ABB ACS260-04 Series User manual

—
ABB MACHINERY DRIVES
ACS260-04 Component Drive
User’s manual
ACS260-04.book Page 1 Thursday, December 24, 2020 4:33 PM

ACS260-04.book Page 2 Thursday, December 24, 2020 4:33 PM

ACS260 Compenent Drive
User’s Manual
3AXD50000672080 Rev A
EN
EFFECTIVE: 2020-12-23
2020 ABB Oy. All Rights Reserved.
1. Safety
Table of contents
3. Mechanical installation
4. Electrical installation
5. Start-up
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Table of contents 5
Table of contents
1. Safety
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Use of warning symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Safety in installation and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Electricity safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
General safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Safety in start-up and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2. Introduction to the manual
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Type designation key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Cybersecurity disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3. Mechanical installation
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Mechanical Dimensions and Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Frame size R1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Frame size R2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Heatsink Capacity Calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Maximum Permissible Heatsink Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Typical Heatsink Requirement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Three Phase Input 380 – 480VAC Supply Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4. Electrical installation
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Power Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Protective Earth (PE) Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Grounding Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Protective Earth Conductor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
PE Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Safety Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Motor Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Ground Fault Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Shield Termination (Cable Screen) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Incoming Power Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Cable Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Fuse / Circuit Breaker Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Motor Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Motor Terminal Box Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
EMC Compliant Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Safety
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6 Table of contents
Conducted Emissions According to EN61800-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Radiated Emissions According to EN61800-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5. Start-up
Motor Control Selection (Advanced Parameter Mode) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Operating Mode Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Quick Start-up Terminal Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Quick Start-up Keypad Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Drive Operating Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Drive Operating Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
6. Application Macros
Overview of macros . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Quick Start-up Terminal Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Terminal Mode 1103 PRIMARY COMMAND SOURCE MODE = 0 . . . . . . . . . . . . . . . . 38
Keypad Mode 1103 PRIMARY COMMAND SOURCE MODE = 1 or 2 . . . . . . . . . . . . . . 41
Modbus Control Mode 1103 PRIMARY COMMAND SOURCE MODE = 4 . . . . . . . . . . . 42
PI Mode 1103 PRIMARY COMMAND SOURCE MODE = 5 . . . . . . . . . . . . . . . . . . . . . . 43
7. Parameters
Parameter Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Group Navigation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Parameter Structure table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
PAR-A Parameter list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Parameters in the Long parameter mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Parameter access locking/unlocking system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Relevant Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Locking Parameter Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Unlocking Parameter Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Terminal Configuration Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Terminal Mode: (1103 = 0) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Modbus control mode: (1103 = 3, 4, 7, 8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
8. Fault tracing
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Fault Code Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
9. Serial Communications
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Modbus RTU Communications Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
RJ45 Connector Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Modbus Telegram Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
RJ45 Data Connection Pin Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Modbus Register Map . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Control and status registers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Control and Status Register Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Read-Write Registers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
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Table of contents 7
Parameter Registers and Scaling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Additional Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
DC Injection Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Communications Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Modbus Exception Response Telegrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Dataflow Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
10. Technical Data
Environmental . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Digital & Analog I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Digital Inputs Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Analog Inputs Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Analog Output Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Relay Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Response Times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Motor Control Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
V/F Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Vector Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Under / Over Voltage Trip Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Automatic Switching Frequency Reduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Output Frequency based Effective Switching Frequency Reduction . . . . . . . . . . . . . . . . 88
Output Current Based Effective Switching Frequency Reduction . . . . . . . . . . . . . . . . . . . 89
Rating table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
11. Options and Kits
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Remote Keypad RCRP-02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
COPYSTICK2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
USB PC Connection Kit ECS100U . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Further information
Product and service inquiries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Product training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Providing feedback on ABB Drives manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Document library on the Internet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
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8 Table of contents
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Safety 9
1
Safety
Contents of this chapter
This chapter contains the safety instructions which you must follow when installing,
operating and servicing the drive. If ignored, physical injury or death may follow, or
damage may occur to the drive, motor or driven equipment. Read the safety
instructions before you work on the unit.
