ABB ACQ580-07 User manual

—
ABB DRIVES FOR WATER
ACQ580-07
Hardware manual

ACQ580-07
Hardware manual
Table of contents
1. Safety instructions
4. Mechanical installation
5. Guidelines for planning the
electrical installation
6. Electrical installation
9. Start-up
3AXD50000045817 Rev E
EN
EFFECTIVE: 2020-09-22

Update notice
3AXD50000695317 Rev BCode
From 2021-03-01 until the next revision of the manual.Valid
Added descriptionsContents
This notice concerns these manuals:
LanguageRevisionManual codeManual name
ENEnglishE3AXD50000045816
ACH580-07 hardware manual
ENEnglishE3AXD50000045817
ACQ580-07 hardware manual
ENEnglishE3AXD50000045815
ACS580-07 hardware manual
ADDED: Connectivity for wired remote monitoring (option
+K496)
This option provides a gateway to connect the drive to ABB Ability™ via a local Ethernet
network. Includes NETA-21 remote monitoring tool and FMBT-21 Modbus/TCP adapter
module.
The NETA and FMBT-21 are installed at the factory and wired internally. An Ethernet
cable for customer connection is routed from the NETA to the external control connections
mounting plate (number 6 in the layout drawing for frames R6...R9, number 12 for frames
R10 and R11). Use an RJ45 coupler (not included) to connect your Ethernet cable to
the additional Ethernet cable.
Code
(English)
Manual
3AUA0000096939
NETA-21 remote monitoring tool user’s manual
3AUA0000096881
NETA-21 remote monitoring tool installation and start-up guide
3AXD50000158607
FMBT-21 Modbus/TCP adapter module user’s manual
3AXD50000158560
FMBT-21 Modbus/TCP adapter module quick installation and start-up guide
ADDED: Connectivity for wireless remote monitoring (option
+K497)
This option provides a gateway to connect the drive to ABB Ability™ via a wireless 4G
network. Includes NETA-21 remote monitoring tool, FMBT-21 Modbus/TCP adapter
module and modem.
Update notice 1

The NETA and FMBT-21 are installed at the factory and wired internally. An Ethernet
cable for customer connection is routed from the NETA to the external control connections
mounting plate (number 6 in the layout drawing for frames R6...R9, number 12 for frames
R10 and R11). Use an RJ45 coupler (not included) to connect your Ethernet cable to
the additional Ethernet cable.
Applicable 4G coverage: United Kingdom, France, Germany, Italy, Poland, Russia,
Sweden, Singapore, South Korea, Malaysia, Switzerland, Finland, Iceland, Spain,
Ukraine, Norway, Belgium, Denmark, Netherlands, Austria.
Code
(English)
Manual
3AUA0000096939
NETA-21 remote monitoring tool user’s manual
3AUA0000096881
NETA-21 remote monitoring tool installation and start-up guide
3AXD50000158607
FMBT-21 Modbus/TCP adapter module user’s manual
3AXD50000158560
FMBT-21 Modbus/TCP adapter module quick installation and start-up guide
ADDED: Thermal protection with Pt100 relays (options
+nL506)
Pt100 temperature monitoring relays are used for overtemperature supervision of motors
equipped with Pt100 sensors. For example, there can be three sensors to measure the
temperature of the motor windings and two sensors for the bearings. As the temperature
rises, the sensor resistance increases linearly. At an adjustable wake-up level, the
monitoring relay de-energizes its output.
The standard Pt100 relay options include two (+2L506), three (+3L506), five (+5L506)
relays. By default, the relays are wired internally to digital input DI6 of the drive control
unit. The loss of the input is set to trigger an external fault. The options include a terminal
block for sensor connection. The output indication on the terminal block can be wired
by the customer, for example, to an external monitoring circuit. See the circuit diagrams
delivered with the drive.
See also
• firmware manual for parameter settings
• Pt100 relay alarm and trip limit setting instructions in the start-up instructions
• circuit diagrams delivered with the drive for the actual wiring.
2 Update notice

