—

ABB GENERAL PURPOSE DRIVES

ACS580-07
Hardware manual
ACS580-07
Hardware manual

Table of contents

1. Safety instructions

4. Mechanical installation

5. Guidelines for planning the

electrical installation

9. Start-up

© 2019 ABB Oy. All Rights Reserved. 3AXD50000045815 Rev D

EN
EFFECTIVE: 2019-07-03
 Table of contents 5

Table of contents

1 Safety instructions
Contents of this chapter .......................................................................... 15
Use of warnings and notes ...................................................................... 15
General safety in installation, start-up and maintenance ................................... 16
General safety in operation ...................................................................... 19
Electrical safety in installation, start-up and maintenance .................................. 20
Electrical safety precautions ................................................................. 20
Additional instructions and notes ............................................................ 22
Optical components ....................................................................... 23
Printed circuit boards ...................................................................... 23
Grounding ...................................................................................... 23
Additional instructions for permanent magnet motor drives ................................ 25
Safety in installation, start-up, maintenance ............................................... 25
Safety in operation ............................................................................ 25

2 Introduction to the manual

Contents of this chapter .......................................................................... 27
Target audience ................................................................................... 27
Related manuals .................................................................................. 27
Categorization by frame size and option code ............................................... 28
Quick installation, start-up and operating flowchart .......................................... 28
Terms and abbreviations ......................................................................... 29

3 Operation principle and hardware description

Contents of this chapter .......................................................................... 31
Product overview .................................................................................. 31
Single-line circuit diagram of the drive ..................................................... 32
General information on the cabinet layout ................................................. 33
Cabinet layout – R6 and R7 (bottom entry and exit of cables) ......................... 33
Cabinet layout – R8 and R9 (bottom entry and exit of cables) ......................... 34
Mounting plate – R6 to R9 ................................................................... 36
Cabinet layout – R10 and R11 (bottom entry and exit of cables) ...................... 38
Mounting plate .............................................................................. 39
Cooling air flow ................................................................................ 41
Overview of power and control connections ............................................... 42
Door switches and lights ..................................................................... 43
Main switch-disconnector Q1 ............................................................ 43
Control panel ................................................................................... 43
Control by PC tools ........................................................................ 44
Common mode filter .......................................................................... 44
Descriptions of cabinet options ................................................................. 44
Degree of protection .......................................................................... 44
Definitions ................................................................................... 44
IP21 .......................................................................................... 45
IP42 (option +B054) ....................................................................... 45
6 Table of contents

IP54 (option +B055) ....................................................................... 45

UL listed (option +C129) ..................................................................... 45
Plinth height (options +C164 and +C179) ................................................. 45
Empty cubicles (options +C196 to +C201) ................................................ 45
du/dt filter (option +E205) .................................................................... 45
Molded case circuit breaker (MCCB, option +F289) ..................................... 46
Cabinet heater with external supply (option +G300) ..................................... 46
Top cable entry/exit (options +H351 and +H353) ......................................... 46
Cable conduit entry (option +H358) ........................................................ 46
Additional terminal block X504 (option +L504) ............................................ 46
Type designation label ........................................................................... 47
Type designation key ............................................................................. 47

4 Mechanical installation
Contents of this chapter .......................................................................... 51
Examining the installation site .................................................................. 51
Necessary tools ................................................................................... 52
Moving and unpacking the drive ................................................................ 53
Unpacking the transport package ........................................................... 55
Checking the delivery ......................................................................... 55
Lifting the cabinet .............................................................................. 56
Moving the cabinet after unpacking ........................................................ 57
Moving on rollers ........................................................................... 57
Final placement ............................................................................ 58
Attaching the cabinet to the floor and wall or roof ............................................ 58
General rules ................................................................................... 58
Attaching methods ............................................................................ 59
Alternative 1 – Clamping .................................................................. 59
Alternative 2 – Using the holes inside the cabinet .................................... 60
Miscellaneous ..................................................................................... 60
Cable duct in the floor below the cabinet .................................................. 60
Arc welding ..................................................................................... 60