Use of warning symbols
Warnings caution you about conditions which can result in serious injury or death
and/or damage to the equipment and advice on how to avoid the danger. The
following warning symbols are used in this manual:
WARNING! Electricity warning warns of hazards from electricity which can
cause physical injury and/or damage to the equipment.
WARNING! General danger warns about conditions, other than those caused
by electricity, which can result in physical injury and/or damage to the
equipment.
Safety in installation and maintenance
These warnings are intended for all who work on the drive, motor cable or motor.
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10 Safety
Electricity safety
WARNING! Ignoring the instructions can cause physical injury or death, or
damage to the equipment. Only qualified electricians are allowed to install
and maintain the drive!
• Never work on the drive, motor cable or motor when input power is applied. After
disconnecting the input power, always wait for 10 minutes to let the intermediate
circuit capacitors discharge before you start working on the drive, motor or motor
cable.
Always ensure by measuring with a multimeter (impedance at least 1 Mohm) that:
• There is no voltage between the drive input phases L1, L2 and L3 and the
ground.
• There is no voltage between terminals + and BR and the ground.
• Do not work on the control cables when power is applied to the drive or to the
external control circuits. Externally supplied control circuits may carry dangerous
voltage even when the input power of the drive is switched off.
• Do not make any insulation or voltage withstand tests on the drive.
• Be sure the system is properly grounded before applying power. Do not apply AC
power before you ensure that all grounding instructions have been followed.
Electrical shock can cause serious or fatal injury.
Note:
Even when the motor is stopped, dangerous voltage is present at the power circuit
terminals L1, L2, L3 and U, V, W and + and BR.
General safety
WARNING! Ignoring the following instructions can cause physical injury or
death, or damage to the equipment.
• The drive is not field repairable. Never attempt to repair a malfunctioning drive;
contact your local ABB representative or Authorized Service Centre for
replacement.
• Make sure that dust from drilling does not enter the drive during the installation.
Electrically conductive dust inside the drive may cause damage or lead to
malfunction.
• Ensure sufficient cooling.
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Safety 11
Safety in start-up and operation
These warnings are intended for all who plan the operation, start up or operate the
drive.
WARNING! Ignoring the following instructions can cause physical injury or
death, or damage to the equipment.
• Before adjusting the drive and putting it into service, make sure that the motor
and all driven equipment are suitable for operation throughout the speed
range provided by the drive. The drive can be adjusted to operate the motor at
speeds above and below the speed provided by connecting the motor directly
to the power line.
• Do not activate automatic fault reset functions if dangerous situations can
occur. When activated, these functions reset the drive and resume operation
after a fault.
• Do not control the motor with an AC contactor or disconnecting device
(disconnecting means); use instead the control panel start and stop keys and
or external commands (I/O). The maximum allowed number of charging
cycles of the DC capacitors (that is, power-ups by applying power) is two per
minute.
Note:
When parameter 1103 PRIMARY COMMAND SOURCE MODE is not set to 1 or 2,
the stop key on the control panel will not stop the drive. To stop the drive open
terminal 2 of the drive control terminals.
Danger: Indicates a risk of electric
shock, which, if not avoided, could
result in damage to the equipment
and possible injury or death.
Danger: Indicates a potentially
hazardous situation other than
electrical, which if not avoided,
could result in damage to
property.
The ACS260 variable speed drive is intended for professional installation and
commissioning into complete equipment or systems as part of a fixed installation.
If installed incorrectly it may present a safety hazard. The ACS260 uses high
voltages and currents, carries a high level of stored electrical energy, and is used
to control mechanical plant that may cause injury. Close attention is required to
system design and electrical installation to avoid hazards in either normal
operation or in the event of equipment malfunction. Only qualified electricians are
allowed to install and maintain this product.
