ABB ACx580-01-02A6-4 Operating instructions

On-Site Service Instructions
Document nbr
3AXD10000303478
ABB Oy, Drives Service ACx580-01 R0-R5
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© Copyright 2018 ABB Oy. All rights reserved. Specifications subject to change without notice.
On-site Service Instructions for
ACx580-01
Frames R0-R5

On-Site Service Instructions
Document nbr
3AXD10000303478
ABB Oy, Drives Service ACx580-01 R0-R5
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ESP300
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2 (41)
© Copyright 2018 ABB Oy. All rights reserved. Specifications subject to change without notice.
Table of Contents
1. General.........................................................................................................................................3
1.1 Warnings ...............................................................................................................................3
1.2 Content..................................................................................................................................4
1.3 Required tools........................................................................................................................4
1.4 Maintenance schedule...........................................................................................................4
2. Preventive maintenance actions ...................................................................................................5
2.1 Heat sink temperature check and cleaning ............................................................................5
2.1.1 Heat sink cleaning ..........................................................................................................5
2.2 Cooling fan replacement........................................................................................................6
2.2.1 Frame R0, Main cooling fan............................................................................................6
2.2.2 Frame R0 IP55, Internal cooling fan................................................................................7
2.2.3 New Frame R1, Main cooling fan....................................................................................8
2.2.4 New Frame R1 IP55, Internal cooling fan......................................................................10
2.2.5 Old Frame R1, Main cooling fan ...................................................................................11
2.2.6 Old Frame R1 IP55, Internal cooling fan.......................................................................12
2.2.7 New Frame R2, Main cooling fan..................................................................................13
2.2.8 New Frame R2 IP55, Internal cooling fan......................................................................15
2.2.9 Old Frame R2, Main cooling fan ...................................................................................17
2.2.10 Old Frame R2 IP55, Internal cooling fan.......................................................................18
2.2.11 New Frame R3, Main cooling fan..................................................................................19
2.2.12 Old Frame R3, Main cooling fan ...................................................................................22
2.2.13 New Frame R3 IP55, Internal cooling fan.........................Error! Bookmark not defined.
2.2.14 Old Frame R3 IP55, Internal cooling fan.......................................................................23
2.2.15 Frame R4, Main cooling fan..........................................................................................24
2.2.16 Frame R4 IP55, Internal cooling fan..............................................................................25
2.2.17 Frame R5, Main cooling fan,.........................................................................................26
2.2.18 Frame R5, Internal cooling fan......................................................................................27
2.2.19 Old Frame R5, Main cooling fan ...................................................................................28
2.2.20 Old Frame R5, Internal cooling fan ...............................................................................28
2.3 Control unit replacement (CCU)...........................................................................................29
2.3.1 Safe torque off function STO.........................................................................................29
2.3.2 Acceptance test procedure...........................................................................................30
2.3.3 Removing CCON-11 / CCON-23 from its assembly mechanics ....................................31
2.3.4 Removing CCON-12 from its assembly mechanics.......................................................31
2.3.5 Rigid connectors for different frame sizes.....................................................................31
2.3.6 Frames R0-R1, CCU-11 or CCU-23 replacement.........................................................32
2.3.7 Frame R2, CCU-11 or CCU-23 replacement.................................................................33
2.3.8 Frame R3, CCU-11 or CCU-23 replacement.................................................................34
2.3.9 Frame R4 IP21, CCU-11 or CCU-23 replacement ........................................................35
2.3.10 Frame R4 IP55, CCU-11 or CCU-23 replacement ........................................................36
2.3.11 Frame R5v1, CCU-12 replacement...............................................................................37
2.3.12 Frame R5v2, CCU-11 or CCU-23 replacement.............................................................38
3. Fault tracing................................................................................................................................39
4. Replacement of interface options................................................................................................41

