ABB ACQ580-01 Series Installation manual

1
This guide is applicable to the global product types. There is a separate guide for the North American product types.
Safety instructions
WARNING! Obey these instructions. If you ignore them, injury or death, or damage to the equipment can occur. If
you are not a qualified electrical professional, do not do electrical installation or maintenance work.
• Do not do work on the drive, motor cable, motor, or control cables when the drive is connected to the input power.
Before you start the work, isolate the drive from all dangerous voltage sources and make sure that it is safe to start the
work. Always wait for 5 minutes after disconnecting the input power to let the intermediate circuit capacitors
discharge.
• Do not do work on the drive when a rotating permanent magnet motor is connected to it. A rotating permanent
magnet motor energizes the drive, including its input and output terminals.
• Frames R1…R2, IP21
(UL Type 1): Do not lift the
drive by holding it from the
cover. The cover can come
loose and cause the drive to
fall.
• Frames R5…R9: Do not tilt the
drive. The drive is heavy and
has a high center of gravity. It
can topple accidentally.
• Frames R5…R9: Lift the drive
with a lifting device. Use the
lifting eyes of the drive.
1. Unpack the delivery
Keep the drive in its package until you are ready to install it. After unpacking, protect the drive from dust, debris and
moisture. Make sure that these items are included:
• cable box (frames R1…R2 and R5…R9, IP21 [UL Type 1])
• drive
• mounting template
• control panel
• quick installation and start-up guide
• multilingual residual voltage warning stickers
• hardware and firmware manuals, if ordered
• options in separate packages, if ordered.
Make sure that there are no signs of damage to the items.
2. Reform the capacitors
If the drive has not been powered up for a year or more, you must reform the DC link capacitors. Refer to Capacitor
reforming instructions (3BFE64059629 [English]) or contact ABB technical support.
Documentation in other languages
Ecodesign information
(EU 2019/1781 and SI 2021 No. 745) About this document
3AXD50000758692 Rev C EN
2023-09-12
© 2023 ABB. All rights reserved.
Original instructions.
—
DRIVES FOR WATER
ACQ580-01 drives
Quick installation and start-up guide
R1…R2 R5…R9R5…R9

2
3. Select the cables and fuses
• Select the power cables. Obey the local regulations.
•Input power cable: ABB recommends to use symmetrical shielded cable (VFD cable) for the best EMC performance.
•Motor cable: Use symmetrical shielded cable (VFD cable) for the best EMC performance. Symmetrical shielded cable
also reduces bearing currents, wear, and stress on motor insulation.
•Power cable types: In IEC installations, use copper or aluminum cables (if permitted). Aluminum cables can only be
used for input power cabling in 230 V drives with frame size R5…R8. In UL installations, use only copper conductors.
•Current rating: max. load current.
•Voltage rating: min. 600 V AC.
•Temperature rating: In IEC installations, select a cable rated for at least 70°C (158°F) maximum permissible
temperature of conductor in continuous use. In UL installations and for drives with option +B056 (IP55, UL Type 12),
select a cable rated for at least 75°C (167°F).
•Size: Refer to Ratings, fuses and typical power cable sizes for the typical cable sizes and to Terminal data for the
power cables for the maximum cable sizes.
• Select the control cables. Use double-shielded twisted-pair cable for analog signals. Use double-shielded or single-
shielded cable for the digital, relay and I/O signals. Do not run 24 V and 115/230 V signals in the same cable.
• Protect the drive and input power cable with the correct fuses. Refer to Ratings, fuses and typical power cable sizes.
4. Examine the installation site
Examine the site where you will install the drive. Make sure that:
• The installation site is sufficiently ventilated or cooled to remove heat from the drive.
• The ambient conditions meet the requirements. Refer to Ambient conditions.
• The installation surface is as close to vertical as possible and strong enough to support the weight of the drive. For the
weights, refer to Weights and free space requirements.
• The installation surface, floor and materials near the drive are not flammable.
• There is sufficient free space around the drive for cooling, maintenance, and operation. For the minimum free space
requirements, refer to Weights and free space requirements.
• There are no sources of strong magnetic fields such as high-current single-core conductors or contactor coils near the
drive. A strong magnetic field can cause interference or inaccuracy in the operation of the drive.
5. Install the drive on the wall
Select fasteners that comply with local requirements applicable to wall surface materials, drive weight and application.
Prepare the installation site
1. Make marks with the help of the mounting template. Remove the mounting template before you install the drive on the
wall.
2. Drill the holes and put anchors or plugs into the holes.
3. Install the screws. Leave a gap between the screw head and mounting surface.
R1 R2 R3 R4 R5 R6 R7 R8 R9
mm in mm in mm in mm in mm in mm in mm in mm in mm in
a98 3.86 98 3.86 160 6.30 160 6.30 612 24.09 571 22.5 623 24.5 701 27.6 718 28.3
b317 12.48 417 16.42 473 18.62 619 24.37 581 22.87 531 20.9 583 23.0 658 25.9 658 25.9
c--------1606.302138.42459.726310.334513.6
d > --------2007.8730011.830011.830011.830011.8
e > --------1003.941556.11556.11556.12007.9
a
b
1 2
c
a
d
e
b
R1…R4 R5…R9
× 4
× 4
× 2
1R1…R2: M5
R3…R5: M6
R6…R9: M8
R1…R9

