ABB ACH580-31-027A-4 Manuals

Manuals and User Guides for ABB ACH580-31-027A-4. We have 1 ABB ACH580-31-027A-4 manual available for free PDF download: Hardware Manual

ABB ACH580-31-027A-4 Hardware Manual (254 pages)

Brand: ABB | Category: DC Drives | Size: 25.65 MB

Table of Contents
5
Safety Instructions
15
Contents of this Chapter
15
Use of Warnings and Notes in this Manual
15
General Safety in Installation, Start-Up and Maintenance
16
Electrical Safety in Installation, Start-Up and Maintenance
18
Precautions before Electrical Work
18
Additional Instructions and Notes
19
Grounding
20
Additional Instructions for Permanent Magnet Motor Drives
22
Safety in Installation, Start-Up and Maintenance
22
Additional Instruction for DC Connection
22
Introduction to the Manual
23
Contents of this Chapter
23
Applicability
23
Target Audience
23
Purpose of the Manual
23
Categorization by Frame (Size)
23
Quick Installation and Commissioning Flowchart
24
Terms and Abbreviations
24
Related Documents
27
Operation Principle and Hardware Description
29
Contents of this Chapter
29
Operation Principle
30
DC Connection
30
Layout
31
Overview of Power and Control Connections
34
Control Panel
35
Control Panel Mounting Platform Cover (Option +J424)
36
Control Panel Door Mounting Kits
36
Remote Control Panel, Panel Bus
36
Type Designation Label
37
Type Designation Key
38
Mechanical Installation
41
Contents of this Chapter
41
Cabinet Installation (Option +P940)
41
Flange Mounting (Option +C135)
41
Safety
42
Examining the Installation Site
43
Required Tools
45
Moving the Drive
45
Unpacking and Examining Delivery
46
Installing the Drive Vertically
51
Installing the Drive Vertically Side by Side
53
Installing the Drive Horizontally
53
Guidelines for Planning the Electrical Installation
55
Contents of this Chapter
55
Selecting the Supply Disconnecting Device
55
European Union
55
Other Regions
56
Examining the Compatibility of the Motor and Drive
56
Protecting the Motor Insulation and Bearings
56
Requirements Table
57
Additional Requirements for ABB Motors of Types Other than M2_, M3_, M4_, HX_ and
59
Additional Requirements for the Regenerative and Low Harmonic Drives
59
Additional Requirements for ABB High-Output and IP23 Motors
59
Additional Requirements for Non-ABB High-Output and IP23 Motors
60
Additional Data for Calculating the Rise Time and Peak Line-To-Line Voltage
60
Additional Note for Sine Filters
62
Selecting the Power Cables
62
General Guidelines, IEC and North America
62
Additional Guidelines, IEC and North America
63
Preferred Power Cable Types
63
Power Cable Types for Limited Use
64
Not Allowed Power Cable Types
65
Additional Guidelines, North America
65
Conductor Type, IEC and North America
67
Power Cable Shield, IEC and North America
67
Typical Power Cable Sizes
68
IEC Ratings
69
UL (NEC) Ratings
70
Selecting the Control Cables
70
Shielding
70
Signals in Separate Cables
71
Signals Allowed to be Run in the same Cable
71
Relay Cable
71
Control Panel Cable
71
Drive Composer PC Tool Cable
71
Routing the Cables
71
General Guidelines, IEC
71
General Guidelines, North America
72
Separate Control Cable Ducts
74
Continuous Motor Cable Shield or Enclosure for Equipment on the Motor Cable
74
Implementing Thermal Overload and Short-Circuit Protection
75
Protecting the Drive and Input Power Cable in Short-Circuits
75
Circuit Breakers
75
Protecting the Motor and Motor Cable in Short-Circuits
75
Protecting the Drive and the Input Power and Motor Cables against Thermal Overload
75
Protecting the Motor against Thermal Overload
75
Implementing a Ground Fault Detection Function
76
Residual Current Device Compatibility
76
Implementing the Emergency Stop Function
76
Implementing the Safe Torque off Function
76
Implementing the ATEX-Certified Safe Motor Disconnection Function (Option +Q971)
76
Implementing the Undervoltage Control (Power-Loss Ride-Through)
76
Using a Safety Switch between the Drive and the Motor
77
Using a Contactor between the Drive and the Motor
77
Protecting the Contacts of Relay Outputs
77
Limiting Relay Output Maximum Voltages at High Installation Altitudes
78
Implementing a Motor Temperature Sensor Connection
79
Connection of Motor Temperature Sensor to the Drive Via an Option Module
80
Connection of Motor Temperature Sensor to the Drive Via a Relay