5 Guidelines for planning the electrical installation

Contents of this chapter .......................................................................... 63
Limitation of liability ............................................................................... 63
Selecting the supply disconnecting device .................................................... 63
Selecting the main contactor .................................................................... 63
Examining the compatibility of the motor and drive .......................................... 64
Protecting the motor insulation and bearings ............................................. 64
Requirements table ........................................................................... 64
Availability of du/dt filter and common mode filter by drive or inverter type ....... 67
Additional requirements for explosion-safe (EX) motors ............................. 67
Additional requirements for ABB motors of types other than M2_, M3_, M4_, HX_
and AM_ ..................................................................................... 67
Additional requirements for braking applications ...................................... 67
Additional requirements for the regenerative and low harmonics drives .......... 67
Additional requirements for ABB high-output and IP23 motors ..................... 67
Additional requirements for non-ABB high-output and IP23 motors ................ 67
Additional data for calculating the rise time and the peak line-to-line voltage .... 68
Additional note for common mode filters ............................................... 69
 Table of contents 7

Selecting the power cables ...................................................................... 69

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

Protecting the contacts of relay outputs ....................................................... 84

Implementing a motor temperature sensor connection ..................................... 85

6 Electrical installation
Contents of this chapter .......................................................................... 87
Warnings ........................................................................................... 87
Attaching the device stickers on the cabinet door ........................................... 87
Layout of the cable entries (frames R6 to R9) ................................................ 88
Layout of the cable entries (frames R10 and R11) ........................................... 89
Connecting the power cables ................................................................... 90
Connection diagram .......................................................................... 90
Checking the insulation of the drive system ............................................... 91
Checking the insulation of the input cable ................................................. 91
Checking the compatibility with IT (ungrounded), corner-grounded delta, midpoint-
grounded delta, and TT systems ............................................................ 91
Ground-to-phase varistor ................................................................. 91
When to disconnect the ground-to-phase varistor: TN-S, IT, corner-grounded
delta and midpoint-grounded delta systems ........................................... 91
Guidelines for installing the drive to a TT system ..................................... 92
Identifying different types of electrical power systems ............................... 93
Disconnecting the EMC filter and ground-to-phase varistor (R6 to R9) ........... 94
Disconnecting the ground-to-phase varistor (R10 and R11) ........................ 94
Connecting the motor cable at the motor end ............................................. 96
Checking the insulation of the motor and motor cable ............................... 96
Connection procedure (IEC, frames R6 to R9) ........................................... 96
Connection procedure (IEC, frames R10 and R11) ...................................... 100
Connecting the control cables .................................................................. 104
Overview of control cable connection procedure ......................................... 104
Grounding the outer shields of the control cables at the cabinet entry ................ 105
Routing the control cables inside the cabinet ............................................. 107
Connecting external wiring to the control unit or optional I/O terminal block ......... 108
Connecting the emergency stop push buttons (options +Q951 and +Q963) ......... 109
Connecting the Safe torque off circuit ...................................................... 109
Connecting external power supply wires for the cabinet heater (option +G300) ..... 110
Setting the voltage range of the auxiliary control voltage transformer (T21) ............. 111
Connecting a PC .................................................................................. 111
Installing option modules ........................................................................ 112
Option slot 2 (I/O extension modules) ...................................................... 112
Option slot 1 (fieldbus adapter modules) .................................................. 113
Wiring the optional modules ................................................................. 113

7 Control unit
Contents of this chapter .......................................................................... 115
Layout .............................................................................................. 115
Default I/O connection diagram ................................................................. 117
Option +E205 in frames R10 and R11: DI6 internal overtemperature supervision ... 118
Power supply connections for PNP with option +L504 ............................... 118
Power supply connections for NPN with option +L504 ............................... 119
Power supply connections for PNP without option +L504 ........................... 119
Power supply connections for NPN without option +L504 ........................... 119
Changing internal overtemperature supervision from DI6 to another digital input .120
 Table of contents 9

Switches ........................................................................................ 120

PNP configuration for digital inputs (X2 & X3) ............................................ 120
NPN configuration for digital inputs (X2 & X3) ............................................ 121
Connection for obtaining 0…10 V from analog output 2 (AO2) ......................... 121
Connection examples of two-wire and three-wire sensors to analog input (AI2) .... 122
DI6 as frequency input ........................................................................ 122
DI6 as PTC input .............................................................................. 122
AI1 and AI2 as Pt100, Pt1000, Ni1000, KTY83 and KTY84 sensor inputs (X1) ..... 123
Safe torque off (X4) ........................................................................... 123
Technical data ..................................................................................... 125

8 Installation checklist of the drive

Contents of this chapter .......................................................................... 129
Checklist ........................................................................................... 129

