules (I/O extension) should not be installed until after the power cables. Refer to Warning and step 8 below.

R6R9

DA

DE

ES

FI

WARNING! If installing modules, obey the instructions in Safety instructions on

page 7. If you ignore them, injury or death, or damage to the equipment can

occur. Option slot 2 in frames R1…R5 is at U

potential. You must disconnect power

DC

supplies before installing or removing an I/O extension module.

See figure on page 28.

1. Install thin-wall conduit clamps for IP21/UL Type 1 or liquid-tight conduit connectors for IP55/UL Type 12 (not supplied). Type 12 has a Pressfit gasket.

2. Connect conduit runs for input power, motor and control cables to the conduit box. Ensure grommets (pointing down) are inserted into all unused holes.

3. Route the input power and motor wiring through separate conduits.

4. Strip wires.

FR

5. Connect the motor and ground wires to the drive terminal. Tighten the screws to

IT

NL

PL

torques shown in the Power wiring torque table.

6. Connect the input power and ground wires to the drive terminal. Tighten the screws to torques shown in the Power wiring torque table.

7. If brake resistor is used — Connect the resistor and ground wires. Tighten the screws to torques shown in the Power wiring torque table.

PT

8. Install option slot 2 modules (I/O extension), if necessary, at this point.

RU

A Frame R1 only: Install the option mounting.

B Put the module carefully into its position on the control board and tighten the

SV

TR

ZH

mounting screw.

C Tighten the grounding screw, which is necessary for proper operation and for

fulfilling EMC requirements.

Note: Frame R1 — The module in option slot 2 covers the power terminals. Do not install a module in option slot 2 before you have installed the power cables.

9. Route the control cables through the conduit (not the same conduit as either input power or motor wiring).

R1…R4 Quick installation guide 27

10. Strip the control cable sheathing and twist the copper screen into a pig-tail.

11. Refer to page 33. Connect the ground screen pig-tail for digital and analog I/O cables. (Ground only at drive end.)

12. Connect the ground screen pig-tail for Embedded fieldbus, EFB (EIA-485) cables at X5. (Ground only at drive end.)

13. Strip and connect the individual control wires to the drive terminals. Tighten the screws to 0.4 lb-ft (0.5…0.6 N-m).

WARNING! To avoid danger or damage to the drive on IT systems and corner grounded TN systems, see section Check the compatibility with IT (ungrounded)

and corner-grounded TN systems on page 23.

R1R4

R5

R6R9

DA

DE

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FI

FR

IT

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PL

PT

RU

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28 R1…R4 Quick installation guide

R1...R2 Type 12

R1R4

R5

R6R9

DA

DE

ES

FR

NL

PL

FI

IT

Typical Type 1

1

9

Relay Outputs

Analog Inputs

and Outputs

Digital Inputs

EMC

6

7

5

9

Option Mounting

8C

8B

8A

1

PT

RU

SV

TR

ZH

Power wiring torque table

Frame size

T1/U, T2/V, T3/W 0.4 1.2...1.5 1.1 1.2...1.5

L1, L2, L3 0.4 1.2...1.5 1.1 1.2...1.5

R+, R- 0.4 1.2...1.5 1.1 1.2...1.5

PE Ground 1.1 1.5 1.1 1.5

lb-ft N-m lb-ft N-m

R1 R2

R1…R4 Quick installation guide 29

Wiring R3

Note: These are instructions for conduit wiring. For cable wiring, see the ACS580

Hardware manual, publication number 3AXD50000018826.

Note: In US deliveries, options are already installed at the factory. If installing on site, option slot 1 modules (fieldbus adapter) may be installed by mounting the module on the control board and tightening the mounting screw, which is also the grounding screw. Option slot 2 modules (I/O extension) may be installed by mounting the module on the control board and tightening both the mounting screw and the grounding screw. Refer to Warning.

WARNING! If installing modules, obey the instructions in Safety instructions on page 7. If you ignore them, injury or death, or damage to the equipment can

occur. Option slot 2 in frames R1…R5 is at U

potential. You must disconnect power

DC

supplies before installing or removing an I/O extension module.

See figure on page 30.

1. Install thin-wall conduit clamps for IP21/UL Type 1 or liquid-tight conduit connectors for IP55/UL Type 12 (not supplied). Type 12 has a Pressfit gasket.

2. Connect conduit runs for input power, motor and control cables to the conduit box. Ensure grommets (pointing down) are inserted into all unused holes.

3. Route the input power and motor wiring through separate conduits.

4. Strip wires.

5. Connect the motor and ground wires to the drive terminal. Tighten the screws to torques shown in the Power wiring torque table.

6. Connect the input power and ground wires to the drive terminal. Tighten the screws to torques shown in the Power wiring torque table.

7. If brake resistor is used — Connect the resistor and ground wires. Tighten the screws to torques shown in the Power wiring torque table.

R1R4

R5

R6R9

DA

DE

ES

FI

FR

IT

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PL

PT

8. Route the control cables through the conduit (not the same conduit as either input power or motor wiring).

9. Strip the control cable sheathing and twist the copper screen into a pig-tail.

10. Refer to page 33. Connect the ground screen pig-tail for digital and analog I/O cables. (Ground only at drive end.)

11. Connect the ground screen pig-tail for Embedded fieldbus, EFB (EIA-485) cables at X5. (Ground only at drive end.)

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30 R1…R4 Quick installation guide

BREAKERSINPUT

PE

MOTOR

R-

R+

UDC+

W/3TV/2TU/1T3L2L1L

BREAKERSINPUT

PE

MOTOR

R-

R+

UDC+

W/3TV/2TU/1T3L2L1L

12. Strip and connect the individual control wires to the drive terminals. Tighten the screws to 0.4 lb-ft (0.5…0.6 N-m).

R1R4

R5

R6R9

DA

grounded TN systems, see section Check the compatibility with IT (ungrounded)

and corner-grounded TN systems on page 23.

R3 Type 12

Power (Green) and

Fault (Red) LEDs

DE

ES

FI

FR

WARNING! To avoid danger or damage to the drive on IT systems and corner

IT

Typical Type 1

NL

EMC

VAR

6

Analog Inputs

and Outputs

Option Mounting

Digital Inputs

5

7

PL

PT

RU

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1

8

Power wiring torque table

Frame size

lb-ft N-m

T1/U, T2/V, T3/W 3.3 2.5...4.5

L1, L2, L3 3.3 2.5...4.5

R+, R- 3.3 2.5...4.5

PE Ground 1.1 1.5

R3

R1…R4 Quick installation guide 31

Wiring R4

Note: These are instructions for conduit wiring. For cable wiring, see the ACS580

Hardware manual, publication number 3AXD50000018826.