On-Site Service Instructions
Document nbr
3AXD10000303478
ABB Oy, Drives Service ACx580-01 R0-R5
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© Copyright 2018 ABB Oy. All rights reserved. Specifications subject to change without notice.
1. General
1.1 Warnings
WARNING!
Any qualified electrician, who according to the local laws has the required legitimacy, is allowed to
perform installation and maintenance work on the ACX580 frame sizes R0-R5.
Do not attempt any work on a powered ACX580. After switching off the mains, always allow the
intermediate circuit capacitors 5 minutes to discharge before working on the frequency converter, the
motor or the motor cable. The voltage between each input terminal (U1, V1, W1) and earth must be
measured with a multimeter (impedance at least 1MΩ) to ensure that the frequency converter is
discharged before beginning work.
Always ensure by measuring with a multimeter (impedance at least 1 MΩ) that:
1. There is no voltage between the drive input phases U1, V1 and W1 and the ground.
2. There is no voltage between terminals UDC+ and UDC- and the ground.
3. There is no voltage between terminals R+ and R- and the ground.
Also make sure that no one can accidentally power the system up while you’re working on the drive.
All insulation tests must be carried out with the ACX580 disconnected from the cabling.
Do not make any insulation or voltage withstand tests on any part of the drive.
The ACX580 motor cable terminals are at a dangerously high voltage when input power is applied,
regardless of motor operation. No work on the motor cable should be attempted with mains power
applied.
There can be dangerous voltage inside the ACX580 from external control circuits when the ACX580
input power is shut off. No work on the control cables should be attempted when power is applied to
the frequency converter or to the external control circuits. Exercise appropriate care when working
with the unit.
ESD (Electro Static Discharge): The printed circuit boards contain integrated circuits that are
extremely sensitive to electrostatic discharge. Use ESD –protection and exercise appropriate care
when working on the unit to avoid permanent damage to the circuits. Avoid unnecessary touching of
the boards.
WARNING!
Before working with the ACX580 read carefully the Safety Instruction on the ACX580 Hardware
Manual. Ignoring the safety instructions can cause injury or death.

On-Site Service Instructions
Document nbr
3AXD10000303478
ABB Oy, Drives Service ACx580-01 R0-R5
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ESP300
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© Copyright 2018 ABB Oy. All rights reserved. Specifications subject to change without notice.
1.2 Content
The purpose of this document is to specify on-site maintenance and repair actions of ACx580-01
frame sizes R0 – R5. Following actions are included in this document:
•Control unit replacement
•Cooling fan replacement
1.3 Required tools
•ESD field service kit
•Cross head screwdriver
•Flathead screwdriver
•Torxhead screwdriver
1.4 Maintenance schedule
Maintenance schedule is available at ABB library. Contact your local ABB representative for more
information.

On-Site Service Instructions
Document nbr
3AXD10000303478
ABB Oy, Drives Service ACx580-01 R0-R5
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© Copyright 2018 ABB Oy. All rights reserved. Specifications subject to change without notice.
2. Preventive maintenance actions
2.1 Heat sink temperature check and cleaning
Need for heat sink temperature check and cleaning depends on the dustiness of the environment.
The heat sink fins pick up dust from the cooling air. The drive runs into over temperature warnings
and faults if the heat sink is not clean. Too high operating temperature causes faster aging of the
drive components. In a normal environment the heat sink should be checked annually and cleaned if
needed, in a dusty environment more often. Heat sink must also be cleaned when replacing a cooling
fan.
NOTE! Compressed air or normal vacuum cleaner must NOT be used to clean any other parts of the
drive than heat sink only. Airflow causes a high risk of ESD damage to components. Fan must also be
removed before cleaning with compressed air. Otherwise strong air flow will affect fan bearings.
2.1.1 Heat sink cleaning
a. Turn off the main input power of the drive
b. Remove the cooling fan
c. Blow clean dry compressed air from the bottom
d. Use a vacuum cleaner on top to trap the dust
e. Install the cooling fan

On-Site Service Instructions
Document nbr
3AXD10000303478
ABB Oy, Drives Service ACx580-01 R0-R5
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Revision
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ESP300
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© Copyright 2018 ABB Oy. All rights reserved. Specifications subject to change without notice.
2.2 Cooling fan replacement
2.2.1 Frame R0, Main cooling fan
Types:
•ACx580-01-02A6-4
•ACx580-01-03A3-4
•ACx580-01-04A0-4
•ACx580-01-05A6-4
The main cooling fan is located at the bottom of the drive. Replace the fan as follows:
a. Release the locking clamp, use a flathead screwdriver to assist
b. Remove the fan by opening the unit (1.) and pushing leftwards at the base (2.)
c. Clean the cooling air duct and the heat sink with compressed air. See separate instructions in
section 2.1.1
d. Check that the fans blowing direction is inside the unit and
install the new fan unit simply by pushing it to its place.
Ensure the fan operation when the drive is powered up
2
1

