ABB ACS560 User manual
—
ABB GENERAL PURPOSE DRIVES
ACS560 drives (0.75 to 160 kW, 1.0 to 215 hp)
Hardware manual
Table of contents
1 Safety instructions
15Contents of this chapter .........................................................................................
15Use of warnings and notes .....................................................................................
16General safety in installation, start-up and maintenance ................................
18Electrical safety in installation, start-up and maintenance .............................
18Electrical safety precautions ..........................................................................
19Additional instructions and notes .................................................................
19Printed circuit boards ..........................................................................
20Grounding ...........................................................................................................
21General safety in operation ....................................................................................
21Additional instructions for permanent magnet motor drives ........................
21Safety in installation, start-up, maintenance ..............................................
22Safety in operation ...........................................................................................
2 Introduction to the manual
23Contents of this chapter .........................................................................................
23Applicability ...............................................................................................................
23Target audience ........................................................................................................
23Purpose of the manual ............................................................................................
23Categorization by frame (size) ..............................................................................
24Quick installation and commissioning flowchart ..............................................
25Terms and abbreviations ........................................................................................
27Related documents ..................................................................................................
3 Operation principle and hardware description
29Contents of this chapter .........................................................................................
30Operation principle ..................................................................................................
31Layout .........................................................................................................................
31Frames R0...R2 ...................................................................................................
32Frames R3 ...........................................................................................................
34Frames R4…R8 ..................................................................................................
36Overview of power and control connections ......................................................
37External control connecting terminal, frames R0…R2 ..............................
40External control connecting terminal, frames R3...R5 ...............................
42External control connection terminals, frames R6…R8 ............................
45Mounting option .......................................................................................................
45Control panel .............................................................................................................
Table of contents 5
46Type designation label ............................................................................................
47Locations of the labels on the drive ..............................................................
48Type designation key ...............................................................................................
4 Mechanical installation
51Contents of this chapter .........................................................................................
52Safety ...................................................................................................................
53Checking the installation site ................................................................................
54Required tools ...........................................................................................................
55Moving the drive .......................................................................................................
55Unpacking and examining delivery, frames R0…R2 ..........................................
56Unpacking and examining delivery, frames R3...R4 ...........................................
57Unpacking and examining delivery, frames R5 ...................................................
59Unpacking and examining delivery, frames R6…R8 ..........................................
61Installing the drive ....................................................................................................
61Installing the drive vertically, frames R0…R2 ..............................................
62Installing the drive vertically, frames R3...R4 ...............................................
63Installing the drive vertically, frames R5…R8 ..............................................
65Installing the drive vertically side by side ....................................................
65Installing the drive horizontally side by side ...............................................
5 Planning the electrical installation
67Contents of this chapter .........................................................................................
67Selecting the supply disconnecting device .........................................................
67European Union .................................................................................................
68Other regions .....................................................................................................
68Checking the compatibility of the motor and drive ..........................................
68Selecting the power cables ....................................................................................
68General rules ......................................................................................................
69Typical power cable sizes ................................................................................
70Alternative power cable types ........................................................................
70Recommended power cable types ....................................................
70Power cable types for limited use .....................................................
71Not allowed power cable types ..........................................................
71Motor cable shield .............................................................................................
71Conduit ...................................................................................................
72Armored cable / shielded power cable .............................................
72Selecting the control cables ...................................................................................
72Shielding .............................................................................................................
72Signals in separate cables ...............................................................................
73Signals allowed to be run in the same cable ................................................
73Relay cable ..........................................................................................................
73Control panel cable ...........................................................................................
73Drive composer PC tool cable .........................................................................
6 Table of contents
73Routing the cables ............................................................................................
73General guidelines – IEC ......................................................................
74General guidelines – North America ..................................................
75
Continuous motor cable shield/conduit or enclosure for
equipment on the motor cable ..........................................................
76Separate control cable ducts .............................................................
76Implementing thermal overload and short-circuit protection ................
77Protecting the drive against ground faults .........................................................
77Residual current device compatibility ..........................................................
77Implementing the Emergency stop function ..............................................
77Implementing the Safe torque off function ........................................................
78Implementing the undervoltage control (power-loss ride-through) .............
78Using a contactor between the drive and the motor ........................................
78Implementing a bypass connection ..............................................................
79Example bypass connection ...........................................................................
80Switching the motor power supply from drive to direct-on-line .
80Switching the motor power supply from direct-on-line to drive .
80Protecting the contacts of relay outputs ............................................................
6 Electrical installation
83Contents of this chapter .........................................................................................
83Warnings ....................................................................................................................