Note: In US deliveries, options are already installed at the factory. If installing on site, option slot 1 modules (fieldbus adapter) may be installed by mounting the module on the control board and tightening the mounting screw, which is also the grounding screw. Option slot 2 modules (I/O extension) may be installed by mounting the module on the control board and tightening both the mounting screw and the grounding screw. Refer to Warning.

WARNING! If installing modules, obey the instructions in Safety instructions on page 7. If you ignore them, injury or death, or damage to the equipment can

occur. Option slot 2 in frames R1…R5 is at U

potential. You must disconnect power

DC

supplies before installing or removing an I/O extension module.

See figure on page 32.

1. Install thin-wall conduit clamps for IP21/UL Type 1 or liquid-tight conduit connectors for IP55/UL Type 12 (not supplied). Type 12 has a Pressfit gasket.

2. Connect conduit runs for input power, motor and control cables to the conduit box. Ensure grommets (pointed down) are inserted into all unused holes.

3. Route the input power and motor wiring through separate conduits.

4. Strip wires.

5. Connect the motor and ground wires to the drive terminal. Tighten the screws to torques shown in the Power wiring torque table.

6. Connect the input power and ground wires to the drive terminal. Tighten the screws to torques shown in the Power wiring torque table.

7. Route the control cables through the conduit (not the same conduit as either input power or motor wiring).

R1R4

R5

R6R9

DA

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FR

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PL

PT

8. Strip the control cable sheathing and twist the copper screen into a pig-tail.

9. Refer to page 33. Connect the ground screen pig-tail for digital and analog I/O cables. (Ground only at drive end.)

10. Connect the ground screen pig-tail for Embedded fieldbus, EFB (EIA-485) cables at X5. (Ground only at drive end.)

11. Strip and connect the individual control wires to the drive terminals. Tighten the screws to 0.4 lb-ft (0.5…0.6 N-m).

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32 R1…R4 Quick installation guide

WARNING! To avoid danger or damage to the drive on IT systems and corner grounded TN systems, see section Check the compatibility with IT (ungrounded)

and corner-grounded TN systems on page 23.

R1R4

R5

R6R9

Analog Inputs

and Outputs

R4 Type 12

Panel Connector

Relay

Digital Inputs

Outputs

DA

DE

EMC

ES

VAR

5

Typical Type 1

FI

6

FR

IT

NL

PL

PT

Note: UDC+ and UDC- terminals are used for external brake chopper units.

1

RU

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T1/U, T2/V, T3/W 3.0 4.0

L1, L2, L3 3.0 4.0

UDC+ and UDC- 3.0 4.0

PE Ground 1.1 1.5

7

1

Power wiring torque table

Frame size

7

R4

lb-ft N-m

Option Mounting

R1…R4 Quick installation guide 33

Default I/O connections

Default I/O connections of the ABB Standard macro are shown below.

X1 Reference voltage and analog inputs and outputs

1 SCR Signal cable shield (screen)

1…10 kohm

max. 500 ohm

2 AI1 Output frequency/speed reference: 0…10 V 3 AGND Analog input circuit common 4 +10V Reference voltage 10 V DC 5 AI2 Not configured 6 AGND Analog input circuit common 7 AO1 Output frequency: 0…20 mA 8 AO2 Output current: 0…20 mA 9 AGND Analog output circuit common

X2 & X3 Aux. voltage output and programmable digital inputs

10 +24V Aux. voltage output +24 V DC, max. 250 mA 11 DGND Aux. voltage output common 12 DCOM Digital input common for all 13 DI1 Stop (0) / Start (1) 14 DI2 Forward (0) / Reverse (1) 15 DI3 Constant frequency/speed selection 16 DI4 Constant frequency/speed selection 17 DI5 18 DI6 Not configured

X6, X7, X8 Relay outputs

19 RO1C 20 RO1A 21 RO1B 22 RO2C 23 RO2A 24 RO2B 25 RO3C 26 RO3A 27 RO3B

X5 EIA-485 Modbus RTU 29 B+ 30 A- 31 DGND

S4 TERM Serial data link termination switch S5 BIAS Serial data link bias resistors switch

X4 Safe torque off 34 OUT1 35 OUT2 36 SGND 37 IN1 38 IN2

Ramp set 1 (0) / Ramp set 2 (1)

Ready run

250 V AC / 30 V DC 2 A

Running

250 V AC / 30 V DC 2 A

Fault (-1)

250 V AC / 30 V DC 2 A

Embedded Modbus RTU (EIA-485)

Safe torque off. Factory connection. Both circuits must be closed for the drive to start. See chapter

The Safe torque off function in ACS580-01 (0.75 to 250 kW (3AXD50000018826 [English]).

, 1.0 to 350 hp

) hardware manual

R1R4

R5

R6R9

DA

DE

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FI

FR

IT

NL

PL

PT

RU

Total load capacity of the Auxiliary voltage output +24V (X2:10) is 6.0 W (250 mA / 24 V DC).

Wire sizes:

0.2…2.5 mm

0.14…1.5 mm

2

(24…14 AWG): Terminals +24V, DGND, DCOM, B+, A-, DGND, Ext. 24V

2

(26…16 AWG): Terminals DI, AI, AO, AGND, RO, STO

Tightening torques: 0.5…0.6 N·m (0.4 lbf·ft)

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34 R1…R4 Quick installation guide

Install optional modules, if any

See chapter Electrical installation in ACS580-01 (0.75 to 250 kW, 1.0 to 350 hp) hardware manual (3AXD50000018826 [English]).

R1-

Reinstall cover

R4

See figure J on page 76.

R5

1. Put the tabs on the inside of the cover top in their counterparts on the housing (1a)

R6R9

DA

DE

ES

FI

and then press the cover at the bottom (1b).

2. Tighten the retaining screw with a screwdriver.

For start-up instructions, see chapter Quick start-up guide on page 61.

FR

NL

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IT

—

ABB GENERAL PURPOSE DRIVES

Quick installation guide

ACS580-01 drives (frames R5)

R0R3

R5

[Page intentionally left blank]

R5 Quick installation guide 37

R5 Quick installation guide

This guide briefly describes how to install the drive. For complete information on installation, see ACS580-01 (0.75 to 250 kW, 1.0 to 350 hp) hardware manual

(3AXD50000018826 [English]). For start-up instructions, see chapter Quick start-up

guide on page 61.

To read a manual, go to www.abb.com/drives/documents number.

Obey the safety instructions

WARNING! Obey these instructions. If you ignore them, injury or death, or

damage to the equipment can occur:

and search for the document

R0R4

R5

R6R9

• If you are not a qualified electrician, do not do electrical installation work.