On-Site Service Instructions
Document nbr
3AXD10000303478
ABB Oy, Drives Service ACx580-01 R0-R5
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ESP300
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© Copyright 2018 ABB Oy. All rights reserved. Specifications subject to change without notice.
2.2.2 Frame R0 IP55, Internal cooling fan
Types:
•ACx580-01-02A6-4
•ACx580-01-03A3-4
•ACx580-01-04A0-4
•ACx580-01-05A6-4
Remove front cover
a. Remove control panel
b. Open mounting screw with a screwdriver
c. Push the front cover slightly upwards and lift it off
Replace internal fan
a. Remove internal fan sledge from plastic housing
b. Assembly new internal fan+sledge combination
i. Place internal fan to sledge, ensure correct blowing direction
ii. Place FR-1 rivets through the holes and push them to bottom
c. Place internal fan sledge to plastic housing
Install components in reverse order

On-Site Service Instructions
Document nbr
3AXD10000303478
ABB Oy, Drives Service ACx580-01 R0-R5
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Date
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ESP300
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© Copyright 2018 ABB Oy. All rights reserved. Specifications subject to change without notice.
2.2.3 New Frame R1, Main cooling fan
Types:
•ACX580-01-04A6-2
•ACX580-01-04A7-2
•ACX580-01-06A6-2
•ACX580-01-06A7-2
•ACX580-01-07A5-2
•ACX580-01-07A6-2
•ACX580-01-10A6-2
•ACX580-01-012A-2
•ACX580-01-017A-2
•ACX580-01-018A-2
•ACX580-01-02A1-4
•ACX580-01-02A7-4
•ACX580-01-03A0-4
•ACX580-01-03A4-4
•ACX580-01-03A5-4
•ACX580-01-04A1-4
•ACX580-01-04A8-4
•ACX580-01-05A7-4
•ACX580-01-06A0-4
•ACX580-01-07A3-4
•ACX580-01-07A6-4
•ACX580-01-09A9-4
•ACX580-01-012A-4
•ACX580-01-12A7-4
The main cooling fan is located on the top of the drive.

On-Site Service Instructions
Document nbr
3AXD10000303478
ABB Oy, Drives Service ACx580-01 R0-R5
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© Copyright 2018 ABB Oy. All rights reserved. Specifications subject to change without notice.
Replace the fan as follows:
1. Release two locking clamps, use a flathead screwdriver to assist.
2. Remove the fan.
3. Clean the cooling air duct and the heat sink with compressed air. See separate instructions in
section 2.1.1.
4. Check that the fan blowing direction is outside the unit and install the new fan in reverse order
to above. Ensure the fan operation when the drive is powered up.

On-Site Service Instructions
Document nbr
3AXD10000303478
ABB Oy, Drives Service ACx580-01 R0-R5
Related to material
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Date
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ESP300
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© Copyright 2018 ABB Oy. All rights reserved. Specifications subject to change without notice.
2.2.4 New Frame R1 IP55, Internal cooling fan
Types:
•ACX580-01-04A6-2
•ACX580-01-04A7-2
•ACX580-01-06A6-2
•ACX580-01-06A7-2
•ACX580-01-07A5-2
•ACX580-01-07A6-2
•ACX580-01-10A6-2
•ACX580-01-012A-2
•ACX580-01-017A-2
•ACX580-01-018A-2
•ACX580-01-02A1-4
•ACX580-01-02A7-4
•ACX580-01-03A0-4
•ACX580-01-03A4-4
•ACX580-01-03A5-4
•ACX580-01-04A1-4
•ACX580-01-04A8-4
•ACX580-01-05A7-4
•ACX580-01-06A0-4
•ACX580-01-07A3-4
•ACX580-01-07A6-4
•ACX580-01-09A9-4
•ACX580-01-012A-4
•ACX580-01-12A7-4
Remove the front cover. You will find the internal cooling fan on the right side of the drive.
1. Remove the transparent plastic cover in front of the fan with a screwdriver.
2. Unlock the wires from the right and take slowly the fan out by pulling the wires.

