ABB ACS580-07-0495A-4 User manual

ABB general purpose drives
Hardware manual
ACS580-07 drives
(250 to 500 kW)

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ACS580-07 manuals

Hardware manual
ACS580-07 drives
3AXD50000032622 Rev A
EN
EFFECTIVE: 2016-03-16
2016 ABB Oy. All Rights Reserved.
1. Safety instructions
4. Mechanical installation
Table of contents
6. Electrical installation
9. Start-up

Update notice 1
Update notice
Safety
ADDED:
•Before you activate the automatic fault reset or automatic restart functions of the drive
control program, make sure that no dangerous situations can occur. These functions
reset the drive automatically and continue operation after a fault or supply break. If
these functions are activated, the installation must be clearly marked as defined in
IEC/EN 61800-5-1, subclause 6.5.3, for example, "THIS MACHINE STARTS
AUTOMATICALLY".
•If bypassing is required, employ mechanically or electrically interlocked contactors
between the motor and the drive and between the motor and the power line. Make
sure with interlocking that the contactors cannot be closed simultaneously. The
installation must be clearly marked as defined in IEC/EN 61800-5-1, subclause 6.5.3,
for example, "THIS MACHINE STARTS AUTOMATICALLY".
Default I/O connection diagram
CHANGED:
11. Internal overtemperature supervision of the cabinet is connected between DI6 and +24V aux. voltage
supply. If DI6 is to be used for another purpose, see section Changing internal overtemperature supervision
from DI6 to another digital input on page 2.
This notice concerns ACS580-07 hardware manual
(3AXD50000032622 [English]) Rev A.
Code: 3AXD50000131464 Rev A
Valid: from 2.6.2017 until the release of revision
B of the manual.
Contents: new or changed instructions
Auxiliary voltage output
10 +24V Auxiliary voltage output +24 V DC, max. 250 mA 4)
11 DGND Auxiliary voltage output common
12 DCOM Digital input common for all
Programmable digital inputs DI1…DI3
13 DI1 Stop (0) / Start (1)
14 DI2 Forward (0) / Reverse (1)
15 DI3 Constant frequency/speed selection 6)
Programmable digital inputs DI4…DI6
16 DI4 Constant frequency/speed selection 6)
17 DI5 Ramp set1 (0) / Ramp set 2 (1)
7)
18 DI6 Internal overtemperature supervision. 0 = Fault
Relay outputs
19 RO1C Ready run
250 V AC / 30 V DC
2 A
20 RO1A
21 RO1B
22 RO2C Running
250 V AC / 30 V DC
2 A
23 RO2A
24 RO2B
25 RO3C Fault (-1)
250 V AC / 30 V DC
2 A
26 RO3A
27 RO3B
EIA/5-485
8)
10)
11)
X504:10
X504:
18

2 Update notice
ADDED:
Changing internal overtemperature supervision from DI6 to another digital input
By default, digital input DI6 is used for the internal overtemperature supervision of the
drive cabinet. If it is required to use DI6 for an other purpose, change the overtemperature
supervision wiring from DI6 to another free digital input either on the control unit or on the
CMOD-01 multifunction extension module. Active the overtemperature supervision in the
new digital input with these parameter settings:
1. Select the correct digital input from parameter 31.01 External event 1 source.
2. Check that parameter 31.02 External event 1 type is set to Fault = 0.
For more information, see the firmware manual.
WARNING! Always connect the internal overtemperature supervision of the drive
cabinet to a free digital input or CMOD-01 multifunction extension module if
disconnected from digital input DI6. Activate the change. Disconnection of
overtemperature supervision leads to overtemperature and can damage the drive.
PNP configuration for digital inputs (DIGITAL IN)
CHANGED:
Note! By default, digital input DI6 is used for the internal overtemperature supervision of
the cabinet. If it needs to be changed, see section Changing internal overtemperature supervision
from DI6 to another digital input on page 2.
X504:10
X504:18
+24 V DC
0VDC
PNP connection (source)
10 +24V
11 DGND
12 DCOM
13 DI1
14 DI2
15 DI3
16 DI4
17 DI5
18 DI6
X504:18
X504:10 10 +24V
11 DGND
12 DCOM
13 DI1
14 DI2
15 DI3
16 DI4
17 DI5
18 DI6
PNP connection (source)
Internal +24 V power supply External +24 V power supply