9 Start-up
Contents of this chapter .......................................................................... 131
Start-up procedure ................................................................................ 131

10 Fault tracing
Contents of this chapter .......................................................................... 133
Warning and fault messages .................................................................... 133

11 Maintenance
Contents of this chapter .......................................................................... 135
Maintenance intervals ............................................................................ 135
Descriptions of symbols ...................................................................... 135
Recommended annual maintenance actions by the user. .............................. 136
Recommended maintenance intervals after start-up ..................................... 136
Cleaning the interior of the cabinet ............................................................. 136
Cleaning the air inlet (door) meshes (IP42 / UL Type 1 Filtered) .......................... 137
Replacing the air filters (IP54 / UL Type 12) .................................................. 137
Inlet (door) filters (IP54 / UL Type 12) ...................................................... 137
Outlet (roof) filters (IP54 / UL Type 12) ..................................................... 138
Heatsink ............................................................................................ 138
Fans ................................................................................................ 139
Replacing the door fan (frames R6 to R9) ................................................. 139
Replacing the cabinet fan (frames R6 to R9) ............................................. 140
Replacing the door fan (frames R10 and R11) ............................................ 141
Replacing the cabinet fan (frames R10 and R11, IP54) ................................. 143
Replacing the drive module main fans (frames R6 to R8) .............................. 144
Replacing the drive module main fans (frame R9) ....................................... 145
Replacing the drive module main fans (frames R10 and R11) ......................... 146
Replacing the auxiliary cooling fan of the drive module (frames R6 to R9) ........... 147
Replacing the circuit board compartment cooling fans (frames R10 and R11) ....... 147
Replacing the drive module (frames R6 to R9) ............................................... 148
Replacing the drive module (frames R10 and R11) .......................................... 154
Replacing the drive module (frames R10 and R11, IP54) .................................. 160
Capacitors ......................................................................................... 166
Reforming the capacitors ..................................................................... 166
10 Table of contents

Fuses ............................................................................................... 166

Replacing AC fuses (frames R6 and R7) .................................................. 166
Replacing AC fuses ........................................................................... 167
Control panel ...................................................................................... 168
Cleaning the control panel ................................................................... 168
Replacing the battery in the assistant control panel ...................................... 168

12 Technical data
Contents of this chapter .......................................................................... 171
Ratings ............................................................................................. 171
NEC ratings .................................................................................... 172
Definitions ...................................................................................... 173
Output derating .................................................................................... 173
Ambient temperature derating ............................................................... 173
Drive types other than ACS580-0414A-4 and ACS580-0430A-4 ................... 173
Drive types ACS580-0414A-4 and ACS580-0430A-4 ................................ 174
Altitude derating ............................................................................... 174
Deratings for special settings in the drive control program .............................. 175
Fuses (IEC) ........................................................................................ 176
Fuses (UL) ......................................................................................... 177
Fuses for branch circuit protection ............................................................. 178
Dimensions and weights ......................................................................... 179
Free space requirements ........................................................................ 179
Maximum allowed plinth height for the extraction/installation ramp ....................... 180
Typical power cable sizes ....................................................................... 180
Losses, cooling data and noise ................................................................. 181
Terminal and entry data for the power cables ................................................ 182
IEC – Standard configuration ................................................................ 182
IEC – With option +E205 ..................................................................... 182
US – Standard configuration ................................................................. 182
US – With option +E205 ...................................................................... 183
Connection drawings ............................................................................. 184
Terminal and connection data for auxiliary control circuits .................................. 210
Electrical power network specification ......................................................... 211
Motor connection data ........................................................................... 211
Control unit connection data .................................................................... 211
Efficiency ........................................................................................... 211
Protection classes ................................................................................ 212
Ambient conditions ............................................................................... 213
Auxiliary circuit power consumption ............................................................ 213
Materials ........................................................................................... 214
Applicable standards ............................................................................. 215
Markings ........................................................................................... 216
CE marking ........................................................................................ 216
Compliance with the European Low Voltage Directive .................................. 216
Compliance with the European EMC Directive ........................................... 216
Compliance with the European Machinery Directive ..................................... 216
Declaration of Conformity ................................................................. 217
Compliance with the EN 61800-3:2004 .................................................... 219
Definitions ................................................................................... 219
Category C2 ................................................................................ 219
Category C3 ................................................................................ 219
 Table of contents 11