• Do not work on the drive, motor cable or motor when main power is applied. If the drive is already connected to the input power, wait for 5 minutes after disconnecting the input power.

• Do not work on the control cables when power is applied to the drive or to the external control circuits.

• Make sure that debris from borings and grindings does not enter the drive when installing.

• Make sure that the floor below the drive and the wall where the drive is installed are non-flammable.

Check if capacitors need to be reformed

If the drive has not been powered (either in storage or unused) for over one year, you must reform the capacitors.

You can determine the manufacturing time from the serial number, which you find on the type designation label attached to the drive. The serial number is of format MYYWWRXXXX. YY and WW tell the manufacturing year and week as follows:

YY: 16, 17, 18, … for 2016, 2017, 2018, WW: 01, 02, 03, … for week 1, week 2, week 3,

For information on reforming the capacitors, see Converter module capacitor reforming instructions (3BFE64059629 [English]), available on the Internet at

www.abb.com/drives/documents

.

…

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38 R5 Quick installation guide

Select the power cables

Size the power cables according to local regulations to carry the nominal current given on the type designation label of your drive.

R0-

Ensure the cooling

R4

See table I on page 13 for the losses. The allowed operating temperature range of the

R5

drive is -15 to +50 °C (+5 to +122 °F).No condensation or frost is allowed. For more information on the ambient temperature and derating, see chapter Technical data in

R6-

ACS580-01 (0.75 to 250 kW, 1.0 to 350 hp) hardware manual (3AXD50000018826

R9

[English]).

Protect the drive and input power cable

See table II on page 16 for the fuses.

If you use gG fuses, make sure that the operating time of the fuse is below 0.5

DA

seconds. Follow the local regulations.

DE

Install the drive on the wall

ES

See figure R5 Figures A on page 77.

FI

Check the insulation of the power cables and the motor

FR

Check the insulation of the input cable according to local regulations before connecting it to the drive.

IT

See figure B on page 77.

NL

1. Check the insulation of the motor cable and motor when the cable is disconnected

PL

PT

RU

SV

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

Note: Moisture inside the motor casing will reduce the insulation resistance. If moisture is suspected, dry the motor and repeat the measurement.

TR

ZH

R5 Quick installation guide 39

Switch off the power and open the cover

See figure B on page 77.

2. Switch off the power from the drive.

3. IP21, Remove the module cover: (3a) and lift the cover from the bottom outwards (3b) and then up (3c).

4. IP21, Remove the box cover and slide the cover downwards (4b).

5. IP55, Remove the front cover and lift the cover from the bottom outwards (4b) and then up (4c).

Loosen the retaining screws with a screwdriver

: Loosen the retaining screws with a screwdriver (4a)

Check the compatibility with IT (ungrounded) and cornergrounded TN systems

R0R4

R5

R6R9

 EMC filter

The internal EMC filter is not suitable for use on an IT (ungrounded) system or on a corner-grounded TN system. Disconnect the EMC filter before connecting the drive to the supply network. Check the table on page 40.

WARNING! Do not install the drive with the internal EMC filter connected on an

IT system (an ungrounded power system or a high-resistance-grounded [over 30 ohms] power system), otherwise the system will be connected to ground potential through the EMC filter capacitors of the drive. This can cause danger, or damage the drive.

Do not install the drive with the internal EMC filter connected on a corner-grounded TN system, otherwise the drive will be damaged.

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

 Ground-to-phase varistor

The ground-to-phase varistor is not suitable for use on an IT (ungrounded) system. Disconnect the ground-to-phase varistor before connecting the drive to the supply network. Check the table on page 40.

WARNING! Do not install the drive with the ground-to-phase varistor connected

on an IT system (an ungrounded power system or a high-resistance-grounded [over 30 ohms] power system), otherwise the varistor circuit can be damaged.

DA

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40 R5 Quick installation guide

Check the table below to determine which screws may be metal for your system. For instructions on how to do this, see page 41.

Ground-

to-phase

5)

varistor

(VAR)

R0R4

R5

Frame

sizes

EMC filter

(EMC)

R5 EMC

R6R9

1 metal,

1 plastic

screw

- VAR 1 metal

screw

DA

1) 2) 3)

DE

ES

FI

Symmetrically

grounded TN

systems

5)

(TN-S systems)

- Do not disconnect:

Metal screws

can be used.

L1

L2

L3

N

PE

Corner grounded

TN systems

1)

Disconnect Maintain plastic screw. Remove

metal screw.

Do not disconnect

Maintain metal

screw.

L1

L2 L3 PE

4)

IT systems

2)

(ungrounded or high-resistance

grounded

[>30 ohms])

:

Disconnect:

Maintain plastic

4)

Remove metal

:

Disconnect:

Remove metal

FR

Drive

IT

4)

R5 frames were evaluated for use on corner grounded networks by UL standards. R5 frames are not to be used on IEC installations of corner grounded networks.

NL

5)

EMC and VAR columns show the screw material when the drive is shipped.

Note: For statements containing “Maintain plastic screw.”: Metal screw must not be used, plastic screw may be maintained or removed from the AC EMC circuit.

PL

Drive Drive

3)

screw.

L1

L2

L3

PT

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R5 Quick installation guide 41

 Disconnect EMC filter or ground-to-phase varistor, if needed

To disconnect the internal EMC filter or ground-to-phase varistor, if needed, do as follows:

1. Switch off the power from the drive.

2. Open the front cover, if not already opened, see figure B on page 77.

3. To disconnect the internal EMC filter, remove the two EMC screws.

4. To disconnect the ground-to-phase varistor, remove the varistor screw.

3

4

3

4

Wiring R5

Note: These are instructions for conduit wiring. For cable wiring, see the ACS580

Hardware manual, publication number 3AXD50000018826.

Note: In US deliveries, options are already installed at the factory. If installing on site, option slot 1 modules (fieldbus adapter) may be installed by mounting the module on the control board and tightening the mounting screw, which is also the grounding screw. Option slot 2 modules (I/O extension) may be installed by mounting the module on the control board and tightening both the mounting screw and the grounding screw. Refer to Warning.

R0R4

R5

R6R9

DA

DE

ES

FI

FR

IT

NL

PL

PT

RU

WARNING! If installing modules, obey the instructions in Safety instructions on

page 7. If you ignore them, injury or death, or damage to the equipment can

occur. Option slot 2 in frames R1…R5 is at U

potential. You must disconnect power

DC

supplies before installing or removing an I/O extension module.

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42 R5 Quick installation guide

See figure on page 43.

1. Install thin-wall conduit clamps for IP21/UL Type 1 or liquid-tight conduit connectors for IP55/UL Type 12 (not supplied). Type 12 has a Pressfit gasket.