System design, installation, commissioning and maintenance must be carried out
only by personnel who have the necessary training and experience. They must
carefully read this safety information and the instructions in this Guide and follow
all information regarding transport, storage, installation and use of the ACS260,
including the specified environmental limitations.
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12 Safety
Do not perform any flash test or voltage withstand test on the ACS260. Any
electrical measurements required should be carried out with the ACS260
disconnected.
Electric shock hazard! Disconnect and ISOLATE the ACS260 before attempting
any work on it. High voltages are present at the terminals and within the drive for
up to 10 minutes after disconnection of the electrical supply. Always ensure by
using a suitable multimeter that no voltage is present on any drive power terminals
prior to commencing any work.
Where supply to the drive is through a plug and socket connector, do not
disconnect until 10 minutes have elapsed after turning off the supply.
Ensure correct grounding connections. The ground cable must be sufficient to
carry the maximum supply fault current which normally will be limited by the fuses.
Suitably rated fuses should be fitted in the mains supply to the drive, according to
any local legislation or codes.
Do not carry out any work on the drive control cables when power is applied to the
drive or to the external control circuits.
Within the European Union, all machinery in which this product is used must
comply with the Machinery Directive 2006/42/EC, Safety of Machinery. In
particular, the machine manufacturer is responsible for providing a main switch
and ensuring the electrical equipment complies with EN60204-1.
The level of integrity offered by the ACS260 control input functions – for example
stop/start, forward/reverse and maximum speed is not sufficient for use in safety-
critical applications without independent channels of protection. All applications
where malfunction could cause injury or loss of life must be subject to a risk
assessment and further protection provided where needed.
The driven motor can start at power up if the enable input signal is present.
The STOP function does not remove potentially lethal high voltages. ISOLATE the
drive and wait 10 minutes before starting any work on it. Never carry out any work
on the Drive, Motor or Motor cable when the input power is still applied.
The ACS260 can be programmed to operate the driven motor at speeds above or
below the speed achieved when connecting the motor directly to the mains supply.
Obtain confirmation from the manufacturers of the motor and the driven machine
about suitability for operation over the intended speed range prior to machine start
up.
Do not activate the automatic fault reset function on any systems whereby this
may cause a potentially dangerous situation.
The ACS260 has an Ingress Protection rating of IP20. IP20 units must be installed
in a suitable enclosure.
ACS260s are intended for indoor use only.
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Safety 13
When mounting the drive, ensure that sufficient cooling is provided. Do not carry
out drilling operations with the drive in place, dust and metal shavings from drilling
may lead to damage.
The entry of conductive or flammable foreign bodies should be prevented.
Flammable material should not be placed close to the drive
Relative humidity must be less than 95% (non-condensing).
Ensure that the supply voltage, frequency and number of phases correspond to
the rating of the ACS260 as delivered.
Never connect the mains power supply to the Output terminals U, V, W.
Do not install any type of automatic switchgear between the drive and the motor.
Wherever control cabling is close to power cabling, maintain a minimum
separation of 4 in. (100 mm) and arrange crossings at 90 degrees
Ensure that all terminals are tightened to the appropriate torque setting.
Do not attempt to carry out any repair of the drive. In the case of suspected fault or
malfunction, contact your local ABB representative for further assistance.
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14 Safety
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Introduction to the manual 15
2
Introduction to the manual
Contents of this chapter
This chapter contains information about the ACS260 including how to identify the
drive.
Type designation key
The type designation contains information on the specification and configuration of
the drive. You find the type designation label attached to the drive. The first digits
from the left express the basic configuration, for example ACS260-04-02A2-4.
The explanations of the type designation label selections are described below.
Sample type code: ACS260-04-02A2-4.
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,
Segment A B C
ACS260 - 04 - 02A2 - 4
Code Description
AConstruction 04 = Module
BCurrent rating For example, 02A2 refers to a nominal output current of 2.2 A.