Category C4 ................................................................................ 219

UL marking ......................................................................................... 220
Disclaimers ........................................................................................ 222
Generic disclaimer ............................................................................ 222
Cybersecurity disclaimer ..................................................................... 222

13 Dimension drawings
Frames R6 and R7 (IP21, UL Type 1) ......................................................... 224
Frames R6 and R7 (+B054: IP42, UL Type 1) ................................................ 225
Frames R6 and R7 (+B055: IP54, UL Type 12) .............................................. 226
Frames R6 and R7 (+H351 and +H353: top entry and exit) ................................ 227
Frames R6 and R7 (+F289) ..................................................................... 228
Frames R6 and R7 (+F289, +H351, +H353) .................................................. 229
Frames R8 and R9 (IP21) ....................................................................... 230
Frames R8 and R9 (+B054: IP42, UL Type 1) ................................................ 231
Frames R8 and R9 (+B055: IP54, UL Type 12) .............................................. 232
Frames R8 and R9 (+H351 and +H353: top entry and exit) ................................ 233
Frames R8 and R9 (+F289) ..................................................................... 234
Frames R8 and R9 (+F289, +H351, +H353) .................................................. 235
Frames R10 and R11 (IP21) .................................................................... 236
Frames R10 and R11 (+B054: IP42, UL Type 1) ............................................. 237
Frames R10 and R11 (+B055: IP54, UL Type 12) ........................................... 238
Frames R10 and R11 (+F289) .................................................................. 239
Frames R10 and R11 (+H351, +H353) ........................................................ 240
Frames R10 and R11 (+B054: IP42, UL type 1, +H351, +H353) .......................... 241
Frames R10 and R11 (+B055: IP54, UL type 12, +H351, +H353) ......................... 242

14 The Safe torque off function

Contents of this chapter .......................................................................... 243
Description ......................................................................................... 243
Compliance with the European Machinery Directive ..................................... 244
Wiring ............................................................................................... 245
Connection principle .......................................................................... 245
Connection with internal power supply ................................................. 245
Connection with external power supply ................................................. 246
Wiring examples ............................................................................... 246
Wiring with internal power supply ....................................................... 246
Wiring with external power supply ....................................................... 247
Activation switch ............................................................................... 247
Cable types and lengths ...................................................................... 247
Grounding of protective shields ............................................................. 248
Operation principle ................................................................................ 249
Start-up including acceptance test ............................................................. 250
Competence ................................................................................... 250
Acceptance test reports ...................................................................... 250
Acceptance test procedure .................................................................. 250
Use .................................................................................................. 252
Maintenance ....................................................................................... 253
Competence ................................................................................... 253
Fault tracing ....................................................................................... 254
12 Table of contents

Safety data ......................................................................................... 255

Abbreviations .................................................................................. 255
Declaration of conformity ..................................................................... 257
TÜV certificate ................................................................................. 258

15 Optional I/O extension modules

Contents of this chapter .......................................................................... 259
CBAI-01 bipolar analog IO extension module ................................................ 259
Hardware description ......................................................................... 259
Product overview .......................................................................... 259
Layout ....................................................................................... 260
Mechanical installation ....................................................................... 260
Necessary tools and instructions ........................................................ 260
Unpacking and checking the delivery ................................................... 260
Installing the module ...................................................................... 260
Electrical installation .......................................................................... 261
Necessary tools and instructions ........................................................ 261
Terminal designations ..................................................................... 261
General cabling instructions .............................................................. 261
Wiring ........................................................................................ 261
Start-up ......................................................................................... 263
Setting the parameters .................................................................... 263
Diagnostics ..................................................................................... 263
LEDs ......................................................................................... 263
Technical data .................................................................................. 264
Dimension drawing ........................................................................ 264
CHDI-01 115/230 V digital input extension module .......................................... 266
Hardware description ......................................................................... 266
Product overview .......................................................................... 266
Layout ....................................................................................... 266
Mechanical installation ....................................................................... 266
Necessary tools and instructions ........................................................ 266
Unpacking and checking the delivery ................................................... 266
Installing the module ...................................................................... 267
Electrical installation .......................................................................... 267
Necessary tools and instructions ........................................................ 267
Terminal designations ..................................................................... 267
General cabling instructions .............................................................. 268
Wiring ........................................................................................ 268
Start-up ......................................................................................... 268
Setting the parameters .................................................................... 268
Diagnostics ..................................................................................... 270
Faults and warning messages ........................................................... 270
LEDs ......................................................................................... 270
Technical data .................................................................................. 270
CMOD-01 multifunction extension module (external 24 V AC/DC and digital I/O) ...... 272
Hardware description ......................................................................... 272
Product overview .......................................................................... 272
Layout ....................................................................................... 272
Mechanical installation ....................................................................... 273
Necessary tools and instructions ........................................................ 273
Unpacking and checking the delivery ................................................... 273
 Table of contents 13