2. Connect conduit runs for input power, motor and control cables to the conduit box.

R0R4

R5

Ensure grommets (pointing down) are inserted into all unused holes.

3. Route the input power and motor wiring through separate conduits.

4. Strip wires.

R6-

5. Connect the motor and ground wires to the drive terminal. Tighten the screws to

R9

torques shown in the Power wiring torque table.

6. Connect the input power and ground wires to the drive terminal. Tighten the screws to torques shown in the Power wiring torque table.

7. Reinstall the shroud on the power

DA

DE

ES

terminals by putting the tabs at the top of the shroud in their counterparts on the drive frame and then pressing the shroud in place.

8. Route the control cables through the

7

7a

conduit (not the same conduit as either input power or motor wiring).

FI

9. Strip the control cable sheathing and

FR

twist the copper screen into a pig-tail.

10. Refer to page 44. Connect the ground

IT

screen pig-tail for digital and analog

NL

PL

PT

I/O cables. (Ground only at drive end.)

11. Connect the ground screen pig-tail for Embedded fieldbus, EFB (EIA-485) cables at X5. (Ground only at drive end.)

12. Strip and connect the individual control wires to the drive terminals. Tighten the screws to 0.4 lb-ft (0.5…0.6 N-m).

RU

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7b

R5 Quick installation guide 43

WARNING! To avoid danger or damage to the drive on IT systems and corner grounded TN systems, see section Check the compatibility with IT (ungrounded)

and corner-grounded TN systems on page 39.

Analog Inputs and Outputs

Digital Inputs

Typical Type 1

EMC

6

3

R5 Type 12

VAR

Panel Connector

Power (Green) and

Fault (Red) LEDs

Relay

Outputs

Option Mounting

5

Shroud

R0R4

R5

R6R9

DA

DE

ES

FI

FR

IT

NL

PL

1

8

1

8

Note: UDC+ and UDC- terminals are used for external brake chopper units.

Power wiring torque table

Frame size

T1/U, T2/V, T3/W 4.1 5.6 L1, L2, L3 4.1 5.6 UDC+ and UDC- 4.1 5.6 PE Ground 1.1 1.5

lb-ft N-m

R5

PT

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44 R5 Quick installation guide

Default I/O connections

Default I/O connections of the ABB Standard macro are shown below.

X1 Reference voltage and analog inputs and outputs

R0R4

R5

R6R9

DA

DE

ES

FI

FR

IT

NL

PL

PT

RU

1…10 kohm

max. 500 ohm

1 SCR Signal cable shield (screen) 2 AI1 Output frequency/speed reference: 0…10 V 3 AGND Analog input circuit common 4 +10V Reference voltage 10 V DC 5 AI2 Not configured 6 AGND Analog input circuit common 7 AO1 Output frequency: 0…20 mA 8 AO2 Output current: 0…20 mA 9 AGND Analog output circuit common

X2 & X3 Aux. voltage output and programmable digital inputs

10 +24V Aux. voltage output +24 V DC, max. 250 mA 11 DGND Aux. voltage output common 12 DCOM Digital input common for all 13 DI1 Stop (0) / Start (1) 14 DI2 Forward (0) / Reverse (1) 15 DI3 Constant frequency/speed selection 16 DI4 Constant frequency/speed selection 17 DI5 18 DI6 Not configured

X6, X7, X8 Relay outputs

19 RO1C 20 RO1A 21 RO1B 22 RO2C 23 RO2A 24 RO2B 25 RO3C 26 RO3A 27 RO3B

X5 EIA-485 Modbus RTU 29 B+ 30 A- 31 DGND

S4 TERM Serial data link termination switch S5 BIAS Serial data link bias resistors switch

X4 Safe torque off 34 OUT1 35 OUT2 36 SGND 37 IN1 38 IN2

Ramp set 1 (0) / Ramp set 2 (1)

Ready run

250 V AC / 30 V DC 2 A

Running

250 V AC / 30 V DC 2 A

Fault (-1)

250 V AC / 30 V DC 2 A

Embedded Modbus RTU (EIA-485)

Safe torque off. Factory connection. Both circuits must be closed for the drive to start. See chapter

The Safe torque off function in ACS580-01 (0.75 to 250 kW (3AXD50000018826 [English]).

, 1.0 to 350 hp

) hardware manual

SV

Total load capacity of the Auxiliary voltage output +24V (X2:10) is 6.0 W (250 mA / 24 V DC).

Wire sizes:

TR

0.2…2.5 mm

0.14…1.5 mm

ZH

Tightening torques: 0.5…0.6 N·m (0.4 lbf·ft)

2

(24…14 AWG): Terminals +24V, DGND, DCOM, B+, A-, DGND, Ext. 24V

2

(26…16 AWG): Terminals DI, AI, AO, AGND, RO, STO

R5 Quick installation guide 45

Install optional modules, if any

See chapter Electrical installation in ACS580-01 (0.75 to 250 kW, 1.0 to 350 hp) hardware manual (3AXD50000018826 [English]).

Reinstall cover

See figure H on page 80.

1. IP21, Reinstall the box cover retaining screws (1b).

2. IP21, Reinstall the module cover counterparts on the housing (2a), press the cover at the bottom (2b) and tighten the retaining screws (2c).

3. IP55, Reinstall the front cover counterparts on the housing (3a), press the cover at the bottom (3a) and tighten the retaining screws (3b).

For start-up instructions, see chapter Quick start-up guide on page 61.

: Slide the cover upwards (1a) and tighten the

: Put the tabs on the inside of the cover top in their

R0R4

R5

R6R9

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46 R5 Quick installation guide

R0R4

R5

R6R9

DA

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ES

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[Page intentionally left blank]

—

ABB GENERAL PURPOSE DRIVES

Quick installation guide

ACS580-01 drives (frames R6 to R9)

[Page intentionally left blank]

R6…R9 Quick installation guide 49

R6…R9 Quick installation guide

This guide briefly describes how to install the drive. For complete information on installation, see ACS580-01 (0.75 to 250 kW) hardware manual (3AXD50000018826 [English]). For start-up instructions, see chapter Quick start-up guide on page 61.

R0R4

To read a manual, go to www.abb.com/drives/documents number.

and search for the document

Obey the safety instructions

WARNING! Obey these instructions. If you ignore them, injury or death, or

damage to the equipment can occur:

• If you are not a qualified electrician, do not do electrical installation work.

• Do not work on the drive, motor cable or motor when main power is applied. If the drive is already connected to the input power, wait for 5 minutes after disconnecting the input power.

• Do not work on the control cables when power is applied to the drive or to the external control circuits.