On-Site Service Instructions
Document nbr
3AXD10000303478
ABB Oy, Drives Service ACx580-01 R0-R5
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Date
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ESP300
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© Copyright 2018 ABB Oy. All rights reserved. Specifications subject to change without notice.
3. Assembly the new internal fan and check that the blowing direction is to upwards. Remember
to reinstall the transparent plastic cover and the wires.
2.2.5 Old Frame R1, Main cooling fan
Types:
•ACX580-01-07A2-4
•ACX580-01-09A4-4
•ACX580-01-12A6-4
The main cooling fan is located at the bottom of the drive. Replace the fan as follows:
a. Release two locking clamps, use a flathead screwdriver to assist
b. Remove the fan
c. Clean the cooling air duct and the heat sink with compressed air. See separate instructions in
section 2.1.1
d. Check that the fans blowing direction is inside the unit and install the new fan in reverse order
to above. Ensure the fan operation when the drive is powered up

On-Site Service Instructions
Document nbr
3AXD10000303478
ABB Oy, Drives Service ACx580-01 R0-R5
Related to material
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Date
Revision
Page
ESP300
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© Copyright 2018 ABB Oy. All rights reserved. Specifications subject to change without notice.
2.2.6 Old Frame R1 IP55, Internal cooling fan
Types:
•ACX580-01-07A2-4
•ACX580-01-09A4-4
•ACX580-01-12A6-4
Remove front cover
a. Remove control panel
b. Open mounting screw with a screwdriver
c. Push the front cover slightly upwards and lift it off
Replace internal fan
a. Remove internal fan sledge from plastic housing
b. Assembly new internal fan+sledge combination
i. Place internal fan to sledge, ensure correct blowing direction
ii. Place FR-1 rivets through the holes and push them to bottom
c. Place internal fan sledge to plastic housing
Install components in reverse order

On-Site Service Instructions
Document nbr
3AXD10000303478
ABB Oy, Drives Service ACx580-01 R0-R5
Related to material
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Date
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ESP300
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© Copyright 2018 ABB Oy. All rights reserved. Specifications subject to change without notice.
2.2.7 New Frame R2, Main cooling fan
Types:
•ACX580-01-024A-2
•ACX580-01-025A-2
•ACX580-01-031A-2
•ACX580-01-032A-2
•ACX580-01-014A-4
•ACX580-01-018A-4
•ACX580-01-023A-4
•ACX580-01-03A9-6
•ACX580-01-06A1-6
•ACX580-01-09A0-6
•ACX580-01-011A-6
•ACX580-01-017A-6
The main cooling fan is located on the top of the drive.
Replace the fan as follows:

On-Site Service Instructions
Document nbr
3AXD10000303478
ABB Oy, Drives Service ACx580-01 R0-R5
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© Copyright 2018 ABB Oy. All rights reserved. Specifications subject to change without notice.
1. Release the two locking clamps, use a flathead screwdriver to assist.
2. Remove the fan.
3. Clean the cooling air duct and the heat sink with compressed air. See separated instructions in
section 2.1.1.
4. Check that the fans blowing direction is outside the unit and install the new fan in reverse
order to above. Ensure the fan operation when the drive is powered up.

On-Site Service Instructions
Document nbr
3AXD10000303478
ABB Oy, Drives Service ACx580-01 R0-R5
Related to material
Department
Date
Revision
Page
ESP300
13.08.2018
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15 (41)
© Copyright 2018 ABB Oy. All rights reserved. Specifications subject to change without notice.
2.2.8 New Frame R2 IP55, Internal cooling fan
Types:
•ACX580-01-024A-2
•ACX580-01-025A-2
•ACX580-01-031A-2
•ACX580-01-032A-2
•ACX580-01-014A-4
•ACX580-01-018A-4
•ACX580-01-023A-4
•ACX580-01-026A-4
•ACX580-01-02A7-6
•ACX580-01-03A9-6
•ACX580-01-06A1-6
•ACX580-01-09A0-6
•ACX580-01-011A-6
•ACX580-01-017A-6
Remove the front cover. You will find the internal cooling fan on the right side of the drive.
1. Remove the transparent plastic cover in front of the fan with a screwdriver.
2. Unlock the wires from the right and take slowly the fan out by pulling the wires.