￭Wiring of Pt100 relays
External wiring of sensor modules is shown below. Contact load capacity 250 V AC 10
A. For the actual wiring, see the circuit diagram delivered with the drive.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
X506
T
T
T
T
T
Sensor 1
Sensor 2
Sensor 3
Sensor 4
Sensor 5
1xPt100
Internal wiring for overheat indication
Sensor 1...3 overtemperature = contact open
Internal wiring for overheat indication
Sensor 4 or 5 overtemperature = contact open
Update notice 3

4 Update notice

Table of contents
1 Safety instructions
17Contents of this chapter ......................................................................................
17Use of warnings and notes .................................................................................
18General safety in installation, start-up and maintenance ....................................
20Electrical safety in installation, start-up and maintenance ..................................
20Electrical safety precautions ........................................................................
23Additional instructions and notes .................................................................
24Optical components ..........................................................................
24Printed circuit boards ........................................................................
25Grounding ....................................................................................................
26General safety in operation .................................................................................
26Additional instructions for permanent magnet motor drives ................................
26Safety in installation, start-up, maintenance ................................................
27Safety in operation .......................................................................................
2 Introduction to the manual
29Contents of this chapter ......................................................................................
29Target audience ..................................................................................................
29Purpose of the manual ........................................................................................
29Categorization by frame size and option code ....................................................
30Quick installation flowchart .................................................................................
31Terms and abbreviations .....................................................................................
32Related documents .............................................................................................
3 Operation principle and hardware description
35Contents of this chapter ......................................................................................
36Product overview ................................................................................................
37Layout .................................................................................................................
37General information on the cabinet layout ...................................................
38Cabinet layout – R6 and R7 (bottom entry and exit of cables) ....................
39
Cabinet layout – R6 and R7 (top entry and exit of cables, options +H351
and +H53) ....................................................................................................
40Cabinet layout – R8 and R9 (bottom entry and exit of cables) ....................
41
Cabinet layout – R8 and R9 (top entry and exit of cables, options +H351
and +H53) ....................................................................................................
42Mounting plate – R6 to R9 ...........................................................................
45Cabinet layout – R10 and R11 (bottom entry and exit of cables) .................
Table of contents 5

47
Cabinet layout – R10 and R11 (top entry and exit of cables, options +H351
and +H353) ..................................................................................................
48Mounting plate – R10 and R11 .....................................................................
50Cooling air flow .............................................................................................
51Door switches and lights ..............................................................................
51Main switch-disconnector Q1 ...........................................................
51Control panel ................................................................................................
52Control by PC tools ...........................................................................
52Common mode filter .....................................................................................
53Overview of power and control connections .......................................................
54Descriptions of options ........................................................................................
54Degree of protection ....................................................................................
54Definitions .........................................................................................
54IP21 (UL Type 1) ...............................................................................
54IP42 (UL Type 1 Filtered) (option +B054) .........................................
54IP54 (UL Type 12) (option +B055) ....................................................
54UL Listed (option +C129) .............................................................................
55Plinth height (options +C164 and +C179) ....................................................
55Empty cubicles on right (options +C196…C198) .........................................
55Empty cubicles on left (options +C199…C201) ...........................................
55du/dtfilter (option +E205) .............................................................................
55Common mode filter (option +E208) ............................................................
55Molded case circuit breaker (MCCB, option +F289) ....................................
56Cabinet heater with external supply (option +G300) ....................................
56Terminals for external control voltage (option +G307) .................................
56Ready/Run/Fault lights (options +G327…G329) .........................................
56Top cable entry/exit (options +H351 and +H353) .........................................
56Cable conduit entry (option +H358) .............................................................
57Additional terminal block X504 (option +L504) ............................................
57Starter for auxiliary motor fan (options +M6xx) ............................................
57What the option contains ..................................................................
57Description ........................................................................................
57
Cables accepted by the terminals of the additional I/O terminal block (option
+L504) .................................................................................................................
58Type designation label ........................................................................................
58Type designation key ..........................................................................................
58Basic code ....................................................................................................
59Option codes ................................................................................................
4 Mechanical installation
63Contents of this chapter ......................................................................................
63Examining the installation site ............................................................................
64Necessary tools ..................................................................................................
64Moving and unpacking the drive .........................................................................
67Unpacking the transport package ................................................................
6 Table of contents