3
Frames R1…R4: Put the drive on the wall and tighten the screws
Frame R5, IP21 (UL Type 1): Install the cable box
3
R1…R4 R5 R6…R9
3 3
× 2 × 2× 2× 2
× 4
31 2
54
21 3 M5×3

4
Frames R5…R9: Put the drive on the wall and tighten the screws
6. Remove the cover(s)
7. Frames R1…R2 and R6…R9, IP21 (UL Type 1): Install the cable box
R1…R2
21
R5 R6…R9
1
R5
R1…R4, IP21 (UL Type 1)
2
1
3
R1…R9, IP55 (UL Type 12)
1
2
3
2
1
3
R5, IP21 (UL Type 1) R5, IP21 (UL Type 1)
4
5
R6…R9, IP21 (UL Type 1)
2
1
3
123

5
R6…R9
8. Attach a residual voltage warning sticker to the drive in the local language
Frames R1…R4: to the control panel mounting platform, Frames R5…R9: next to the control unit.
9. Make sure that the drive is compatible with the grounding system
You can connect all drives to a symmetrically grounded TN-S system (center-grounded wye). If you install the drive to a
different system, you must disconnect the EMC screw (disconnect the EMC filter) and/or disconnect the VAR screw
(disconnect the varistor circuit).
10. Measure the insulation resistance of the power cables and the motor
Measure the insulation resistance of the input cable before you connect it to the
drive. Obey local regulations.
Measure the insulation resistance of the motor cable and motor when the cable is
disconnected from the drive. Measure the insulation resistance between each
phase conductor and the PE conductor. Use a measuring voltage of 1000 V DC. The
insulation resistance of an ABB motor must be more than 100 Mohm (reference
value at 25 °C [77 °F]). For the insulation resistance of other motors, see the
manufacturer’s instructions. Moisture inside the motor decreases the insulation
resistance. If you think that there is moisture inside the motor casing, dry the motor
and do the measurement again.
Frame size Symmetrically
grounded TN-S systems
(center-grounded wye)
Corner-grounded delta
and midpoint-grounded
delta systems
IT systems (ungrounded
or high-resistance
grounded)
TT systems 1) 2)
1) A residual current device must be installed in the supply system.
2) ABB does not guarantee the EMC category or the operation of the ground leakage detector built inside the drive.
R1…R3
R4 v2
Do not disconnect EMC
or VAR screw.
Disconnect EMC screw.
Do not disconnect VAR
screw.
Disconnect EMC and VAR
screws.
Disconnect EMC and VAR
screws.
R4…R5 Do not disconnect EMC
or VAR screw.
Note: The drive is not
evaluated for use on
these systems by IEC
standards.
Disconnect EMC screws
(2 pieces) and VAR screw.
Disconnect EMC screws
(2 pieces) and VAR screw.
R6…R9 Do not disconnect EMC
or VAR screw.
Do not disconnect EMC
AC or VAR screws.
Disconnect EMC DC
screw.
Disconnect EMC screws
(2 pieces) and VAR screw.
Disconnect EMC screws
(2 pieces) and VAR screw.
1 2 M8×6
U1-PE, V1-PE, W1-PE
U1
V1
W1
PE
M
3~
ohm