Installing the module ...................................................................... 273

Electrical installation .......................................................................... 273
Necessary tools and instructions ........................................................ 273
Terminal designations ..................................................................... 273
General cabling instructions .............................................................. 274
Wiring ........................................................................................ 274
Start-up ......................................................................................... 275
Setting the parameters .................................................................... 275
Diagnostics ..................................................................................... 277
Faults and warning messages ........................................................... 277
LEDs ......................................................................................... 277
Technical data .................................................................................. 278
CMOD-02 multifunction extension module (external 24 V AC/DC and isolated PTC
interface) ........................................................................................... 280
Hardware description ......................................................................... 280
Product overview .......................................................................... 280
Layout ....................................................................................... 281
Mechanical installation ....................................................................... 281
Necessary tools and instructions ........................................................ 281
Unpacking and checking the delivery ................................................... 281
Installing the module ...................................................................... 282
Electrical installation .......................................................................... 282
Necessary tools and instructions ........................................................ 282
Terminal designations ..................................................................... 282
General cabling instructions .............................................................. 282
Wiring ........................................................................................ 283
Start-up ......................................................................................... 284
Setting the parameters .................................................................... 284
Diagnostics ..................................................................................... 284
Faults and warning messages ........................................................... 284
LEDs ......................................................................................... 284
Technical data .................................................................................. 284
CPTC-02 ATEX-certified thermistor protection module (external 24 V AC/DC and
isolated PTC interface) ........................................................................... 286

Further information
14
 Safety instructions 15

1
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.
16 Safety instructions

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, etc.
• Lift a heavy drive with a lifting device. Use the designated lifting points. See the dimension
drawings.
• Secure the drive cabinet to the floor to prevent it from toppling over. The cabinet has a
high center of gravity. When you pull out heavy components or power modules, there
is a risk of overturning. Secure the cabinet also to the wall when necessary.

• Do not stand or walk on the cabinet roof. Make sure that nothing presses against the
roof, side or back plates or door. Do not store anything on the roof while the drive is in
operation.
• Frames R10 and R11: Do not use the module installation ramp with plinth heights which
exceeds the maximum allowed height. See the technical data.
• Frames R10 and R11: Secure the module extraction/installation ramp carefully.
• Frames R10 and R11: To prevent the drive module from falling, attach its top lifting lugs
with chains to the cabinet lifting lug before you push the module into the cabinet and
pull it from the cabinet. Push the module into the cabinet and pull it from the cabinet
carefully preferably with help from another person. Keep a constant pressure with one
foot on the base of the module to prevent the module from falling on its back. Make
sure that the module does not topple over when you move it on the floor. To extend the
support legs, press each leg a little down (1, 2) and turn it aside. Whenever possible
secure the module also with chains. The module overturns from a sideways tilt of 5
degrees.
 Safety instructions 17

1 3

• 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 the dust inside the drive.
• Make sure that debris from drilling, cutting and grinding does not enter the drive during
the installation. Electrically conductive debris inside the drive may cause damage or
malfunction.
• Make sure that there is sufficient cooling. See the technical data.
• Keep the cabinet doors closed when the drive is powered. With the doors open, a risk
of a potentially fatal electric shock, arc flash or high-energy arc blast exists. If you cannot
avoid working on a powered drive, obey the local laws and regulations on live working
(including – but not limited to – electric shock and arc protection).
• Before you adjust the drive operation limits, make sure that the motor and all driven
equipment can operate throughout the set operation limits.
18 Safety instructions

• 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 61800-5-1, subclause 6.5.3, for example, "THIS MACHINE STARTS
AUTOMATICALLY".
• The maximum drive power cycles is five times in ten minutes. Power cycling the drive
too often can damage the charging circuit of the DC capacitors.
• Validate any safety circuits (for example, Safe torque off or emergency stop) in 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.
• Depending on the wiring and parametrization of the drive, the stop key on the control
panel may not stop the drive.
• Only authorized persons are allowed to repair a malfunctioning drive.
 Safety instructions 19

General safety in operation

These instructions are for all personnel that operate the drive.