68Examining the delivery .................................................................................
68Lifting the cabinet .........................................................................................
70Lifting lugs .........................................................................................
72Moving the cabinet after unpacking .............................................................
73Moving the cabinet with rollers .........................................................
73Moving the cabinet to its final placement with a slate bar ................
73Attaching the cabinet to the floor and wall or roof ...............................................
73General rules ................................................................................................
74Attaching the cabinet (non-marine units) .....................................................
74Alternative 1 – Clamping ...................................................................
76Alternative 2 – Using the holes inside the cabinet ............................
77Alternative 3 – Cabinets with plinth options +C164 and +C179 .......
78Miscellaneous .....................................................................................................
78Cable duct in the floor below the cabinet .....................................................
78Arc welding ...................................................................................................
5 Guidelines for planning the electrical installation
79Contents of this chapter ......................................................................................
79Limitation of liability .............................................................................................
79Selecting the supply disconnecting device .........................................................
79Selecting the main contactor or breaker .............................................................
80Examining the compatibility of the motor and drive ............................................
80Protecting the motor insulation and bearings ...............................................
80Requirements table ......................................................................................
83Availability of du/dtfilter and common mode filter by drive type .......
83Additional requirements for explosion-safe (EX) motors ..................
83
Additional requirements for ABB motors of types other than M2_,
M3_, M4_, HX_ and AM_ .................................................................
83Additional requirements for ABB high-output and IP23 motors ........
84Additional requirements for non-ABB high-output and IP23 motors ..
85
Additional data for calculating the rise time and the peak line-to-line
voltage ..............................................................................................
87Selecting the power cables .................................................................................
87General guidelines .......................................................................................
88Typical power cable sizes ............................................................................
88Power cable types ........................................................................................
88Preferred power cable types .............................................................
89Alternate power cable types .............................................................
90Not allowed power cable types .........................................................
90Additional guidelines, North America ...........................................................
91Metal conduit ....................................................................................
91Power cable shield .......................................................................................
92Selecting the control cables ................................................................................
92Shielding ......................................................................................................
92Signals in separate cables ...........................................................................
Table of contents 7

92Signals that can be run in the same cable ...................................................
92Relay cable ..................................................................................................
92Control panel to drive cable .........................................................................
92PC tool cable ................................................................................................
93Routing the cables ..............................................................................................
93General guidelines – IEC .............................................................................
94General guidelines – North America ............................................................
95
Continuous motor cable shield/conduit or enclosure for equipment on the
motor cable ..................................................................................................
95Separate control cable ducts .......................................................................
95Implementing short-circuit and thermal overload protection ...............................
95Protecting the input cabling and drive in short-circuits .................................
96Protecting the motor and motor cable in short-circuits .................................
96Protecting the drive and the power cables against thermal overload ..........
96Protecting the motor against thermal overload ............................................
97Protecting the drive against ground faults ..........................................................
97Residual current device compatibility ...........................................................
97Implementing the emergency stop function ........................................................
97Implementing the Safe torque off function ..........................................................
97Implementing the power loss ride-through function ............................................
98Using power factor compensation capacitors with the drive ...............................
99Using a safety switch between the drive and the motor .....................................
99Implementing an ATEX-certified motor thermal protection .................................
99Controlling a contactor between drive and motor ...............................................
100Implementing a bypass connection ....................................................................
100Protecting the contacts of relay outputs ..............................................................
101Implementing a motor temperature sensor connection ......................................
102Connecting motor temperature sensor to the drive via an option module ....
103Supplying power for the auxiliary circuits ............................................................
6 Electrical installation
105Contents of this chapter ......................................................................................
105Warning ...............................................................................................................
105Attaching the device stickers on the cabinet door ..............................................
106Layout of the cable entries (frames R6…R9) .....................................................
107Layout of the cable entries (frames R10 and R11) .............................................
107Connecting the motor cable at the motor end .....................................................
108Measuring the insulation .....................................................................................
108Measuring the insulation of the drive ...........................................................
108Measuring the insulation of the input power cable .......................................
108Measuring the insulation of the motor and motor cable ...............................
109Grounding system compatibility check ...............................................................
109Connecting the power cables .............................................................................
109
Preparing the cable ends and making 360-degree grounding at the cable
entry .............................................................................................................
8 Table of contents