• Use the lifting eyes of the drive when you lift 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.

• Make sure that debris from borings and grindings does not enter the drive when installing.

• Make sure that the floor below the drive and the wall where the drive is installed are non-flammable.

Check if capacitors need to be reformed

If the drive has not been powered (either in storage or unused) for over one year, you must reform the capacitors.

You can determine the manufacturing time from the serial number, which you find on the type designation label attached to the drive. The serial number is of format MYYWWRXXXX. YY and WW tell the manufacturing year and week as follows:

YY: 13, 14, 15, … for 2013, 2014, 2015, WW: 01, 02, 03, … for week 1, week 2, week 3,

…

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50 R6…R9 Quick installation guide

For information on reforming the capacitors, see Converter module capacitor reforming instructions (3BFE64059629 [English]), available on the Internet at

www.abb.com/drives/documents

Select the power cables

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Size the power cables according to local regulations to carry the nominal current given on the type designation label of your drive.

R6-

Ensure the cooling

R9

See table I on page 13 for the losses. The allowed operating temperature range of the drive is -15 to +50 °C (+5 to +122 °F). No condensation or frost is allowed. For more information on the ambient temperature and derating, see chapter Technical data in ACS580-01 (0.75 to 250 kW) hardware manual (3AXD50000018826 [English]).

Protect the drive and input power cable

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See table II on page 16 for the fuses.

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If you use gG fuses, make sure that the operating time of the fuse is below 0.5 seconds. Follow the local regulations.

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Install the drive on the wall

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Warning! The drive module is heavy (42 to 103 kg / 93 to 227 lb). Use a suitable

lifting device. Do not lift the module manually. Make sure that the wall and the

fixing devices can carry the weight.

See figure A on page 81.

R6…R9 Quick installation guide 51

Check the insulation of the power cables and the motor

Check the insulation of the input cable according to local regulations before connecting it to the drive.

See figure B on page 81.

1. Check the insulation of the motor cable and motor before connecting it to the drive. Measure the insulation resistance between each phase conductor and then between each phase conductor and the Protective Earth conductor using a measuring voltage of 1000 V DC. The insulation resistance of an ABB motor must exceed 100 Mohm (reference value at 25 °C or 77 °F). For the insulation resistance of other motors, see the manufacturer’s instructions.

Note: Moisture inside the motor casing will reduce the insulation resistance. If moisture is suspected, dry the motor and repeat the measurement.

Check the compatibility with IT (ungrounded) and cornergrounded TN systems

 EMC filter

The internal EMC filter is not suitable for use on an IT (ungrounded) system or on a corner-grounded TN system. Disconnect the EMC filter before connecting the drive to the supply network. Check the table on page 52.

WARNING! Do not install the drive with the internal EMC filter connected on an

IT system (an ungrounded power system or a high-resistance-grounded [over 30 ohms] power system), otherwise the system will be connected to ground potential through the EMC filter capacitors of the drive. This can cause danger, or damage the drive.

Do not install the drive with the internal EMC filter connected on a corner-grounded TN system, otherwise the drive will be damaged.

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

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 Ground-to-phase varistor

The ground-to-phase varistor is not suitable for use on an IT (ungrounded) system. Disconnect the ground-to-phase varistor before connecting the drive to the supply network. Check the table on page 52.

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52 R6…R9 Quick installation guide

WARNING! Do not install the drive with the ground-to-phase varistor connected

on an IT system (an ungrounded power system or a high-resistance-grounded [over 30 ohms] power system), otherwisethe varistor circuit can be damaged.

R0-

Check the table below to determine which screws may be metal for your system. For

R4

instructions on how to do this, see page 53.

R6R9

Frame

sizes

EMC filter

(EMC)

Ground-

to-phase

5)

varistor

(VAR)

Symmetrically

grounded TN

systems

5)

(TN-S systems)

Corner grounded

TN systems

1)

IT systems

2)

(ungrounded or

high-resistance

grounded

[>30 ohms])

R6…R9 EMC

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1 metal, 1 plastic

screw

- Do not disconnect:

Metal screws

can be used.

Disconnect

Maintain plastic

screw.

Remove metal

Disconnect

:

Maintain plastic

Remove metal

screw.

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1 2 3

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5)

EMC and VAR columns show the screw material when the drive is shipped.

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Note: For statements containing “Maintain plastic screw.”: Metal screw must not be used, plastic screw may

be maintained or removed from the AC EMC circuit.

- VAR 1 metal

screw

Drive

L1

L2

L3

N

PE

Do not disconnect

Maintain metal

screw.

L1

L2 L3 PE

Drive Drive

Disconnect

:

Remove metal

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3)

:

screw.

:

screw.

L1

L2

L3

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R6…R9 Quick installation guide 53

 Disconnect EMC filter or ground-to-phase varistor, if needed

To disconnect the internal EMC filter or ground-to-phase varistor, if needed, do as follows:

1. Switch off the power from the drive.

2. Open the front cover, if not already opened, see steps 5, IP21 and 5, IP55 in figure

A on page 81.

3. To disconnect the internal EMC filter, remove the two EMC screws.

4. To disconnect the ground-to-phase varistor, remove the varistor screw.

3

4

3

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54 R6…R9 Quick installation guide

Wiring R6…R9

Note: These are instructions for conduit wiring. For cable wiring, see the ACS580

Hardware manual, publication number 3AXD50000018826.

Note: In US deliveries, options are already installed at the factory. If installing on site,

R0-

see the appropriate option module manual for specific installation and wiring.

R4

See figure on page 55.

1. Install thin-wall conduit clamps for IP21/UL Type 1 or liquid-tight conduit connectors

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for IP55/UL Type 12 (not supplied). Type 12 has a Pressfit gasket.

2. Connect conduit runs for input power, motor and control cables to the conduit box. Ensure grommets (pointing down) are inserted into all unused holes.

3. Route the input power and motor wiring through separate conduits.

4. Strip wires.

5. Connect the motor and ground wires to the drive terminal. Tighten the screws to torques shown in the Power wiring torque table.

Note: Frames R8…R9 — If you connect only one conductor to the connector, we recommend that you put it under the upper pressure plate.

6. Connect the input power and ground wires to the drive terminal. Tighten the screws to torques shown in the Power wiring torque table.

7. Frames R8…R9 — If parallel cables are used, install the parallel power cables.

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8. Reinstall the shroud on the power terminals and the conduit box side plates.

9. Route the control cables through the conduit (not the same conduit as either input power or motor wiring).

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10. Strip the control cable sheathing and twist the copper screen into a pig-tail.