WARNING!
Obey these instructions. If you ignore them, injury or death, or damage to the
equipment can occur.

• Do not power up the drive more than five times in ten minutes. Too frequent power-ups
can damage the charging circuit of the DC capacitors. If you need to start or stop the
drive, use the control panel start and stop keys or commands through the I/O terminals
of the drive.
• Give a stop command to the drive before you reset a fault. If you have an external source
for the start command and the start is on, the drive will start immediately after the fault
reset, unless you configure the drive for pulse start. See the firmware manual.
• Before you activate automatic fault reset 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.

Note:
When the control location is not set to Local, the stop key on the control panel will not stop
the drive.
20 Safety instructions

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 electrician, do not do installation or maintenance work.
Go through these steps before you begin any installation or maintenance work.

1. Keep the cabinet doors closed when the drive is powered. With the doors open, a risk
of a potentially fatal electric shock, arc flash or high-energy arc blast exists.
2. Clearly identify the work location and equipment.
3. 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.
• Open the charging switch if present.
• Open the disconnector of the supply transformer. (The main disconnecting device
in the drive cabinet does not disconnect the voltage from the AC input power busbars
of the drive cabinet.)
• Open the auxiliary voltage switch-disconnector (if present), and all other possible
disconnecting devices that isolate the drive from dangerous voltage sources.
• 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 any 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.
4. Protect any other energized parts in the work location against contact.
5. Take special precautions when close to bare conductors.
6. Measure that the installation is de-energized. If the measurement requires removal or
disassembly of shrouding or other cabinet structures, obey the local laws and regulations
applicable to live working (including – but not limited to – electric shock and arc
protection).
• Use a multimeter with an impedance greater than 1 Mohm.
• Make sure that the voltage between the drive input power terminals (L1, L2, L3)
and the grounding (PE) busbar is close to 0 V.
• Make sure that the voltage between the drive DC busbars (+ and -) and the
grounding (PE) busbar is close to 0 V.
• If you have a permanent magnet motor connected to the drive, make sure that the
voltage between the drive output terminals (T1/U, T2/V, T3/W) and the grounding
(PE) busbar is close to 0 V.
 Safety instructions 21

Measuring points of frames R6 to R9 are shown below.

PE

L1, L2, L3

„
22 Safety instructions

Measuring points of frames R10 and R11 are shown below. You can also remove the
metallic shield and measure through the holes in the clear plastic shroud behind it.

L1 L2 L3

7. Install temporary grounding as required by the local regulations.

8. Ask the person in control of the electrical installation work for a permit to work.

￭ 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 electrician, 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.
• ABB recommends not to secure the cabinet by arc welding. If you have to, obey the
welding instructions in the drive manuals.
Note:
• The motor cable terminals of the drive are at a dangerous voltage when the input power
is on, regardless of whether the motor is running or not.
• When the input power is on, the drive DC bus is at a dangerous voltage.
 Safety instructions 23

• 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.

Optical components

WARNING!
Obey these instructions. If you ignore them, damage to the equipment can occur.

• Handle the fiber optic cables with care.

• When you unplug the fiber optic cables, always hold the connector, not the cable itself.
• Do not touch the ends of the fibers with bare hands as the ends are extremely sensitive
to dirt.
• Do not bend the fiber optic cables too tightly. The minimum allowed bend radius is
35 mm (1.4”).

Printed circuit boards

WARNING!
Use a grounding wrist band when you handle printed circuit boards. Do not touch
the boards unnecessarily. The boards contain components sensitive to electrostatic
discharge.

￭ 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 electrician, do not do grounding work.

