ABB ACS580-07 User manual

—
ABB GENERAL PURPOSE DRIVES
ACS580-07
Hardware manual

ACS580-07
Hardware manual
Table of contents
1. Safety instructions
4. Mechanical installation
5. Guidelines for planning the
electrical installation
9. Start-up
© 2019 ABB Oy. All Rights Reserved. 3AXD50000045815 Rev D
EN
EFFECTIVE: 2019-07-03

Table of contents
1 Safety instructions
15Contents of this chapter ..........................................................................
15Use of warnings and notes ......................................................................
16General safety in installation, start-up and maintenance ...................................
19General safety in operation ......................................................................
20Electrical safety in installation, start-up and maintenance ..................................
20Electrical safety precautions .................................................................
22Additional instructions and notes ............................................................
23Optical components .......................................................................
23Printed circuit boards ......................................................................
23Grounding ......................................................................................
25Additional instructions for permanent magnet motor drives ................................
25Safety in installation, start-up, maintenance ...............................................
25Safety in operation ............................................................................
2 Introduction to the manual
27Contents of this chapter ..........................................................................
27Target audience ...................................................................................
27Related manuals ..................................................................................
28Categorization by frame size and option code ...............................................
28Quick installation, start-up and operating flowchart ..........................................
29Terms and abbreviations .........................................................................
3 Operation principle and hardware description
31Contents of this chapter ..........................................................................
31Product overview ..................................................................................
32Single-line circuit diagram of the drive .....................................................
33General information on the cabinet layout .................................................
33Cabinet layout – R6 and R7 (bottom entry and exit of cables) .........................
34Cabinet layout – R8 and R9 (bottom entry and exit of cables) .........................
36Mounting plate – R6 to R9 ...................................................................
38Cabinet layout – R10 and R11 (bottom entry and exit of cables) ......................
39Mounting plate ..............................................................................
41Cooling air flow ................................................................................
42Overview of power and control connections ...............................................
43Door switches and lights .....................................................................
43Main switch-disconnector Q1 ............................................................
43Control panel ...................................................................................
44Control by PC tools ........................................................................
44Common mode filter ..........................................................................
44Descriptions of cabinet options .................................................................
44Degree of protection ..........................................................................
44Definitions ...................................................................................
45IP21 ..........................................................................................
45IP42 (option +B054) .......................................................................
Table of contents 5

45IP54 (option +B055) .......................................................................
45UL listed (option +C129) .....................................................................
45Plinth height (options +C164 and +C179) .................................................
45Empty cubicles (options +C196 to +C201) ................................................
45du/dt filter (option +E205) ....................................................................
46Molded case circuit breaker (MCCB, option +F289) .....................................
46Cabinet heater with external supply (option +G300) .....................................
46Top cable entry/exit (options +H351 and +H353) .........................................
46Cable conduit entry (option +H358) ........................................................
46Additional terminal block X504 (option +L504) ............................................
47Type designation label ...........................................................................
47Type designation key .............................................................................
4 Mechanical installation
51Contents of this chapter ..........................................................................
51Examining the installation site ..................................................................
52Necessary tools ...................................................................................
53Moving and unpacking the drive ................................................................
55Unpacking the transport package ...........................................................
55Checking the delivery .........................................................................
56Lifting the cabinet ..............................................................................
57Moving the cabinet after unpacking ........................................................
57Moving on rollers ...........................................................................
58Final placement ............................................................................
58Attaching the cabinet to the floor and wall or roof ............................................
58General rules ...................................................................................
59Attaching methods ............................................................................
59Alternative 1 – Clamping ..................................................................
60Alternative 2 – Using the holes inside the cabinet ....................................
60Miscellaneous .....................................................................................
60Cable duct in the floor below the cabinet ..................................................
60Arc welding .....................................................................................
5 Guidelines for planning the electrical installation
63Contents of this chapter ..........................................................................
63Limitation of liability ...............................................................................
63Selecting the supply disconnecting device ....................................................
63Selecting the main contactor ....................................................................
64Examining the compatibility of the motor and drive ..........................................
64Protecting the motor insulation and bearings .............................................
64Requirements table ...........................................................................
67Availability of du/dtfilter and common mode filter by drive or inverter type .......
67Additional requirements for explosion-safe (EX) motors .............................
67
Additional requirements for ABB motors of types other than M2_, M3_, M4_, HX_
and AM_ .....................................................................................
67Additional requirements for braking applications ......................................
67Additional requirements for the regenerative and low harmonics drives ..........
67Additional requirements for ABB high-output and IP23 motors .....................
67Additional requirements for non-ABB high-output and IP23 motors ................
68Additional data for calculating the rise time and the peak line-to-line voltage ....
69Additional note for common mode filters ...............................................
6 Table of contents