83Required tools ...........................................................................................................
84Checking the insulation of the assembly ............................................................
84Drive .....................................................................................................................
84Input power cable .............................................................................................
84Measuring the insulation resistance of the motor and motor cable ......
85Brake resistor assembly R0...R3 .....................................................................
85
Checking the compatibility with IT (ungrounded) and corner-grounded TN
systems ......................................................................................................................
85EMC filter ............................................................................................................
86Ground-to-phase varistor ................................................................................
87Frames R0…R3 ..................................................................................................
87Frames R4…R8 ..................................................................................................
90Connecting the power cables ................................................................................
90Connection diagram .........................................................................................
91Connection procedure: frames R0…R2 ........................................................
91Motor cable ............................................................................................
93Input power cable .................................................................................
94Finalization .............................................................................................
95Connection procedure, frames R3...R4 .........................................................
95Motor cable ............................................................................................
96Notes: ......................................................................................................
96Input power cable .................................................................................
98Finalization .............................................................................................
Table of contents 7
100Connection procedure, frames R5…R8 ........................................................
101Motor cable ............................................................................................
102Input power cable .................................................................................
104DC connection ...........................................................................................................
104Connecting the control cables ...............................................................................
105Default control connections of ABB standard macro .......................................
105Connection diagram .........................................................................................
106Terminal sizes ........................................................................................
106Notes: ......................................................................................................
107Switches .....................................................................................................................
107PNP configuration for digital inputs ....................................................................
108NPN configuration for digital inputs ....................................................................
108Connection for obtaining 0…10 V from analog output 2 (AO2) .....................
109Connection examples of two-wire and three-wire sensors .............................
110DI5 as frequency input .............................................................................................
110AI1 and AI2 as Pt100 sensor inputs (X1) ...............................................................
111Safe torque off (X4) .................................................................................................
111Control cable connection procedure R0…R8 .....................................................
113R0...R2 ..................................................................................................................
114R3...R5 ..................................................................................................................
115R6...R8 ..................................................................................................................
115
Auxiliary voltage connection (For R0...R2 frames with optional BAPO-01
module) ......................................................................................................................
116Installing option modules .......................................................................................
118To install a front option ...................................................................................
119Front option slot 1 ................................................................................
120Front option slot 2 (applicable for R3...R5 frames) ........................
121To remove a front option ................................................................................
121To install a side option .....................................................................................
122To remove a side option ..................................................................................
122Wiring the modules ...........................................................................................
122Reinstalling covers ...................................................................................................
122Reinstalling cover, frames size R0…R2 .........................................................
123Reinstalling covers, frame size R3, R4 ...........................................................
123Reinstalling side plates and covers, frames size R5…R8 ..........................
124Connecting a PC .......................................................................................................
7 Installation checklist
127Contents of this chapter .........................................................................................
127Checklist .....................................................................................................................
8 Maintenance and hardware diagnostics
129Contents of this chapter .........................................................................................
8 Table of contents
129Maintenance intervals .............................................................................................
129Description of symbols ....................................................................................
130Recommended annual maintenance actions by the user .........................
130Recommended maintenance action by the user ........................................
131Heatsink .....................................................................................................................
132Fans .............................................................................................................................
132Replacing the cooling fan, frames size R0…R4 ...........................................
133Replacing the main cooling fan, frame R5 ...................................................
134Replacing the main cooling fan, frames R6…R8 .........................................
135Replacing the auxiliary cooling fan, frames R5...R8 ....................................
135Capacitors ..................................................................................................................
136Reforming the capacitors ................................................................................
136Control panel .............................................................................................................
136Cleaning the control panel ..............................................................................
136Replacing the battery in the control panel ...................................................
137LEDs ............................................................................................................................
137Drive LEDs (R3...R8) ...........................................................................................
137Control panel LEDs ...........................................................................................
9 Technical data
139Contents of this chapter .........................................................................................
139Ratings ........................................................................................................................
139IEC ratings ..........................................................................................................
140Definitions ..........................................................................................................
141Sizing ...................................................................................................................
141Derating ......................................................................................................................
141Ambient temperature derating, IP20 ............................................................
142Altitude derating ...............................................................................................
143Switching frequency derating ........................................................................
143Output frequency derating .............................................................................
143Fuses (IEC) .................................................................................................................
144uR and aR fuse ...................................................................................................
145gG fuses ..............................................................................................................
145gR fuses ...............................................................................................................
147Circuit breakers ........................................................................................................
148Dimensions, weights and free space requirements ..........................................
148Standard frames .......................................................................................................