11. Refer to page 56. Connect the ground screen pig-tail for digital and analog I/O cables. (Ground only at drive end.)

12. Connect the ground screen pig-tail for Embedded fieldbus, EFB (EIA-485) cables at X5. (Ground only at drive end.)

13. Strip and connect the individual control wires to the drive terminals. Tighten the screws to 0.4 lb-ft (0.5…0.6 N-m).

WARNING! To avoid danger or damage to the drive on IT systems and corner grounded TN systems, see section Check the compatibility with IT (ungrounded)

and corner-grounded TN systems on page 51.

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Analog Inputs and Outputs

Digital Inputs

Typical Type 1

6

R7 Type 12

R6…R9 Quick installation guide 55

Panel Connector

Power (Green) and

Fault (Red) LEDs

Relay Outputs

5

Shroud

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1

9

1

9

Note: UDC+ and UDC- terminals are used for external brake chopper units.

Power wiring torque table

Frame size

T1/U, T2/V, T3/W 22.1 30 29.5 40 29.6 40 51.6

L1, L2, L3 22.1 30 29.5 40 29.6 40 51.6

UDC+ and UDC- 22.1 30 29.5 30 29.5 40 51.6

PE Ground 1.1 1.5 1.1 1.5 1.1 1.5 1.1

R6 R7 R8 R9

lb-ft N-m lb-ft N-m lb-ft N-m lb-ft

N-m

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56 R6…R9 Quick installation guide

Default I/O connections

Default I/O connections of the ABB Standard macro are shown below.

S1 AI1 U/I Voltage/Current selection for AI1:

1)

S2 AI2 U/I Voltage/Current selection for AI2:

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1…10 kohm

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max. 500 ohm

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1)

All control boards do not have switches S1, S2 and S3. In that case, select voltage or current

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for inputs AI1 Total load capacity of the Auxiliary voltage output +24V (X2:10) is 6.0 W (250 mA / 24 V DC). Wire sizes: 0.14…2.5 mm Tightening torques: 0.5…0.6 N·m (0.4 lbf·ft)

and AI2 and output AO1 with parameters. See the firmware manual.

X1 Reference voltage and analog inputs and outputs

1 SCR Signal cable shield (screen) 2 AI1 Output frequency/speed reference: 0…10 V 3 AGND Analog input circuit common 4 +10V Reference voltage 10 V DC 5 AI2 Not configured 6 AGND Analog input circuit common 7 AO1 Output frequency: 0…20 mA 8 AO2 Output current: 0…20 mA

1)

9 AGND Analog output circuit common

S3 AO1 I/U Voltage/Current selection for AO1:

X2 & X3 Aux. voltage output and programmable digital inputs

10 +24V Aux. voltage output +24 V DC, max. 250 mA 11 DGND Aux. voltage output common 12 DCOM Digital input common for all 13 DI1 Stop (0) / Start (1) 14 DI2 Forward (0) / Reverse (1) 15 DI3 Constant frequency/speed selection 16 DI4 Constant frequency/speed selection 17 DI5 18 DI6 Not configured

X6, X7, X8 Relay outputs

19 RO1C 20 RO1A 21 RO1B 22 RO2C 23 RO2A 24 RO2B 25 RO3C 26 RO3A 27 RO3B

X5 EIA-485 Modbus RTU

29 B+ 30 A- 31 DGND

S4 TERM Serial data link termination switch S5 BIAS Serial data link bias resistors switch

X4 Safe torque off

34 OUT1 35 OUT2 36 SGND 37 IN1 38 IN2

X10 24 V AC/DC

40

24 V AC/DC+ in

41

24 V AC/DC- in

2

(26…16 AWG): All terminals

Ramp set 1 (0) / Ramp set 2 (1)

Ready run

250 V AC / 30 V DC 2 A

Running

250 V AC / 30 V DC 2 A

Fault (-1)

250 V AC / 30 V DC 2 A

Embedded Modbus RTU (EIA-485)

Safe torque off. Factory connection. Both circuits must be closed for the drive to start. See chapter

The Safe torque off function in ACS580-01 (0.75 to 250 kW) hardware manual (3AXD50000018826

[English]).

Ext. 24V AC/DC input to power up the control unit when the main supply is

disconnected.

U

I

U

I

UI

R6…R9 Quick installation guide 57

Install optional modules, if any

See chapter Electrical installation in ACS580-01 (0.75 to 250 kW) hardware manual (3AXD50000018826 [English]).

Install side plates and covers

See figure on page 83.

IP21

1. Reinstall the side plates of the cable entry box. Tighten the retaining screws with a screwdriver.

2. Slide the cover of the cable entry box on the module from below until the cover snaps into place.

3. Reinstall the module cover. Tighten the two retaining screws with a screwdriver.

IP55

1. Reinstall the module cover. Tighten the two retaining screws with a screwdriver.

For start-up instructions, see chapter Quick start-up guide on page 61.

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58 R6…R9 Quick installation guide

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—

ABB GENERAL PURPOSE DRIVES

Quick start-up guide

ACS580-01 drives (frames R1 to R9)

R1R4

R5

R6R9

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Rev 2016-02-17

61

Quick start-up guide

This guide describes how to start-up the drive using the First start assistant on the assistant control panel.

Before you start

Ensure that the drive has been installed as described in chapter R1…R4 Quick

installation guide on page 21, in chapter R5 Quick installation guide page 37chapter R6…R9 Quick installation guide on page 49 (frames R6…R9) or in chapter R6…R9 Quick installation guide on page 49.

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Start-up with the First start assistant on an assistant control panel

Safety

Make sure that the installation work is complete. Make sure that cover of the drive and the cable box, if included, are on place.

Check that the starting of the motor does not cause any danger. De-couple the driven machine if there is a risk of damage in case of an incorrect direction of rotation.

Hints on using the assistant control panel

The two commands at the bottom of the display (Options and Menu in the figure on the right), show the functions of the two softkeys and

located below the display. The commands assigned to the softkeys vary depending on the context.

Use keys , , and to move the cursor and/or change values depending on the active view.

Key shows a context-sensitive help page.

?

1 – First start assistant guided settings:

Language, date and time, and motor nominal values

Have the motor name plate data at hand.

Power up the drive.

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The First start assistant guides you through the first start-up.

The assistant begins automatically. Wait until the control panel enters the view shown on the right.

Select the language you want to use by highlighting it (if not already highlighted) and pressing (OK).

Note: After you have selected the language, it takes a few minutes for the control panel to wake up.

Select Start set-up and press (Next).

Select the localization you want to use and press

(Next).

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Change the units shown on the panel if needed.

• Go to the edit view of a selected row by

pressing .

• Scroll the view with and .

Go to the next view by pressing (Next).