69Selecting the power cables ......................................................................
69General guidelines ............................................................................
70Typical power cable sizes ....................................................................
71Power cable types .............................................................................
71Preferred power cable types .............................................................
71Alternate power cable types ..............................................................
72Not allowed power cable types ..........................................................
72Additional guidelines, North America .......................................................
73Metal conduit ...............................................................................
73Power cable shield ............................................................................
73Selecting the control cables .....................................................................
73Shielding ........................................................................................
74Signals in separate cables ...................................................................
74Signals that can be run in the same cable .................................................
74Relay cable type ...............................................................................
74Control panel to drive connection ...........................................................
75Routing the cables ................................................................................
75General guidelines – IEC .....................................................................
76General guidelines – North America ........................................................
77
Continuous motor cable shield/conduit or enclosure for equipment on the motor
cable .............................................................................................
77Separate control cable ducts ................................................................
77Implementing thermal overload and short-circuit protection ................................
77Protecting the input cabling and the drive upon a short-circuit .........................
77Protecting the motor and motor cable in short-circuits ...................................
77Protecting the drive and the power cables against thermal overload ..................
78Protecting the motor against thermal overload ...........................................
78Protecting the drive against ground faults .................................................
78Residual current device compatibility ...................................................
78Implementing the emergency stop function ...............................................
78Implementing the Safe Torque Off function ................................................
78Implementing the Power loss ride-through function ......................................
79Using power factor compensation capacitors with the drive ............................
79Implementing a safety switch between the drive and the motor ........................
79Using a contactor between the drive and the motor ......................................
80Implementing a bypass connection .........................................................
80Implementing the ATEX-certified Safe motor disconnection function (option +Q971) .
80Protecting the contacts of relay outputs ....................................................
81Connecting motor temperature sensor to the drive via an option module ............
82Protecting the drive against ground faults .....................................................
82Residual current device compatibility ......................................................
82Implementing the emergency stop function ...................................................
82Implementing ATEX-certified thermistor protection ..........................................
82Implementing the Safe torque off function ....................................................
82Implementing the ATEX-certified Safe motor disconnection function (option +Q971) ...
83Implementing the Power-loss ride-through function .........................................
83Units with line contactor (option +F250) ...................................................
83Supplying power for the auxiliary circuits ......................................................
83Using power factor compensation capacitors with the drive ................................
83Implementing a safety switch between the drive and the motor ...........................
84Using a contactor between the drive and the motor .........................................
84Implementing a bypass connection ............................................................
Table of contents 7

84Protecting the contacts of relay outputs .......................................................
85Implementing a motor temperature sensor connection .....................................
6 Electrical installation
87Contents of this chapter ..........................................................................
87Warnings ...........................................................................................
87Attaching the device stickers on the cabinet door ...........................................
88Layout of the cable entries (frames R6 to R9) ................................................
89Layout of the cable entries (frames R10 and R11) ...........................................
90Connecting the power cables ...................................................................
90Connection diagram ..........................................................................
91Checking the insulation of the drive system ...............................................
91Checking the insulation of the input cable .................................................
91
Checking the compatibility with IT (ungrounded), corner-grounded delta, midpoint-
grounded delta, and TT systems ............................................................
91Ground-to-phase varistor .................................................................
91
When to disconnect the ground-to-phase varistor: TN-S, IT, corner-grounded
delta and midpoint-grounded delta systems ...........................................
92Guidelines for installing the drive to a TT system .....................................
93Identifying different types of electrical power systems ...............................
94Disconnecting the EMC filter and ground-to-phase varistor (R6 to R9) ...........
94Disconnecting the ground-to-phase varistor (R10 and R11) ........................
96Connecting the motor cable at the motor end .............................................
96Checking the insulation of the motor and motor cable ...............................
96Connection procedure (IEC, frames R6 to R9) ...........................................
100Connection procedure (IEC, frames R10 and R11) ......................................
104Connecting the control cables ..................................................................
104Overview of control cable connection procedure .........................................
105Grounding the outer shields of the control cables at the cabinet entry ................
107Routing the control cables inside the cabinet .............................................
108Connecting external wiring to the control unit or optional I/O terminal block .........
109Connecting the emergency stop push buttons (options +Q951 and +Q963) .........
109Connecting the Safe torque off circuit ......................................................
110Connecting external power supply wires for the cabinet heater (option +G300) .....
111Setting the voltage range of the auxiliary control voltage transformer (T21) .............
111Connecting a PC ..................................................................................
112Installing option modules ........................................................................
112Option slot 2 (I/O extension modules) ......................................................
113Option slot 1 (fieldbus adapter modules) ..................................................
113Wiring the optional modules .................................................................
7 Control unit
115Contents of this chapter ..........................................................................
115Layout ..............................................................................................
117Default I/O connection diagram .................................................................
118Option +E205 in frames R10 and R11: DI6 internal overtemperature supervision ...
118Power supply connections for PNP with option +L504 ...............................
119Power supply connections for NPN with option +L504 ...............................
119Power supply connections for PNP without option +L504 ...........................
119Power supply connections for NPN without option +L504 ...........................
120Changing internal overtemperature supervision from DI6 to another digital input .
8 Table of contents