111Connection diagram .....................................................................................
113Connection procedure (frames R6…R9) .....................................................
114
Connection procedure (frames R6 and R7 with options +H351 and
+H353) .........................................................................................................
116
Connection procedure (frames R8 and R9 with options +H351 and
+H353) .........................................................................................................
119Connection procedure (frames R10 and R11) .............................................
120
Connection procedure (frames R10 and R11 with options +H351 and
+H353) .........................................................................................................
123Connecting the control cables ............................................................................
124Overview of control cable connection procedure .........................................
124Grounding the outer shields of the control cables at the cabinet entry ........
128Routing the control cables inside the cabinet ..............................................
131Connecting external wiring to the control unit or optional I/O terminal block .
132Connecting the emergency stop push buttons (options +Q951 and +Q963) .
132Frames R6…R9 ................................................................................
133Frames R10 and R11 ........................................................................
133Connecting the Safe torque off circuit ..........................................................
133
Connecting external power supply wires for the cabinet heater (option
+G300) .........................................................................................................
134Setting the voltage range of the auxiliary control voltage transformer (T21) ......
135Connecting a PC .................................................................................................
136Installing option modules ....................................................................................
136Option slot 2 (I/O extension modules) ..........................................................
137Option slot 1 (fieldbus adapter modules) .....................................................
137Wiring the optional modules .........................................................................
7 Control unit
139Contents of this chapter ......................................................................................
140Layout .................................................................................................................
141Default I/O connection diagram ..........................................................................
142
DI6 for internal overtemperature supervision with option +E205 in frames
R10 and R11 ................................................................................................
143PNP and NPN configurations for digital inputs ............................................
143PNP configurations with option +L504 ..............................................
143NPN configurations with option +L504 .............................................
144PNP configurations without option +L504 .........................................
144NPN configurations without option +L504 ........................................
145Switches .......................................................................................................
145Additional information on I/O connections ..........................................................
145Connection for obtaining 0…10 V from analog output 2 (AO2) ...................
146
Connection examples of two-wire and three-wire sensors to analog input
(AI2) .............................................................................................................
146DI5 as frequency input .................................................................................
146DI6 as PTC input ..........................................................................................
Table of contents 9

147
AI1 and AI2 as Pt100, Pt1000, Ni1000, KTY83 and KTY84 sensor inputs
(X1) ..............................................................................................................
147Safe torque off (X4) ......................................................................................
148Technical data .....................................................................................................
8 Installation checklist
153Contents of this chapter ......................................................................................
153Checklist .............................................................................................................
9 Start-up
155Contents of this chapter ......................................................................................
155Start-up procedure ..............................................................................................
10 Fault tracing
157Contents of this chapter ......................................................................................
157Warning and fault messages ..............................................................................
11 Maintenance
159Contents of this chapter ......................................................................................
159Maintenance intervals .........................................................................................
159Descriptions of symbols ...............................................................................
160Recommended annual maintenance actions by the user ............................
160Recommended maintenance intervals after start-up ...................................
161Cleaning the interior of the cabinet .....................................................................
161Cleaning the air inlet (door) meshes (IP42 / UL Type 1 Filtered) ........................
162Replacing the air filters (IP54 / UL Type 12) .......................................................
163Inlet (door) filters (IP54 / UL Type 12) ..........................................................
163Outlet (roof) filters (IP54 / UL Type 12) ........................................................
164Heatsink (frames R6 to R9) ...............................................................................
164Fans ....................................................................................................................
164Replacing the door fan (frames R6…R9) .....................................................
165Replacing the cabinet fan (frames R6…R9) ................................................
166Replacing the door fan (frames R10 and R11) ............................................
168Replacing the cabinet fan (frames R10 and R11, IP54 / UL Type 12) .........
169Replacing the drive module main fans (frames R6…R8) .............................
170Replacing the drive module main fans (frame R9) .......................................
171Replacing the drive module main fans (frames R10 and R11) ....................
172Replacing the auxiliary cooling fan of the drive module (frames R6…R9) ...
174
Replacing the circuit board compartment cooling fans (frames R10 and
R11) ..............................................................................................................
174Replacing the drive module (frames R6…R9) ....................................................
182Replacing the drive module (frames R10 and R11) ............................................
188Replacing the drive module (frames R10 and R11, IP54 / UL Type 12) .............
10 Table of contents