CVoltage rating 4 = 3-phase 380...480 V
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16 Introduction to the manual
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.
See also section Locking Parameter Access (page 65).
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Mechanical installation 17
3
Mechanical installation
Contents of this chapter
The chapter describes the mechanical installation procedure of the drive.
General
WARNING! ACS260 units may become damaged if operated without a
suitable heatsink. Do not operate the unit without providing suitable heatsink
capacity for the drive and application requirement.
• ACS260 Power Modules must be mounted onto a suitable flat metallic surface
with sufficiently low thermal resistance to allow dissipation of the heat produced.
• Surface flatness must be =<+ / - 0.2mm over the mounting area.
• The chosen mounting location must ensure the unit is not subject to vibration
levels in excess of the limits specified in section Vibration.
• Units should be mounted only using the integral mounting holes.
• The ACS260 must be installed in a pollution degree 1 or 2 environment only.
• Ensure that the ambient air temperature range around the unit during operation
does not exceed the permissible limits given in section 11.1.
• Do not mount flammable material close to the ACS260.
• Units may be mounted in any orientation.
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18 Mechanical installation
Mechanical Dimensions and Mounting
Frame size R1
Overall Dimensions
Mounting Points
Depth:
74mm,
Weight:
0.7kg, 1.54lb
Use 3 x M4 (No. 8) bolts or
screws,
tightening torque: 4Nm / 3ft-lb
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Mechanical installation 19
Frame size R2
Overall Dimensions
Mounting Points
Depth:
89mm,
Weight:
1.3kg, 2.87lb
Use 3 x M4 (No. 8) bolts or
screws, tightening torque:
4Nm / 3ft-lb
tightening torque: 4Nm / 3ft-lb
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20 Mechanical installation
Heatsink Capacity Calculation
ACS260 Units are designed to be mounted to a metallic, heat conducting surface in
order to maintain the unit operating temperature. Thermostrate or heatsink compound
must be added to ensure optimal heat transfer and minimum thermal resistance.
In order to calculate the necessary heatsink requirement, the following formula can
be used. Example values based on typical conditions are given in the table below.
• Determine the maximum ambient air temperature around the heatsink, TAMB
• Select the desired PWM operating frequency from the available options in
Parameter 2606.
• From the table below, determine the maximum permissible heatsink temperature,
TMAX
• Determine the maximum allowed Temperature Rise
•T
RISE = TMAX - TAMB
• Calculate the motor absorbed electrical power, PMOT, based on the motor rated
voltage, current and efficiency
•P
MOT = √3 * Rated Voltage * Rated Current * Power Factor * Efficiency
• Calculate the losses in the drive, PLOSS, based on the required motor power
•P
LOSS = PMOT * (1 - Drive Efficiency)
• Typical drive efficiency values are shown in the table below for each available
effective switching frequency
• Calculate the required heatsink maximum thermal resistance RMAX
•R
MAX = TRISE / PLOSS
Maximum Permissible Heatsink Temperature
The maximum permissible heatsink temperature allowed for the ACS260 drive is
linked to the desired effective switching frequency selected by parameter 2606. In
order to maintain operation at a certain switching frequency, the heatsink temperature
must be maintained below the threshold level shown in the table below. If the tem-
perature exceeds the threshold, the switching frequency will automatically reduce.
Note: Switching frequency may be automatically reduced under certain operating
conditions, refer to section Automatic Switching Frequency Reduction on page 88 for
further information.
Temperature Threshold Action
65℃Auto reduce from 32kHz to 24kHz
70℃Auto reduce from 24kHz to 16kHz
80℃Auto reduce from 16kHz to 12kHz
85℃Auto reduce from 12kHz to 8kHz
94℃Over temperature trip if 2606 >= 8kHz
97℃Over temperature trip if 2606< 8kHz
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