120Switches ........................................................................................
120PNP configuration for digital inputs (X2 & X3) ............................................
121NPN configuration for digital inputs (X2 & X3) ............................................
121Connection for obtaining 0…10 V from analog output 2 (AO2) .........................
122Connection examples of two-wire and three-wire sensors to analog input (AI2) ....
122DI6 as frequency input ........................................................................
122DI6 as PTC input ..............................................................................
123AI1 and AI2 as Pt100, Pt1000, Ni1000, KTY83 and KTY84 sensor inputs (X1) .....
123Safe torque off (X4) ...........................................................................
125Technical data .....................................................................................
8 Installation checklist of the drive
129Contents of this chapter ..........................................................................
129Checklist ...........................................................................................
9 Start-up
131Contents of this chapter ..........................................................................
131Start-up procedure ................................................................................
10 Fault tracing
133Contents of this chapter ..........................................................................
133Warning and fault messages ....................................................................
11 Maintenance
135Contents of this chapter ..........................................................................
135Maintenance intervals ............................................................................
135Descriptions of symbols ......................................................................
136Recommended annual maintenance actions by the user. ..............................
136Recommended maintenance intervals after start-up .....................................
136Cleaning the interior of the cabinet .............................................................
137Cleaning the air inlet (door) meshes (IP42 / UL Type 1 Filtered) ..........................
137Replacing the air filters (IP54 / UL Type 12) ..................................................
137Inlet (door) filters (IP54 / UL Type 12) ......................................................
138Outlet (roof) filters (IP54 / UL Type 12) .....................................................
138Heatsink ............................................................................................
139Fans ................................................................................................
139Replacing the door fan (frames R6 to R9) .................................................
140Replacing the cabinet fan (frames R6 to R9) .............................................
141Replacing the door fan (frames R10 and R11) ............................................
143Replacing the cabinet fan (frames R10 and R11, IP54) .................................
144Replacing the drive module main fans (frames R6 to R8) ..............................
145Replacing the drive module main fans (frame R9) .......................................
146Replacing the drive module main fans (frames R10 and R11) .........................
147Replacing the auxiliary cooling fan of the drive module (frames R6 to R9) ...........
147Replacing the circuit board compartment cooling fans (frames R10 and R11) .......
148Replacing the drive module (frames R6 to R9) ...............................................
154Replacing the drive module (frames R10 and R11) ..........................................
160Replacing the drive module (frames R10 and R11, IP54) ..................................
166Capacitors .........................................................................................
166Reforming the capacitors .....................................................................
Table of contents 9

166Fuses ...............................................................................................
166Replacing AC fuses (frames R6 and R7) ..................................................
167Replacing AC fuses ...........................................................................
168Control panel ......................................................................................
168Cleaning the control panel ...................................................................
168Replacing the battery in the assistant control panel ......................................
12 Technical data
171Contents of this chapter ..........................................................................
171Ratings .............................................................................................
172NEC ratings ....................................................................................
173Definitions ......................................................................................
173Output derating ....................................................................................
173Ambient temperature derating ...............................................................
173Drive types other than ACS580-0414A-4 and ACS580-0430A-4 ...................
174Drive types ACS580-0414A-4 and ACS580-0430A-4 ................................
174Altitude derating ...............................................................................
175Deratings for special settings in the drive control program ..............................
176Fuses (IEC) ........................................................................................
177Fuses (UL) .........................................................................................
178Fuses for branch circuit protection .............................................................
179Dimensions and weights .........................................................................
179Free space requirements ........................................................................
180Maximum allowed plinth height for the extraction/installation ramp .......................
180Typical power cable sizes .......................................................................
181Losses, cooling data and noise .................................................................
182Terminal and entry data for the power cables ................................................
182IEC – Standard configuration ................................................................
182IEC – With option +E205 .....................................................................
182US – Standard configuration .................................................................
183US – With option +E205 ......................................................................
184Connection drawings .............................................................................
210Terminal and connection data for auxiliary control circuits ..................................
211Electrical power network specification .........................................................
211Motor connection data ...........................................................................
211Control unit connection data ....................................................................
211Efficiency ...........................................................................................
212Protection classes ................................................................................
213Ambient conditions ...............................................................................
213Auxiliary circuit power consumption ............................................................
214Materials ...........................................................................................
215Applicable standards .............................................................................
216Markings ...........................................................................................
216CE marking ........................................................................................
216Compliance with the European Low Voltage Directive ..................................
216Compliance with the European EMC Directive ...........................................
216Compliance with the European Machinery Directive .....................................
217Declaration of Conformity .................................................................
219Compliance with the EN 61800-3:2004 ....................................................
219Definitions ...................................................................................
219Category C2 ................................................................................
219Category C3 ................................................................................
10 Table of contents