81
Ptc (Iec 60800-5-1)
81
Pt100 (IEC 60800-5-1)
81
Electrical Installation - IEC
83
Contents of this Chapter
83
Warnings
83
Grounding the Motor Cable Shield at the Motor End
84
Measuring the Insulation
84
Drive
84
Input Power Cable
84
Motor and Motor Cable
84
Brake Resistor Assembly
85
Tems
86
EMC Filter
86
Ground-To-Phase Varistor
86
When to Disconnect EMC Filter or Ground-To-Phase Varistor: TN-S, IT, Corner-Grounded Delta and Midpoint-Grounded Delta Systems and TT Systems
87
Identifying Different Types of Electrical Power Systems
89
Disconnecting Internal EMC Filter and Ground-To-Phase Varistor - Frame R3
90
Disconnecting Internal EMC Filter and Ground-To-Phase Varistor - Frame R6
91
Disconnecting Internal EMC Filter and Ground-To-Phase Varistor -Frame R8
92
Connecting the Power Cables
93
Connection Diagram
93
Connection Procedure
94
R8 Power Cable Connection if You Detach the Cable Connectors
101
Connecting the Control Cables
103
Default I/O Connection Diagram (HVAC Default Configuration)
104
Switches
105
Additional Information on I/O Connections
105
PNP Configuration for Digital Inputs
106
NPN Configuration for Digital Inputs
106
Connection for Obtaining 0
107
Connection Examples of Two-Wire and Three-Wire Sensors
108
DI5 as Frequency Input
108
DI6 as PTC Input
108
AI1 and AI2 as Pt100, Pt1000, Ni1000, KTY83 and KTY84 Sensor Inputs (X1)
109
Safe Torque off (X4)
109
Control Cable Connection Procedure
110
Installing Optional Modules
114
Mechanical Installation of Option Modules
114
Option Slot 2 (I/O Extension Modules)
114
Option Slot 1 (Fieldbus Adapter Modules)
115
Wiring the Optional Modules
115
Reinstalling Cover(S)
116
Connecting a PC
117
Connecting a Remote Panel, or Chaining One Panel to Several Drives
117
Electrical Installation - North America
119
Contents of this Chapter
119
Warnings
119
Required Tools
119
Measuring the Insulation
119
Drive
120
Input Power Cable
120
Motor and Motor Cable
120
Brake Resistor Assembly
120
Tems
121
Connecting the Power Cables
122
Connection Diagram
122
Connection Procedure
123
R8 Power Cable Connection if You Detach the Connectors
130
Connecting the Control Cables
132
Default I/O Connection Diagram (HVAC Default Configuration)
133
Switches
134
Additional Information on Control Connections
134
Control Cable Connection Procedure
135
Installing Optional Modules
139
Reinstalling Cover(S)
139
Connecting a PC
139
Connecting a Remote Panel, or Chaining One Panel to Several Drives
140
Installation Checklist
141
Contents of this Chapter
141
Warnings
141
Checklist
141
Start-Up
143
Contents of this Chapter
143
Start-Up Procedure
143
Maintenance and Hardware Diagnostics
145
Contents of this Chapter
145
Maintenance Intervals
145
Description of Symbols
146
Recommended Annual Maintenance Actions by the User
146
Recommended Maintenance Actions by the User
146
Heatsink
147
Fans
147
Replacing the Main Cooling Fan, Frame R3
148
Replacing the Main Cooling Fan, Frame R6
149
Replacing the Main Cooling Fan, Frame R8
150
Replacing the Main Cooling Fan, Frame R6
150
Replacing the Auxiliary Cooling Fan, IP55 (UL Type 12) Frame R3
151
Replacing the Auxiliary Cooling Fan, Frame R6
152
Stop the Drive and Disconnect It from the Power Line. Wait for 5 Minutes and then Make Sure by Measuring that There Is no Voltage. See Section Electrical Work on Page
152
Replacing the Auxiliary Cooling Fan, Frame R8
153
Replacing the Second Auxiliary Cooling Fan IP55 (UL Type 12), Frame R8
154
Capacitors
156
Reforming the Capacitors
156
Control Panel
156
Drive Leds
157
Technical Data
159
Contents of this Chapter
159
Ratings
159
IEC Ratings
159
UL (NEC) Ratings
160
Definitions
161
Sizing
161
Derating
161
Derating in Case of Several Situations
161
Example
161
Ambient Temperature Derating, IP21 (UL Type 1)
162
Ambient Temperature Derating, IP55 (UL Type 12)
163
Ambient Temperature Derating in Table Format
164
Altitude Derating
165
Switching Frequency Derating
167
Fuses (IEC)
169
Ar Fuses DIN 43653 Stud-Mount
169
Ar Fuses DIN 43620 Blade Style
169
Gg Fuses DIN 43620 Blade Style
170
Calculating the Short-Circuit Current of the Installation
171
Fuses (UL)
173
Circuit Breakers
174
Dimensions, Weights and Free Space Requirements
174
Free Space Requirements
174
Losses, Cooling Data and Noise
175