194Capacitors ...........................................................................................................
194Reforming the capacitors .............................................................................
194Fuses ..................................................................................................................
194Replacing AC fuses (frames R6 and R7) .....................................................
195Replacing AC fuses .....................................................................................
196Control panel .......................................................................................................
196Cleaning the control panel ...........................................................................
196Replacing the battery ...................................................................................
12 Technical data
197Contents of this chapter ......................................................................................
197Ratings ................................................................................................................
197IEC ratings ...................................................................................................
198UL (NEC) ratings ..........................................................................................
199Definitions ....................................................................................................
199Output derating ...................................................................................................
199Ambient temperature derating .....................................................................
199Drive types other than -0414A-4 and -0430A-4 ................................
200Drive types -0414A-4 and -0430A-4 .................................................
200Altitude derating ...........................................................................................
201Deratings for special settings in the drive control program ..........................
202Fuses (IEC) .........................................................................................................
204Fuses (UL) ..........................................................................................................
205Fuses for branch circuit protection ......................................................................
205Dimensions and weights .....................................................................................
206Free space requirements ....................................................................................
207Maximum allowed plinth height for the extraction/installation ramp ....................
207Typical power cable sizes ...................................................................................
208Losses, cooling data and noise ..........................................................................
209Terminal and entry data for the power cables .....................................................
209IEC – Standard configuration .......................................................................
210IEC – With option +E205 ..............................................................................
210US – Standard configuration ........................................................................
211US – With option +E205 ...............................................................................
212Connection drawings ..........................................................................................
238Terminal and connection data for auxiliary control circuits .................................
239Electrical power network specification ................................................................
239Motor connection data ........................................................................................
240Control unit connection data ...............................................................................
240Efficiency .............................................................................................................
240Protection classes ...............................................................................................
241Ambient conditions ..............................................................................................
242Auxiliary circuit power consumption ....................................................................
242Materials .............................................................................................................
242Cabinet .........................................................................................................
Table of contents 11

242Finish ............................................................................................................
242Package .......................................................................................................
242Vertical package ...............................................................................
243Horizontal package ...........................................................................
243
Package dimensions and weights for drives without empty cubicles (without
options +C196 … +C201) ...................................................................................
244Package weights ..........................................................................................
245Applicable standards ...........................................................................................
246Markings .............................................................................................................
246CE marking .........................................................................................................
246Compliance with the European Low Voltage Directive ................................
247Compliance with the European EMC Directive ............................................
247Compliance with the European Machinery Directive ...................................
248Compliance with the EN 61800-3:2004 .......................................................
248Definitions .........................................................................................
248Category C2 ......................................................................................
248Category C3 ......................................................................................
249Category C4 ......................................................................................
250UL marking ..........................................................................................................
250UL and CSA checklist ..................................................................................
251Design lifetime expectancy .................................................................................
252Disclaimers .........................................................................................................
252Generic disclaimer .......................................................................................
252Cybersecurity disclaimer ..............................................................................
13 Dimension drawings
254Frames R6 and R7 (IP21, UL Type 1) ................................................................
255Frames R6 and R7 (+B054: IP42, UL Type 1 Filtered) .......................................
256Frames R6 and R7 (+B055: IP54, UL Type 12) ..................................................
257Frames R6 and R7 (+H351 and +H353: top entry and exit) ...............................
258Frames R6 and R7 (+F289) ................................................................................
259Frames R6 and R7 (+F289, +H351, +H353) ......................................................
260Frames R8 and R9 (IP21, UL Type 1) ................................................................
261Frames R8 and R9 (+B054: IP42, UL Type 1 Filtered) .......................................
262Frames R8 and R9 (+B055: IP54, UL Type 12) ..................................................
263Frames R8 and R9 (+H351 and +H353: top entry and exit) ...............................
264Frames R8 and R9 (+F289) ................................................................................
265Frames R8 and R9 (+F289, +H351, +H353) ......................................................
266Frames R10 and R11 (IP21, UL Type 1) .............................................................
267Frames R10 and R11 (+B054: IP42, UL Type 1 Filtered) ...................................
268Frames R10 and R11 (+B055: IP54, UL Type 12) ..............................................
269Frames R10 and R11 (+F289) ............................................................................
270Frames R10 and R11 (+H351, +H353) ...............................................................
271Frames R10 and R11 (+B054: IP42, UL type 1 filtered, +H351, +H353) ............
272Frames R10 and R11 (+B055: IP54, UL type 12, +H351, +H353) ......................
12 Table of contents