149Thermal losses, cooling data and noise ...............................................................
150Terminal and lead-through data for the power cables .....................................
151Terminal and lead-through data for the control cables ...................................
153Electrical power network specification ...............................................................
153Motor connection data ............................................................................................
154EMC compatibility and motor cable length .................................................
155Brake resistor connection data for frames R0…R3 ...........................................
155Control connection data .........................................................................................
Table of contents 9
159Energy efficiency data (ecodesign) ......................................................................
160Auxiliary circuit power consumption ....................................................................
160Degree of protection ...............................................................................................
160Ambient conditions .................................................................................................
162Materials .....................................................................................................................
162Applicable standards ...............................................................................................
163CE marking .................................................................................................................
164Compliance with the European Low Voltage Directive .............................
165Compliance with the European EMC Directive ...........................................
165Compliance with the European ROHS II Directive 2011/65/EU ...............
166
Compliance with the European Machinery Directive 2006/42/EC 2nd
Edition – June 2010 ...........................................................................................
168Compliance with the EN 61800-3:2004 + A1:2012 ..............................................
168Definitions ..........................................................................................................
168Category C1 ........................................................................................................
168Category C2 ........................................................................................................
169Category C3 ........................................................................................................
169Category C4 ........................................................................................................
10 Dimension drawings
171Contents of this chapter .........................................................................................
171Frame R0, IP20 ..........................................................................................................
172Frame R1, IP20 ...........................................................................................................
173Frame R2, IP20 ...........................................................................................................
174Frame R3, IP20 ...........................................................................................................
175Frame R4, IP20 ..........................................................................................................
176Frame R5, IP20 ...........................................................................................................
177Frame R6, IP20 ..........................................................................................................
178Frame R7, IP20 ...........................................................................................................
179Frame R8, IP20 ..........................................................................................................
11 Resistor braking
181Contents of this chapter .........................................................................................
181Operation principle and hardware description ..................................................
181Resistor braking, frames R0…R3 ..........................................................................
181Planning the braking system ..........................................................................
181Selecting the brake resistor ...............................................................
185Selecting and routing the brake resistor cables ............................
185Placing the brake resistor ...................................................................
186Protecting the system in brake circuit fault situations ................
187Mechanical installation ....................................................................................
187Electrical installation ........................................................................................
187Start-up ...............................................................................................................
10 Table of contents
188Resistor braking, frames R4…R8 ..........................................................................
188Planning the braking system ..........................................................................
12 The Safe torque off function
191Contents of this chapter .........................................................................................
191Description ................................................................................................................
192
Compliance with the European Machinery Directive and the UK Supply
of Machinery (Safety) Regulations ................................................................
193Wiring ..........................................................................................................................
193Connection principle (R0…R2) .......................................................................
193Connection with internal power supply ...........................................
194Connection with external power supply ..........................................
194Wiring examples (R0…R2) ...............................................................................
194Wiring with internal power supply ....................................................
195Wiring with external power supply ....................................................
195Connection principle (R3…R8) .......................................................................
195Connection with internal power supply ...........................................
196Connection with external power supply ..........................................
196Wiring examples (R3…R8) ...............................................................................
196Wiring with internal power supply ....................................................
197Wiring with external power supply ....................................................
197Activation switch ...............................................................................................
197Cable types and lengths ..................................................................................
198Grounding of protective shields ....................................................................
199Operation principle ..................................................................................................
200Start-up including validation test .........................................................................
200Competence .......................................................................................................
200Validation test reports .....................................................................................
200Validation test procedure ...............................................................................
202Use ...............................................................................................................................
204Maintenance ..............................................................................................................
204Competence .......................................................................................................
205Fault tracing ..............................................................................................................
206Safety data .................................................................................................................
208Terms and abbreviations .................................................................................
210TÜV certificate ...................................................................................................
210Declarations of conformity .............................................................................
13 Optional panel bus adapters and extension modules
213Contents of this chapter .........................................................................................
213Safety instructions ...................................................................................................
213BIO-01 I/O extension module .................................................................................
213Hardware description ......................................................................................
213Product overview ..................................................................................
Table of contents 11
214Layout .....................................................................................................
214Mechanical installation ....................................................................................
214Electrical installation ........................................................................................
215Start-up ...............................................................................................................
215Technical data ....................................................................................................
215Control connection data .....................................................................
216Dimensions ............................................................................................
217CMOD-01 multifunction extension module (external 24 V AC/DC) ................
217
CMOD-01 multifunction extension module (external 24 V AC/DC and
digital I/O) ..........................................................................................................