6
11. Connect the power cables
Connection diagram (shielded cables)
Connection procedure
1. Frames R5…R9: Remove the shroud(s) on the power cable terminals.
Frames R6…R9: Remove the side plates (a). Remove the shroud (b), then make the necessary holes for the cables. In
frames R8…R9, if you install parallel cables, also make the necessary holes in the lower shroud.
PE
PE
L1 L2 L3 R- R+
UDC+
U1 W1
M
3
T1/U T2/V T3/W
V1
(PE) (PE) L1 L2 L3
PE
Frames R1…R3 have a built-in brake
chopper. If necessary, you can con-
nect a brake resistor to terminals R-
and UDC+/R+. The brake resistor is
not included in the drive delivery.
In frames R4…R9, you can connect
an external brake chopper to termi-
nals UDC+ and UDC-. The brake
chopper is not included in the drive
delivery.
1. Two protective earth (ground) conductors. Drive safety standard IEC/EN 61800-5-1 requires two PE conductors if the
cross-sectional area of the PE conductor is less than 10 mm2Cu or 16 mm2Al. For example, you can use the cable
shield in addition to the fourth conductor.
2. Use a separate grounding cable or a cable with a separate PE conductor for the line side if the conductivity of the
fourth conductor or shield does not meet the requirements for the PE conductor.
3. Use a separate grounding cable for the motor side if the conductivity of the shield is not sufficient, or if there is no
symmetrically constructed PE conductor in the cable.
4. 360° grounding of the cable shield is required for the motor cable and brake resistor cable (if used). It is also
recommended for the input power cable.
5. If necessary, install an external filter (du/dt, common mode, or sine filter). Filters are available from ABB.
1
2
4 4
3
5
R5 R6…R9
11a 1b
R6…R9

7
2. Prepare the power cables:
•Remove the rubber grommets from the cable entry.
•Cut a sufficient hole in the rubber grommet. Slide the grommet onto the cable (a).
•Prepare the ends of the input power cable and motor cable as illustrated in the figure (b).
•Slide the cables through the holes in the cable entry and attach the grommets to the holes.
•If you use aluminum cables, apply grease to the stripped conductors before you connect them to the drive.
3. Connect the power cables. For the tightening torques, refer to Terminal data for the power cables.
•Connect the phase conductors of the motor cable to terminals T1/U, T2/V and T3/W. Connect the twisted shield of
the cable to the grounding terminal. (a)
•Connect the input power cable to terminals L1, L2 and L3. Connect the twisted shield of the cable and the additional
PE conductor to the grounding terminal. (b)
•Frames R8…R9: If you use only one conductor, ABB recommends that you put it under the upper pressure plate. If
you use parallel power cables, put the first conductor under the lower pressure plate and the second under the upper
pressure plate.
•Frames R8…R9: If you use parallel power cables, install the second grounding shelf for the parallel power cables.
•Tighten the clamps of the power cable grounding shelf onto the stripped part of the cables (c). Torque the clamps to
1.2 N·m (10.6 lbf·in).
•If used, connect the brake resistor or brake chopper cables. In frames R1…R2, you must install the grounding shelf
before you can connect the brake cables (refer to the next step).
•Frames R6…R9: After you connect the power cables, install the shroud on the terminals (d).
PE
2a 2b
MOTOR
T1
U
T2
V
T3
W
INPUT
L1 L2 L3
BRAKE RES
R-R+
UDC+
PE
R1…R4
PE
R5
R6…R9 R6…R9
3a3b
3c
3a3b
3c
3a3b
3c
3d
Note: The illustration above shows frames R1…R2. Frames
R3…R4 are similar.