Cooling Air Flow and Heat Dissipation for Flange Mounting (Option +C135)
176
Terminal and Entry Data for the Power Cables
177
Iec
177
UL Listed Cable Lugs and Tools
179
Terminal and Entry Data for the Control Cables
180
Iec
180
Electrical Power Network Specification
180
Voltage (U1)
180
Motor Connection Data
182
CCU-24 Control Unit Connection Data
184
Efficiency
188
Degree of Protection
188
Materials
188
Applicable Standards
190
Ambient Conditions
191
Markings
192
EMC Compliance (IEC/EN 61800-3:2004 + A1:2012)
193
Definitions
193
Category C2
194
Category C3
194
Category C4
195
UL Checklist
195
EU Declaration of Conformity (Machinery Directive)
197
Disclaimers
197
General Disclaimer
197
Cybersecurity Disclaimer
197
Dimension Drawings
199
Contents of this Chapter
199
R3, IP21 (UL Type 1)
200
R3 - Option +B056 (IP55, UL Type 12)
201
R6, IP21 (UL Type 1)
202
R6 - Option +B056 (IP55, UL Type 12)
203
R8, IP21 (UL Type 1)
204
R8 - Option +B056 (IP55, UL Type 12)
205
The Safe Torque off Function
207
Contents of this Chapter
207
Description
207
Compliance with the European Machinery Directive
208
Wiring
208
Connection with Internal +24 V DC Power Supply
209
Connection with External +24 V DC Power Supply
210
Wiring Examples
210
Activation Switch
211
Cable Types and Lengths
211
Grounding of Protective Shields
212
Operation Principle
212
Start-Up Including Acceptance Test
212
Competence
212
Acceptance Test Reports
212
Acceptance Test Procedure
212
Use
214
Maintenance
215
Competence
216
Fault Tracing
216
Safety Data (SIL, PL)
217
Abbreviations
218
Resistor Braking
219
Contents of this Chapter
219
Operation Principle and Hardware Description
219
Planning the Braking System
219
Selecting the Brake Circuit Components
219
Selecting a Custom Resistor
220
Selecting and Routing the Brake Resistor Cables
220
Minimizing Electromagnetic Interference
221
Maximum Cable Length
221
EMC Compliance of the Complete Installation
221
Placing the Brake Resistors
221
Protecting the System against Thermal Overload
222
Protecting the System in Fault Situations
222
Protecting the Resistor Cable against Short-Circuits
222
Mechanical Installation
223
Electrical Installation
223
Measuring the Insulation
223
Connection Diagram
223
Connection Procedure
223
Start-Up
223
Technical Data
223
Ratings
223
Terminals and Cable Lead-Through Data
223
Common Mode, Du/Dt and Sine Filters
225
Contents of this Chapter
225
Common Mode Filters
225
Du/Dt Filters
226
When Is a Du/Dt Filter Needed
226
Du/Dt Filter Types
226
Description, Installation and Technical Data of the Filters
227
Sine Filters
228
Derating
228
Optional I/O Extension Modules
229
What this Chapter Contains
229
CHDI-01 115/230 V Digital Input Extension Module
229
Hardware Description
229
Product Overview
229
Layout
230
Mechanical Installation
230
Necessary Tools and Instructions
230
Unpacking and Checking the Delivery
230
Installing the Module
231
Electrical Installation
231
Warnings
231
Necessary Tools and Instructions
231
Terminal Designations
231
General Cabling Instructions
232
Wiring
232
Start-Up
233
Setting the Parameters
233
Diagnostics
233
Faults and Warning Messages
233
Leds
233
Technical Data
234
CMOD-01 Multifunction Extension Module (External 24 V AC/DC and Digital I/O)
236
Hardware Description
236
Product Overview
236
Layout
237
Mechanical Installation
237
Necessary Tools and Instructions
237
Diagnostic LED
237
Unpacking and Checking the Delivery
238
Installing the Module
238
Electrical Installation
238
Warnings
238
Necessary Tools and Instructions
238
Terminal Designations
238
Open the Option Package
238
Make Sure that the Package Contains
238
Support Part
238
Make Sure that There Are no Signs of Damage
238
General Cabling Instructions
239
Wiring
239
Start-Up
241
Setting the Parameters
241
Diagnostics
242
Faults and Warning Messages
242
Leds
242
Technical Data
243
Hardware Description
245
Product Overview
245
Layout
246
Mechanical Installation
246
Necessary Tools and Instructions
246
Unpacking and Checking the Delivery
247
Installing the Module
247
Electrical Installation
247
Warnings
247
Necessary Tools and Instructions
247
Terminal Designations
247
General Cabling Instructions
248
Wiring
248
Start-Up
249
Setting the Parameters
249
Diagnostics
250

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