To select a value in an edit view:

• Use and to select the value.

Press (Save) to accept the new setting, or press (Cancel) to go back to the previous view without making changes.

Set the date and time as well as date and time display formats.

• Go to the edit view of a selected row by

pressing .

• Scroll the view with and .

Go to the next view by pressing (Next).

To change a value in an edit view:

• Use and to move the cursor left and

right.

• Use and to change the value.

• Press (Save) to accept the new setting,

or press (Cancel) to go back to the previous view without making changes.

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To give the drive a name that will be shown at the top, press . If you do not want to change the default name (ACS580), continue straight to the set-up of the motor nominal values by pressing (Next).

For information on editing text, see ACS580

standard control program firmware manual

(3AXD50000016097 [English]).

Refer to the motor nameplate for the following nominal value settings of the motor. Enter the values exactly

Example of a nameplate of an induction (asynchronous) motor:

as shown on the motor nameplate.

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64

Check that the motor data is correct. Values are predefined on the basis of the drive size but you should verify that they correspond to the motor.

Start with the motor type.

Motor nominal cosΦ and nominal torque are optional.

Press (Next) to continue.

This step is optional, and requires rotating the motor. Do not do this if it could cause any risk, or if the mechanical set-up does not allow it.

To do the direction test, select Spin the motor and press (Next).

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Press the Start key on the panel to start the drive.

Check the direction of the motor.

If it is forward, select Yes, motor is spinning forward and press (Next) to continue.

If the direction is not forward, select No, fix direction and press (Next) to continue.

If you want to make a backup of the settings made so far, select Backup and press (Next).

If you do not want to make a backup, select Not now and press (Next).

The first start is now complete and the drive is ready for use.

Press (Done) to enter the Home view.

The Home view monitoring the values of the selected signals is shown on the panel.

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2 – Additional settings in the Primary settings menu

Make any additional adjustments, for example macro, ramps and limits, starting from the Main menu – press (Menu) to enter the Main menu.

Select Primary settings and press (or ).

We recommend that you make at least these additional settings:

• Choose a macro or set start, stop and reference

values individually

• Ramps

• Limits

With the Primary settings menu, you can also adjust settings related to the motor, PID, fieldbus, advanced functions and clock, region and display. In addition, the menu contains an item to reset the panel Home view.

To get more information on the Primary settings menu items, press to open the help page.

?

(Select)

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2 – Additional settings: Start, stop and reference values

If you do not wish to use a macro, define the settings for start, stop and reference:

Select Start, stop, reference and press (Select) (or ).

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Adjust the parameters according to your needs.

Select a parameter and, depending on the parameter type, press (Select) (or ).

When you change the settings, you also change the use of the I/O signals in the drive. Make sure the actual I/O wiring and the use of I/O in the control program match each other. You can check the current I/O use in the I/O menu under the Main menu.

After making the adjustments, go back to the Primary settings menu by pressing (Back).

(Edit) or press

2 – Additional settings: Ramps

(acceleration and deceleration times for the motor)

Select Ramps and press (Select) (or ).

Adjust the parameters according to your needs.

Select a parameter and press

After making the adjustments, go back to the Primary settings menu by pressing (Back).

(Edit).

2 – Additional settings: Limits

Select Limits and press (Select) (or ).

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Adjust the parameters according to your needs.

Select a parameter and press

After making the adjustments, go back to the Primary settings menu by pressing (Back).

(Edit).

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69

Compliance with the European Machinery Directive 2006/42/EC

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70

Compliance with the European Machinery Directive 2006/42/EC

NOTICE

The ratings listed below are NOT included in the compliance directive and do not carry the CE mark.

ACS580-01-343A-2 125 HP at 230 V

ACS580-01-396A-2 150 HP at 230 V

These ratings do carry UL listing (cULus).

UL PENDING

—

ABB GENERAL PURPOSE DRIVES

Quick installation guide

ACS580-01 drives

R1R4

R5

Installation figures

R6R9

[Page intentionally left blank]

R1…R4 Figures A

a

b

× 4

4a

R1…R2: M5 R3…R4: M6

× 4

4b 5

73

B2

321

R1 R2 R3…R4

7

C1

ACS580-01 R1…R4

PE

L1 L2 L3

UDC+

R+R-

T1/U T2/V T3/W

× 4

V1

U1

× 4

L1 L2 L3(PE) (PE)PE

W1

3 ~ M

B3

B1

1

1000

V DC,

ohm

>

100

Mohm

IP21 R1…R2

3 3 3 3

3c

3b

IP21 R1…R2 IP21 R1…R2 IP21 R1…R2

4

U1

M

V1

3~

W1

PE

IP21 R3…R4

3a

5 6

U1-V1, U1-W1, V1-W1 U1-PE, V1-PE, W1-PE

3c

3b

3a

x2

3c

3b

ONLY IT AND CORNER-GROUNDED TN SYSTEMS

1

2

C2:

3a 3b

R1…R4 R1…R3

L1

L2

L3

EMC

VAR

ACS580ACS580

R4

IP55 R4IP55 R1…R3

See page 23.