14 The Safe torque off function
273Contents of this chapter ......................................................................................
273Description ..........................................................................................................
274Compliance with the European Machinery Directive ...................................
275Wiring ..................................................................................................................
275Connection principle ....................................................................................
275Single ACQ580-07 drive, internal power supply ...............................
276Single ACQ580-07 drive, external power supply ..............................
276Wiring examples ...........................................................................................
276Single ACQ580-07 drive, internal power supply ...............................
277Single ACQ580-07 drive, external power supply ..............................
278Multiple ACQ580-07 drives, internal power supply ...........................
279Multiple ACQ580-07 drives, external power supply ..........................
280Activation switch ...........................................................................................
280Cable types and lengths ..............................................................................
280Grounding of protective shields ...................................................................
281Operation principle ..............................................................................................
282Start-up including acceptance test ......................................................................
282Competence .................................................................................................
282Acceptance test reports ...............................................................................
282Acceptance test procedure ..........................................................................
284Use ......................................................................................................................
286Maintenance .......................................................................................................
286Competence .................................................................................................
287Fault tracing ........................................................................................................
288Safety data ..........................................................................................................
289Abbreviations ...............................................................................................
290TÜV certificate ..............................................................................................
291Declaration of conformity .............................................................................
15 CHDI-01 115/230 V digital input extension module
293Contents of this chapter ......................................................................................
293Product overview ................................................................................................
294Layout and connection examples .......................................................................
295Mechanical installation ........................................................................................
295Necessary tools ............................................................................................
295Unpacking and examining the delivery ........................................................
295Installing the module ....................................................................................
295Electrical installation ...........................................................................................
295Necessary tools ............................................................................................
295Wiring ...........................................................................................................
295Start-up ...............................................................................................................
295Setting the parameters .................................................................................
296Parameter setting example for relay output ......................................
Table of contents 13

296Fault and warning messages ..............................................................................
296Technical data .....................................................................................................
297Dimension drawing .............................................................................................
16 CMOD-01 multifunction extension module (external 24 V AC/DC and digital
I/O)
299Contents of this chapter ......................................................................................
299Product overview ................................................................................................
300Layout and example connections .......................................................................
301Mechanical installation ........................................................................................
301Necessary tools ............................................................................................
301Unpacking and examining the delivery ........................................................
301Installing the module ....................................................................................
301Electrical installation ...........................................................................................
301Necessary tools ............................................................................................
301Wiring ...........................................................................................................
302Start-up ...............................................................................................................
302Setting the parameters .................................................................................
303Diagnostics ...................................................................................................
303Faults and warning messages ..........................................................
303LEDs .................................................................................................
303Technical data .....................................................................................................
304Dimension drawing .............................................................................................
17 CMOD-02 multifunction extension module (external 24 V AC/DC and
isolated PTC interface)
307Contents of this chapter ......................................................................................
307Product overview ................................................................................................
308Layout and example connections .......................................................................
309Mechanical installation ........................................................................................
309Necessary tools ............................................................................................
309Unpacking and examining the delivery ........................................................
309Installing the module ....................................................................................
309Electrical installation ...........................................................................................
309Necessary tools and instructions .................................................................
310Wiring ...........................................................................................................
310Start-up ...............................................................................................................
310Setting the parameters .................................................................................
310Diagnostics .........................................................................................................
310Faults and warning messages .....................................................................
310LEDs ............................................................................................................
310Technical data .....................................................................................................
311Dimension drawing .............................................................................................
14 Table of contents

18 Disconnecting EMC filter and ground-to-phase varistor
313
When to disconnect the ground-to-phase varistor: TN-S, IT, corner-grounded
delta and midpoint-grounded delta systems .......................................................
315Guidelines for installing the drive to a TT system ...............................................
315Identifying the grounding system of the electrical power network ......................
317Disconnecting the EMC filter and ground-to-phase varistor (frames R6…R9) ....
317Disconnecting the ground-to-phase varistor (frames R10 and R11) ...................
Further information
Table of contents 15

16