On-Site Service Instructions
Document nbr
3AXD10000303478
ABB Oy, Drives Service ACx580-01 R0-R5
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Date
Revision
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ESP300
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© Copyright 2018 ABB Oy. All rights reserved. Specifications subject to change without notice.
3. Assembly the new internal fan and check that the blowing direction is to downwards.
Remember to reinstall the transparent plastic cover and the wires.

On-Site Service Instructions
Document nbr
3AXD10000303478
ABB Oy, Drives Service ACx580-01 R0-R5
Related to material
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Date
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ESP300
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17 (41)
© Copyright 2018 ABB Oy. All rights reserved. Specifications subject to change without notice.
2.2.9 Old Frame R2, Main cooling fan
Types:
•ACX580-01-017A-4
•ACX580-01-025A-4
The main cooling fan is located at the bottom of the drive.
Replace the fan as follows:
a. Release two locking clamps, use a flathead
screwdriver to assist
b. Remove the fan
c. Clean the cooling air duct and the heat sink with
compressed air. See separate instructions in
section 2.1.1
d. Check that the fans blowing direction is inside the unit and
install the new fan in reverse order to above. Ensure the fan
operation when the drive is powered up

On-Site Service Instructions
Document nbr
3AXD10000303478
ABB Oy, Drives Service ACx580-01 R0-R5
Related to material
Department
Date
Revision
Page
ESP300
13.08.2018
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18 (41)
© Copyright 2018 ABB Oy. All rights reserved. Specifications subject to change without notice.
2.2.10 Old Frame R2 IP55, Internal cooling fan
Types:
•ACX580-01-017A-4
•ACX580-01-025A-4
Remove front cover
a. Remove control panel
b. Open mounting screw with a screwdriver
c. Push the front cover slightly upwards and lift it off
Remove control unit
a. Remove mounting screws with a screwdriver
b. Release mounting clamps and lift CCU-11/CCU-23 and the rigid connector off
Replace internal fan
a. Remove internal fan sledge and cable from plastic housing
b. Assembly new internal fan+sledge combination
i. Place internal fan to sledge, ensure correct blowing direction
ii. Place FR-1 rivets through the holes and push them to bottom
c. Place internal fan sledge to plastic housing
Install components in reverse order

On-Site Service Instructions
Document nbr
3AXD10000303478
ABB Oy, Drives Service ACx580-01 R0-R5
Related to material
Department
Date
Revision
Page
ESP300
13.08.2018
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© Copyright 2018 ABB Oy. All rights reserved. Specifications subject to change without notice.
2.2.11 New Frame R3, Main cooling fan
Types:
•ACX580-01-046A-2
•ACX580-01-047A-2
•ACX580-01-059A-2
•ACX580-01-060A-2
•ACX580-01-027A-4
•ACX580-01-033A-4
•ACX580-01-034A-4
•ACX580-01-039A-4
•ACX580-01-044A-4
•ACX580-01-046A-4
•ACX580-01-022A-6
•ACX580-01-027A-6
•ACX580-01-032A-6
The main cooling fan is located on the top of the drive.
Replace the fan as follows:
1. Release the locking clamp, use a flathead screwdriver to assist.

On-Site Service Instructions
Document nbr
3AXD10000303478
ABB Oy, Drives Service ACx580-01 R0-R5
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© Copyright 2018 ABB Oy. All rights reserved. Specifications subject to change without notice.
2. Remove the fan by opening the unit and pushing rightwards at the base.
3. Clean the cooling air duct and the heat sink with compressed air. See separate instructions in
section 2.1.1
4. Check that the fans blowing direction is outside the unit and install the new fan unit simply by
pushing it to its place.
Ensure the fan operation when the drive is powered up