217Contents of this chapter .....................................................................
217Product overview ..................................................................................
217Layout and example connections ......................................................
218Mechanical installation ........................................................................
219Electrical installation ............................................................................
219Start-up ...................................................................................................
220Technical data .......................................................................................
221Dimension drawing ..............................................................................
222BAPO-01 auxiliary power extension module .......................................................
222Hardware description ......................................................................................
223Layout .....................................................................................................
223Mechanical installation ....................................................................................
223Electrical installation ........................................................................................
224Start-up ...............................................................................................................
224Technical data ....................................................................................................
225RDUM-01 blank control panel .................................................................................
225Hardware description ......................................................................................
225Product overview ..................................................................................
226Layout .....................................................................................................
226
Example: Connecting a RDUM-01 panel to an assistant or basic control
panel mounted on a cabinet door .................................................................
227Installing assistant or basic control panel on the cabinet door ..............
227CDPI-02 panel bus adapters ...................................................................................
227BREL-01 relay output extension module ..............................................................
227Contents of this chapter .................................................................................
227Safety instructions ...........................................................................................
228Hardware description ......................................................................................
228Product overview ..................................................................................
228Layout .....................................................................................................
228Mechanical installation ....................................................................................
229Electrical installation ........................................................................................
229Start-up ...............................................................................................................
229Configuration parameters ..............................................................................
231Technical data ....................................................................................................
12 Table of contents
14 External input choke
233Contents of this chapter .........................................................................................
233Why external input chokes are required? ............................................................
233Specification ..............................................................................................................
234External input choke types .....................................................................................
234Mechanical dimensions ...........................................................................................
15 d
u
/d
t
filters
237Contents of this chapter .........................................................................................
237d
u
/d
t
filters ...............................................................................................................
237Where is a d
u
/d
t
filter needed? .....................................................................
237d
u
/d
t
filter types ..............................................................................................
238Description, installation and technical data of the FOCH filters ............
238
Description, installation and technical data of the AOCH and NOCH
filters ...................................................................................................................
Further information
Table of contents 13
14
Safety instructions
Contents of this chapter
This chapter contains the safety instructions which you must obey when you install,
start-up, operate and do maintenance work on the drive. If you ignore the safety
instructions, injury, death or damage can occur.
Use of warnings and notes
Warnings tell you about conditions which can cause injury or death, or damage to
the equipment. They also tell you how to prevent the danger. Notes draw attention
to a particular condition or fact, or give information on a subject.
The manual uses these warning symbols:
WARNING!
Electricity warning tells about hazards from electricity which can cause injury
or death, or damage to the equipment.
WARNING!
General warning tells about conditions other than those caused by electricity,
which can cause injury or death, or damage to the equipment.
WARNING!
Electrostatic sensitive devices warning tells you about the risk of electrostatic
discharge which can cause damage to the equipment.
1
Safety instructions 15
General safety in installation, start-up and maintenance
These instructions are for all personnel who do work on the drive.
WARNING!
Obey these instructions. If you ignore them, injury or death, or damage to
the equipment can occur.
• Keep the drive in its package until you install it. After unpacking, protect the
drive from dust, debris and moisture.
• Use the required personal protective equipment: safety shoes with metal toe
cap, safety glasses, protective gloves and long sleeves, etc. Some parts have
sharp edges.
• Lift a heavy drive with a lifting device. Use the designated lifting points. See
the dimension drawings.
• Be careful when handling a tall module. The module overturns easily because
it is heavy and has a high center of gravity. Whenever possible, secure the
module with chains. Do not leave an unsupported module unattended especially
on a sloping floor.
• Beware of hot surfaces. Some parts, such as heatsinks of power
semiconductors, and brake resistors, remain hot for a while after disconnection
of the electrical supply.
• Vacuum clean the area around the drive before the start-up to prevent the
drive cooling fan from drawing dust inside the drive.
• Make sure that debris from drilling, cutting and grinding does not go into the
drive during installation. Electrically conductive debris inside the drive can
cause damage or malfunction.
• Make sure that there is sufficient cooling. See the technical data.
• Before you connect voltage to the drive, make sure that all covers are in place.
Do not remove the covers when voltage is connected.
16 Safety instructions
3
• Before you adjust the drive operation limits, make sure that the motor and all
driven equipment can operate throughout the set operation limits.
• Before you activate the automatic fault reset or automatic restart functions
of the drive control program, make sure that no dangerous situations can
occur. These functions reset the drive automatically and continue operation
after a fault or supply break. If these functions are activated, the installation
must be clearly marked as defined in IEC/EN/UL 61800-5-1, subclause 6.5.3,
for example, "THIS MACHINE STARTS AUTOMATICALLY".