• Always ground the drive, the motor and adjoining equipment. This is necessary for the
personnel safety. Proper grounding also reduces electromagnetic emission and
interference.
• Make sure that the conductivity of the protective earth (PE) conductors is sufficient. See
the electrical planning instructions of the drive. Obey the local regulations.
• Connect the power cable shields to protective earth (PE) terminals of the drive to make
sure of personnel safety.
• Make a 360° grounding of the power and control cable shields at the cable entries to
suppress electromagnetic disturbances.
• In a multiple-drive installation, connect each drive separately to the protective earth
(PE) busbar of the power supply.
Note:
• You can use power cable shields as grounding conductors only when their conductivity
is sufficient.
• As the normal touch current of the drive is higher than 3.5 mA AC or 10 mA DC, you
must use a fixed protective earth (PE) connection. The minimum size of the protective
earth conductor must comply with the local safety regulations for high protective earth
24 Safety instructions

conductor current equipment. See standard IEC/EN 61800-5-1, 4.3.5.5.2., and the
electrical planning instructions of the drive.
 Safety instructions 25

Additional instructions for permanent magnet motor drives

￭ Safety in installation, start-up, maintenance
These are additional warnings concerning permanent magnet motor drives. The other safety
instructions in this chapter are also valid.

WARNING!
Obey these instructions. If you ignore them, injury or death, or damage to the
equipment can occur.
If you are not a qualified electrician, do not do installation or maintenance work.

• 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
power terminals.
Before installation, start-up and maintenance work on the drive:
• Stop the drive.
• Disconnect the motor from the drive with a safety switch or by other means.
• If you cannot disconnect the motor, make sure that the motor cannot rotate during work.
Make sure that no other system, like hydraulic crawling drives, can rotate the motor
directly or through any mechanical connection like felt, nip, rope, etc.
• Do the steps in section Electrical safety precautions (page 20)
• Measure that the installation is de-energized.
• Use a multimeter with an impedance greater than 1 Mohm.
• Make sure that the voltage between the drive output terminals (T1/U, T2/V, T3/W)
and the grounding (PE) busbar is close to 0 V.
• Make sure that the voltage between the drive input power terminals (L1, L2, L3)
and the grounding (PE) busbar is close to 0 V.
• Make sure that the voltage between the drive DC busbars (+ and -) and the
grounding (PE) busbar is close to 0 V.
• Install temporary grounding to the drive output terminals (U2, V2, W2). Connect the
output terminals together as well as to the PE.
During the start up:
• Make sure that the motor cannot be run into overspeed, eg, driven by the load. Motor
overspeed causes overvoltage that can damage or destroy the capacitors in the
intermediate circuit of the drive.

￭ Safety in operation
WARNING!
Make sure that the motor cannot be run into overspeed, e.g. driven by the load.
Motor overspeed causes overvoltage that can damage or destroy the capacitors
in the intermediate circuit of the drive.
26
 Introduction to the manual 27

2
Introduction to the manual

Contents of this chapter

This chapter describes the manual. It contains a flowchart of steps in checking the delivery,
installing and starting up the drive. The flowchart refers to chapters/sections in this manual
and to other manuals.

Target audience
This manual is intended for people who plan the installation, install, start up and service the
drive, or create instructions for the end user of the drive concerning the installation and
maintenance of the drive.
Read the manual before working on the drive. You are expected to know the fundamentals
of electricity, wiring, electrical components and electrical schematic symbols.
The manual is written for readers worldwide. Both SI and imperial units are shown.

Related manuals
Name Code
Drive hardware manuals and guides
Drive/converter/inverter safety instructions Multilingual code:
3AXD50000037978
ACS580-07 drives /75 to 500 kW) hardware manual 3AXD50000045815
Converter module lifting device for drive cabinets hardware manual 3AXD50000210268
ACX-AP-x Assistant control panels user’s manual 3AUA0000085685
Drive firmware manuals and guides
ACS580 standard control program firmware manual 3AXD50000016097
Quick start-up guide for ACS580 drives with ACS580 standard control program 3AXD50000048035
28 Introduction to the manual

Name Code
Option manuals and guides
Emergency stop, stop category 0 (option +Q951) for ACS580-07, ACH580-07 and 3AXD50000171828
ACQ580-07 drives user's manual
Emergency stop, stop category 0 (option +Q963) without opening main contactor with 3AXD50000171835
safety relay for ACS580-07, ACH580-07 and ACQ580-07 drives user's manual
CPTC-02 ATEX-certified thermistor protection module, Ex II (2) GD (+L537+Q971) user's 3AXD50000030058
manual
FCAN-01 CANopen adapter module user's manual 3AFE68615500
FCNA-01 ControlNet adapter module user's manual 3AUA0000141650
FDNA-01 DeviceNet™ adapter module user's manual 3AFE68573360
FECA-01 EtherCAT adapter module user's manual 3AUA0000068940
FENA-01/-11/-21 Ethernet adapter module user's manual 3AUA0000093568
FEPL-02 Ethernet POWERLINK adapter module user's manual 3AUA0000123527
FPBA-01 PROFIBUS DP adapter module user's manual 3AFE68573271
FSCA-01 RS-485 adapter module user's manual 3AUA0000109533
Tool and maintenance manuals and guides
Drive composer start-up and maintenance PC tool user's manual 3AUA0000094606
Converter module capacitor reforming instructions 3BFE64059629