Update notice 3
NPN configuration for digital inputs (DIGITAL IN)
CHANGED:
Note! By default, digital input DI6 is used for the internal overtemperature supervision of
the cabinet. If it needs to be changed, see section Changing internal overtemperature supervision
from DI6 to another digital input on page 2.
Internal +24 V power supply External +24 V power supply
10 +24V
11 DGND
12 DCOM
13 DI1
14 DI2
15 DI3
16 DI4
17 DI5
18 DI6
NPN connection (sink) NPN connection (sink)
10 +24V
11 DGND
12 DCOM
13 DI1
14 DI2
15 DI3
16 DI4
17 DI5
18 DI6
0VDC
+24 V DC
X504:10
X504:18
X504:10
X504:18

4 Update notice

5
Table of contents
1. Safety instructions
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Use of warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
General safety in installation, start-up and maintenance . . . . . . . . . . . . . . . . . . . . . . . . 14
Electrical safety in installation, start-up and maintenance . . . . . . . . . . . . . . . . . . . . . . . 16
Precautions before electrical work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Additional instructions and notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Additional instructions for permanent magnet motor drives . . . . . . . . . . . . . . . . . . . . . . 19
Safety in installation, start-up and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2. Introduction to the manual
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Target audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Contents of the manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Related manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Categorization by frame size and option code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Quick installation, start-up and operating flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Terms and abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3. Operation principle and hardware description
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Product overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Single-line circuit diagram of the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
General information on the cabinet layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Cabinet layout – bottom entry and exit of cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Overview of power and control connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Door switches and lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Main switch-disconnector Q1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Control by PC tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Common mode filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Descriptions of cabinet options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Degree of protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
IP42 and UL Type 1 Filtered (standard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
IP54 and UL Type 12 (option +B055) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Empty cubicles (options +C196 to +C201) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
du/dt filter (option +E205) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Cabinet heater with external supply (option +G300) . . . . . . . . . . . . . . . . . . . . . . . . . 33
UK gland/conduit plate (option +H358) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Additional terminal block X504 (option +L504) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Type designation label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Type designation key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

6
4. Mechanical installation
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Examining the installation site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Necessary tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Moving and unpacking the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Unpacking the transport package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Checking the delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Lifting the cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Moving the cabinet after unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Laying the cabinet on its back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Moving on rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Final placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Installing the IP54 roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Attaching the cabinet to the floor and wall or roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
General rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Attaching methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Alternative 1 – Clamping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Alternative 2 – Using the holes inside the cabinet . . . . . . . . . . . . . . . . . . . . . . . . 47
Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Cable duct in the floor below the cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Arc welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
5. Guidelines for planning the electrical installation
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Limitation of liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Selecting the supply disconnecting device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Selecting the main contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Protecting the motor insulation and bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Examining the compatibility of the motor and drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Requirements table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Additional requirements for ABB motors of types other than M2_, M3_, M4_, HX_ and
AM_ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Additional requirements for ABB high-output and IP23 motors . . . . . . . . . . . . . . 52
Additional requirements for non-ABB high-output and IP23 motors . . . . . . . . . . . 52
Additional data for calculating the rise time and the peak line-to-line voltage . . . 53
Additional note for common mode filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Selecting the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
General rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Typical power cable sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Alternative power cable types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Recommended power cable types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Power cable types for limited use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Not allowed power cable types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Motor cable shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Selecting the control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Shielding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Signals in separate cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Signals allowed to be run in the same cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Relay cable type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Control panel cable length and type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Routing the cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Separate control cable ducts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57