ACS580

x6

3c

3b

3a

L1

L2 L3 PE

L1

L2 L3 PE

EMC

VAR

C2

3a

4

PE

3b

PE

6b

6a

4a

4b

74

MOTOR

T1/U T2/V T3/W

INPUT

L1 L2 L3

BREAKERS

R-

R+

UDC+

PE

BREAKERSINPUT

PE

MOTOR

R-

R+

UDC+

L1 L2 L3 T1/U T2/V T3/W

MOTOR

T1/U T2/V T3/W

INPUT

L1 L2 L3

BREAKERS

R-

R+

UDC+

PE

BREAKERSINPUT

PE

MOTOR

R-

R+

UDC+

L1 L2 L3 T1/U T2/V T3/W

MOTOR

T1/U T2/V T3/W

INPUT

L1 L2 L3

BREAKERS

R-

R+

UDC+

PE

BREAKERSINPUT

PE

MOTOR

R-

R+

UDC+

L1 L2 L3 T1/U T2/V T3/W

D

R1…R2

E2

R3

5

R1…R2

5b

7c

5c

5b

7b

7d

R3

77

7b

7c

7d

G1

9

PE

E1

R4

6a

5a

5

5c

5b

Frame

size

T1/U, T2/

R1 R2

N·m lbf·ft N·m lbf·ft

0.5…0.6

0.4

5a

1.2…1.5

1.1

R4

7

7b

7a

7d

V, T3/W

PE,

1.5 1.1 1.5 1.1

7a

Frame

size

L1, L2, L3 0.5…0.6

PE,

N·m lbf·ft N·m lbf·ft

1.5 1.1 1.5 1.1

1.2 0.9 1.2 0.9

R1 R2

0.4

1.2…1.5

1.1

G2

10 10

10c

10b

R3R1…R2

10b

10c

3AXD50000044838Rev B

1.2 0.9 1.2 0.9

5a

6b

Frame

size

T1/U, T2/

V, T3/W

PE,

R3 R4

N·m lbf·ft N·m lbf·ft

2.5…4.5

3.3

4.0

1.5 1.1 2.9 2.1

1.2 0.9 1.2 0.9

6c

7a

3.0

F

8 8

Frame

size

N·m lbf·ft N·m lbf·ft

L1, L2, L3 2.5…4.5

PE,

1.5 1.1 2.9 2.1

1.2 0.9 1.2 0.9

R4R1…R2

R3 R4

3.3

4.0

3.0

10a

Frame

size

R-, R+ 0.5…0.6

PE,

10a

R1 R2 R3

N·m lbf·ft N·m lbf·ft N·m lbf·ft

0.4

1.2…1.5

1.5 1.1 1.5 1.1 1.5 1.1

1.2 0.9 1.2 0.9 1.2 0.9

1.1

2.5…4.5

3.3

PE

R1…R4 Figures H I I2

BREAKERSINPUT

PE

MOTOR

R-

R+

UDC+

L1 L2 L3 T1/U T2/V T3/W

MOTOR

T1/U T2/V T3/W

INPUT

L1 L2 L3

BREAKERS

R-

R+

UDC+

PE

BREAKERSINPUT

PE

MOTOR

R-

R+

UDC+

L1 L2 L3 T1/U T2/V T3/W

R1…R2

R3

5

11

R3R1…R2

11

75

R4

0.5…0.6 N·m

R4

11

13

0.5…0.6 N·m

5

6

0.5…0.6 N·m

4

0.5…0.6 N·m

6

4

0.5…0.6 N·m

6

5

6

4

3

2

3

2

76

J

IP21

1a

2

3AXD50000044838Rev B

1b

IP55 R1…R2

1b

2

IP21 R4, IP55 R3

1b

IP55 R4

1b

× 2× 2

2

× 2

2

R5 Figures A B

c

a

d

e

b

77

1

× 2

a 612 24.09 612 24.09

b 581 22.87 581 22.87

c 160 6.30 160 6.30

d > 200 7.9 200 7.9

e > 200 7.9 200 7.9

× 2

2

3

R5 IP21 R5 IP55

mm in mm in

R5 IP21 R5 IP55

kg lb kg lb

28.3 62.4 28.6 63.1

6

IP21

M5 × 3

8 9

IP21

8b

7

IP21

7b

7a

1

1000

V DC,

ohm

>

100

Mohm

U1-V1, U1-W1, V1-W1 U1-PE, V1-PE, W1-PE

4 5

IP21

U1

M

V1

3~

W1

PE

3

IP21

3c

3b

3a

IP55

× 2

4a

× 6

× 2

8a

9b

4b

9a

5c

× 2

9b

5a

× 8

5b

4

IP21 IP21

5

4a

4c

4b

10

6

ONLY IT SYSTEMS

See page 39

ACS580

L1

L2

L3

EMC

VAR

ACS580

L1

L2 L3 PE

78

PE

C D E

1 2

ACS580-01 R5

L1 L2 L3

PE

2a

T1/U T2/V T3/W

2b

2a

3

4a

4a 4b

4b

PE

5 6

PE

6c

7b7a

PE

3AXD50000044838Rev B

8

9

8c

8b

8a

9a

9b

6b

V1

U1

3 ~ M

W1

6a

L1 L2 L3PE

Frame size T1/U, T2/V, T3/W PE,

N·m lbf·ft M N·m lbf·ft N·m lbf·ft

R5 5.6 4.1 M5 4.5 3.3

1.2 0.9

Frame size L1, L2, L3, PE,

N·m lbf·ft M N·m lbf·ft N·m lbf·ft

R5 5.6 4.1 M5 4.5 3.3

1.2 0.9

10

10a

10b

R5 Figures F G H

79

12

0.5…0.6 N·m

IP21

1 2

3

6

5

6

IP55

3

5

4

1b

1a

3a

IP21

2a

1b

2b

2c

3c

× 8

3b

3

2

80

c

a

d

e

b

A

1

a

(mm/in)

b

(mm/in)

c

(mm/in)

d >

(mm/in)

e >

(mm/in)

R6 R7 R8 R9

571/

22.5 531/

20.9 213/

300/

11.8 200/

8.4

7.9

623/

24.5 583/

22.9 245/

9.7

300/

11.8 200/

7.9

701/

27.6 658/

25.9 263/

10.4 300/

11.8 200/

7.9

718/

28.3 658/

25.9 345/

13.6 300/

11.8 200/

7.9

× 4

5

6

2

3

× 2 × 2

7

2

M6×12

7

8

See page 51

L1

L2

L3

EMC

VAR

ACS580ACS580

L1

L2 L3 PE

EMC

C

1

2

4

5

× 2

B

1

ohm

U1

M

V1

3~

W1

PE

3

4

81

ACS580-01 R6

PE

5

L1 L2 L3

L1 L2 L3PE

6a 6b

6a

T1/U T2/V T3/W

U1

3 ~ M

PE

V1

W1

8

8b

M5×25/35

L1, L2, L3, T1/U, T2/V, T3/W 40 30 40 30 70 52

PE 10 7 10 7 10 7 10 7

8c

8a 9a

N·m lbf·ft N·m lbf·ft N·m lbf·ft N·m lbf·ft

9

R6 R7 R8 R9

9c

9b

R8...R9 only

10a

M5×25

10b

14

3AXD50000009286 Rev D

D

6b

PE

11

M5×12

12

82

1

3 1

2

Further information

Product and service inquiries

Address any inquiries about the product to your local ABB representative, quoting the type designation and serial number of the unit in question. A listing of ABB sales, support and service contacts can be found by navigating to

www.abb.com/searchchannels

Product training

For information on ABB product training, navigate to new.abb.com/service/training.

Providing feedback on ABB Drives manuals

Your comments on our manuals are welcome. Navigate to

new.abb.com/drives/manuals-feedback-form

Document library on the Internet

You can find manuals and other product documents in PDF format on the Internet at

www.abb.com/drives/documents

.

www.abb.com/drives

3AXD50000049129 REVE Effective 06/15/2021

ABB ACS580-01-012A-4, ACS580-01-027A-4, ACS580-01-052A-4, ACS580-01-044A-4, ACS580-01-03A0-4 Quick Start Guide

Specifications and Main Features

Frequently Asked Questions

User Manual