• The maximum number of drive power-ups is five in ten minutes. Too frequent
power-ups can damage the charging circuit of the DC capacitors.
• If you have connected safety circuits to the drive (for example, Safe torque off
or emergency stop), validate them at start-up. See separate instructions for
the safety circuits.
• Beware of hot air exiting from the air outlets.
• Do not cover the air inlet or outlet when the drive is running.
Note:
• If you select an external source for the start command and it is on, the drive
will start immediately after fault reset unless you configure the drive for pulse
start. See the firmware manual.
• If the drive is in remote control mode, you cannot stop or start the drive with
the control panel.
• Only authorized persons are allowed to repair a malfunctioning drive.
Safety instructions 17
Electrical safety in installation, start-up and maintenance
￭Electrical safety precautions
These electrical safety precautions are for all personnel who do work on the drive,
motor cable or motor.
WARNING!
Obey these instructions. If you ignore them, injury or death, or damage to
the equipment can occur.
If you are not a qualified electrical professional, do not do installation or
maintenance work.
Do these steps before you begin any installation or maintenance work.
1. Clearly identify the work location and equipment.
2. Disconnect all possible voltage sources. Make sure that re-connection is not
possible. Lock out and tag out.
• Open the main disconnecting device of the drive.
• If you have a permanent magnet motor connected to the drive, disconnect
the motor from the drive with a safety switch or by other means.
• Disconnect all dangerous external voltages from the control circuits.
• After you disconnect power from the drive, always wait 5 minutes to let
the intermediate circuit capacitors discharge before you continue.
3. Protect any other energized parts in the work location against contact.
4. Take special precautions when close to bare conductors.
5. Measure that the installation is de-energized. Use a quality voltage tester.
Before and after you measure the installation, verify the operation of the
voltage tester on a known voltage source.
•
• Make sure that the voltage between the drive input power terminals (L1,
L2, L3) and the grounding (PE) busbar is zero.
•Make sure that the voltage between the drive output terminals (T1/U, T2/V,
T3/W) and the grounding (PE) busbar is zero.
• Make sure that the voltage between the drive DC terminals (UDC+ and
UDC-) and the grounding (PE) terminal is zero.
Note: If cables are not connected to the drive DC terminals, measuring the
voltage from the DC terminal screws can give incorrect results.
6. Install temporary grounding as required by the local regulations.
7. Ask for a permit to work from the person in control of the electrical installation
work.
18 Safety instructions
3
￭Additional instructions and notes
WARNING!
Obey these instructions. If you ignore them, injury or death, or damage to
the equipment can occur.
If you are not a qualified electrical professional, do not do installation or
maintenance work.
• Make sure that the electrical power network, motor/generator, and
environmental conditions agree with the drive data.
• Do not do insulation or voltage withstand tests on the drive.
• If you have a cardiac pacemaker or other electronic medical device, keep away
from the area near motor, drive, and the drive power cabling when the drive
is in operation. There are electromagnetic fields present which can interfere
with the function of such devices. This can cause a health hazard.
Note:
• When the drive is connected to the input power, the motor cable terminals
and the DC bus are at a dangerous voltage.
After disconnecting the drive from the input power, these remain at a
dangerous voltage until the intermediate circuit capacitors have discharged.
• External wiring can supply dangerous voltages to the relay outputs of the
control units of the drive.
• The Safe torque off function does not remove the voltage from the main and
auxiliary circuits. The function is not effective against deliberate sabotage or
misuse.
Printed circuit boards
WARNING!
Use a grounding wristband when you handle printed circuit boards. Do not
touch the boards unnecessarily. The boards contain components sensitive
to electrostatic discharge.
Safety instructions 19
￭Grounding
These instructions are for all personnel who are responsible for the grounding of
the drive.
WARNING!
Obey these instructions. If you ignore them, injury or death, or equipment
malfunction can occur, and electromagnetic interference can increase.
If you are not a qualified electrical professional, do not do grounding work.
•Always ground the drive, the motor and adjoining equipment. This is necessary
for the personnel safety.
• Make sure that the conductivity of the protective earth (PE) conductors is
sufficient and that other requirements are met. See the electrical planning
instructions of the drive. Obey the applicable national and local regulations.
• When using shielded cables, make a 360° grounding of the cable shields at the
cable entries to reduce electromagnetic emission and interference.
• In a multiple-drive installation, connect each drive separately to the protective
earth (PE) busbar of the power supply.
20 Safety instructions
3
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