ABB ACS560 Installation manual

—
ABB GENERAL PURPOSE DRIVES
ACS560 standard control program
Quick installation and start-up guide
EN
English ............ 3
HI
 ............. 117

EN - Quick installation and start-up
guide
This guide briefly instructs how to install and start-up the ACS560 drive of all frame sizes
(R0...R8). For complete information, see the drive ACS560 standard control program firmware
manual (3AXD50000044997[English]) and ACS560 drives (0.75 to 160 kW, 1.0 to 215 hp)
hardware manual (3AXD50000044998[English]).
General considerations
￭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.
￭Reform the capacitors
Reform the capacitors if the drive is stored for a year or more.
The manufacturing date is on the type designation label which is attached to the drive. The
serial number format MYYWWRXXXX represents the month, year and the week.
YY: 13, 14, 15, … for 2013, 2014, 2015, …
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]).
￭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. See Ratings (page 93).
￭Ensure the cooling
The maximum ambient temperature without derating is:
• 50 °C (+122 °F) for R0...R2 frames
EN - Quick installation and start-up guide 3
EN
HI

• 40°C (+104 °F) for R3...R8 frames
No condensation or frost is allowed. For more information on the ambient temperature, see
the hardware manual.
￭Protect the drive and input power cable
If you use gG fuses, make sure that the operating time of the fuse is below 0.5 seconds.
Follow the local regulations.
4 EN - Quick installation and start-up guide
EN
HI

Install the drive
You can install the drive
• to a DIN installation rail with integrated lock. This method applies to frames R0...R2
only.
or
• with screws to a suitable surface (wall or assembly plate). This method applies to all
frames R0...R8.
￭Required tools for installing the drive
• A drill and suitable drill bits.
• Screwdriver (Standard, Phillips head, and Torx)
• wrench with suitable bits and sizes (appropriate for the installation hardware used). See
the required screw sizes in below installation instructions
• A tape measure and spirit level.
• Personal protective equipment.
￭Installing a drive to DIN installation rail (frames R0...R2 only)
1. On the top center of the drive move the locking part to the left.
2. Push and hold the locking button down.
3. Put the top tabs on the drive onto the top edge of the DIN rail.
4. Put the drive against the bottom edge of the DIN installation rail.
5. Release the locking button.
6. Move the locking part to the right.
7. Make sure the drive is installed correctly.
￭Removing drive from the DIN installation rail (frames R0...R2 only)
To remove the drive, open the locking part using a flat-head screwdriver.
EN - Quick installation and start-up guide 5
EN
HI

￭Installing a drive with screws (frames R0...R8)
All drives of frames R0...R8 can be installed on the wall with screws. See the required screw
sizes in below mounting dimensions table. See also Dimensions, weights and free space
requirements (page 99)
WARNING!
The drive module (frames R6...R8) is heavy (45 to 70 kg). Consider the following:
• 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 data
in the table below.
1. Mark the mounting hole locations using the mounting template included in the package.
Mounting dimensionsMounting template
R8R7R6R5R4R3R2R1R0Frames
M8M6M5Screws
(mm)
658583531581619473191a
701623571612-b
2632452131601487550
-75d
20075e
70.055.045.028.023.014.867.544.574.47Weight
(kg)
2. Drill the mounting holes.
3. Tighten the screws into the mounting holes.
4. Position the drive onto the screws on the wall.
5. Tighten the mounting screws.
6 EN - Quick installation and start-up guide
EN
HI

See the example of mounting screws in frame R0
6. Frames R5...R8 only: Remove the front cover with fastening screws (6a), move the
cover to the top side (6b) and then up (6c).
7. Frames R5...R8 only: Attach the cable conduit box to the drive frame.
Note:
Cable conduit box is optional and is not part of standard delivery.
8. Frames R5...R8 only: Tighten the box screws: two at the top and four at the bottom.
EN - Quick installation and start-up guide 7
EN
HI

Checking the insulation of the motor and motor cable
Obey the safety instructions of the drive. If you ignore them, injury or death,
or damage to the equipment can occur.
If you are not a qualified electrician, do not do installation or maintenance
work.
1. Stop the drive and do the steps in section Electrical safety precautions before you start
the work.
2. Check that the motor cable is disconnected from the drive output terminals U2, V2 and
W2.
3. Measure the insulation resistance between the phase conductors and then between
each phase conductor and the Protective Earth conductor. Use 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, consult
the manufacturer’s instructions.
Note:
Moisture inside the motor casing reduces the insulation resistance. If moisture is
suspected, dry the motor and repeat the measurement.
1000 V DC,
>100 Mohm
U1-V1, U1-W1, V1-W1
U1-PE, V1-PE, W1-PE
M
3~
U1
V1
W1 PE
ohm
ohm
8 EN - Quick installation and start-up guide
EN
HI

Connecting the power cables
￭Connection diagram
For alternatives, see hardware manual.1
Use a separate grounding PE cable (2a) or a cable with a separate PE conductor (2b) if the conductivity
of the shield does not meet the requirements for the PE conductor (see hardware manual).
2
360-degree grounding is recommended if shielded cable is used. Ground the other end of the input cable
shield or PE conductor at the distribution board.
3
360-degree grounding is required.4
External brake resistor (for frames R4...R8 only).5
Use a separate grounding cable if the shield does not meet the requirements of IEC 61439-1 and there
is no symmetrically constructed grounding conductor in the cable. For more information, see hardware
manual.
6
Note:
If there is a symmetrically constructed grounding conductor on the motor cable in addition to the conductive
shield, connect the grounding conductor to the grounding terminal at the drive and motor ends.
Do not use an asymmetrically constructed motor cable for motors above 30 kW. Earthing at the motor increases
bearing current and power consumption, damages the motor bearing and even the motor.
EN - Quick installation and start-up guide 9
EN
HI

￭Connection procedure: frames R0…R2
WARNING!
If the drive is connected on an IT (ungrounded) system, make sure that the EMC
Filter and Varistor (VAR) is disconnected. For more information, see hardware
manual.
1. Remove the front cover as follows:
• Loosen the retaining screw with a screwdriver (1a).
• Lift the cover from the bottom outwards (1b).
1a
1b
Motor cable
2. Prepare the ends of the cable as illustrated in the figure. Two different motor cable types
are shown in the figures (2a.and 2b).
Note:
The bare shield will be grounded 360 degrees.
10 EN - Quick installation and start-up guide
EN
HI