8
4. Frames R1…R2, R4, R6…R9: Install the grounding shelf. In frames R6…R9, this is the grounding shelf for the control
cables.
5. Frame R5: Install the cable box plate (a) and shroud (b).
6. Attach the cables outside the drive mechanically.
7. Ground the motor cable shield at the motor end. For minimum radio frequency interference, ground the motor cable
shield 360° at the cable entry of the motor terminal box.
R1…R2 R4
R6…R9
4 4
4
R5
5a 5b
7

9
12. Connect the control cables
Make the connections according to the application. Keep the signal wire pairs twisted as near to the terminals as possible
to prevent inductive coupling.
1. Cut a hole into the rubber grommet and slide the grommet onto the cable.
2. Ground the outer shield of the cable 360° under the grounding clamp. Keep the cable unstripped as close to the
terminals of the control unit as possible. Ground also the pair-cable shields and grounding wire at the SCR terminal.
3. Tie all control cables to the provided cable tie mounts.
Default I/O connections (Water default)
Total load capacity of the auxiliary voltage output +24V (X2:10) is 6.0 W (250 mA / 24 V DC).
Terminals Wire size Tightening torque
+24V, DGND, DCOM, B+, A-, DGND, Ext. 24V 0.2 … 2.5 mm2(24 … 14 AWG) 0.5 … 0.6 N·m (5 lbf·in)
DI, AI, AO, AGND, RO, OUT, IN, SGND 0.14 … 1.5 mm2(26 … 16 AWG)
4BGFUPSRVFPGG450#PUIDJSDVJUTNVTUCFDMPTFEGPSUIF
ESJWFUPTUBSU5IFESBXJOHTIPXTUIFTJNQMJGJFEDPOOFDUJPO
PGBTBGFUZDJSDVJUUISPVHITBGFUZDPOUBDUT*G450JTOPUVTFE
MFBWFUIFGBDUPSZJOTUBMMFEKVNQFSTJOQMBDF4FFBMTPTFDUJPO
4BGFUPSRVFPGG450
R6… R9 only: Ext 24V AC/DC input to power up the
control unit when the main supply is disconnected.

10
Control cable installation examples
This section shows examples for routing the control cables in frames R4 and R6…R9. Frames R1…R3 and R5 are similar to
frame R4.
Embedded fieldbus connection
You can connect the drive to a serial communication link with a fieldbus adapter module or the embedded fieldbus
interface. The embedded fieldbus interface supports Modbus RTU.
To configure Modbus RTU communication with the embedded fieldbus:
1. Connect the fieldbus cable and the required I/O signals. Use Belden 9842 or equivalent. Belden 9842 is a dual twisted,
shielded pair cable with a wave impedance of 120 Ohms.
2. If the drive is at the end of the fieldbus, set the termination switch to ON.
3. Power up the drive and set the required parameters. Refer to Fieldbus communication.
A connection example is shown below.
1) The devices at the ends of the fieldbus must have termination on. All other devices must have termination off.
2) One device must have bias on. It is recommended that this device is at the end of the fieldbus.
3) Attach the cable shields together at each drive, but do not connect them to the drive. Connect the shields only to the
grounding terminal in the automation controller.
4) Connect the signal ground (DGND) conductor to the signal ground reference terminal in the automation controller. If the
automation controller does not have a signal ground reference terminal, connect the signal ground to the cable shields
through a 100 ohm resistor, preferably near the automation controller.
R6…R9R4
GR - +
DGND DGND DGND
ON
1
ON
1
ON
1
ON
1
ON
1
ON
1
B+
A-
B+
A-
B+
A-
Automation
controller
Drive Drive Drive
Termination ON1) Termination and bias OFF Termination and bias OFF Termination and bias
ON1)2)
3)
4)