Categorization by frame size and option code

Some instructions, technical data and dimension drawings which concern only certain frame
sizes are marked with the symbol of the frame size, for example, R7. The frame size is
marked on the type designation label, see Type designation label (page 47).
The instructions, technical data and dimension drawings which concern only certain optional
selections are marked with option codes (such as +L504). The options included in the drive
can be identified from the option codes visible on the type designation label. The option
selections are listed in section Type designation key (page 47).

Quick installation, start-up and operating flowchart

Task See

Plan the electrical installation and acquire the accessories needed (cables, Guidelines for planning the
fuses, etc.). electrical installation (page 63)
Check the ratings, required cooling air flow, input power connection, compat- Technical data (page 171)
ibility of the motor, motor connection, and other technical data.

Check the installation site. Ambient conditions (page 213)

Unpack and check the units (only intact units may be started up). Mechanical installa-
Examine that all necessary option modules and equipment are present and tion (page 51)
correct. If the drive has been non-opera-
Mount the drive. tional for more than one year,
the converter DC link capacitors
need to be reformed (Reforming
the capacitors (page 166))
 Introduction to the manual 29

Task See

Route the cables. Routing the cables (page 75)

Check the insulation of the supply cable, the motor and the motor cable. Checking the insulation of the
motor and motor
cable (page 96)

Connect the power cables. Connecting the power

Connect the control cables. cables (page 90), Connecting
the control cables (page 104)

Check the installation. Installation checklist of the

drive (page 129)

Start the drive up. Start-up (page 131)

Operate the drive: start, stop, speed control etc. Start-up (page 131) and firmware
manual

Terms and abbreviations

Term/ Description
Abbreviation
CBAI-01 Bipolar analog IO extension module
CCU-24 Type of control unit
CHDI-01 115/230 V digital input extension module
CMOD-01 Multifunction extension module (external 24 V AC/DC and digital I/O extension)
CMOD-02 Multifunction extension module (external 24 V AC/DC and isolated PTC interface)
CPTC-02 Multifunction extension module (external 24 V and ATEX-certified PTC interface)
EMC Electromagnetic compatibility
FBIP-21 BACnet/IP adapter module
FCAN Optional CANopen® adapter module
FCNA-01 Optional ControlNet™ adapter module
FDCO-01 DDCS communication module with two pairs of 10 Mbit/s DDCS channels
FDNA-01 Optional DeviceNet™ adapter module
FECA-01 Optional EtherCAT® adapter module
FENA-11 Optional Ethernet adapter module for EtherNet/IP™, Modbus TCP® and PROFINET IO®
protocols
FENA-21 Optional Ethernet adapter module for EtherNet/IP™, Modbus TCP® and PROFINET IO®
protocols, 2-port
FEPL-01 Optional Ethernet POWERLINK adapter module
FPBA-01 Optional PROFIBUS DP® adapter module
Frame, frame Physical size of the drive or power module
size
IGBT Insulated gate bipolar transistor
STO Safe torque off (IEC/EN 61800-5-2)
30
 Operation principle and hardware description 31

3
Operation principle and hardware
description

Contents of this chapter

This chapter briefly describes the operation principle and construction of the drive.

Product overview
The ACS580-07 is an air-cooled cabinet-installed drive for controlling asynchronous AC
induction motors and permanent magnet motors.
32 Operation principle and hardware description

￭ „Single-line circuit diagram of the drive

R6 R7
Q1 Q2 T1 R11 R12

M
3~

F21
T21 F22

R8…R11
Q1 Q2 T1 R11 R12

M
3~

F21
T21 F22

Q1 In frames R6 and R7: Switch fuse or molded case circuit breaker (option +F289).
In frames R8 to R11: Switch-disconnector or molded case circuit breaker (option +F289).
Q2 Line contactor (option +F250)
T21 Auxiliary voltage transformer supplying 24 V and 230/115 V control voltage for, eg, cabinet fan(s), control
devices and I/O extension adapter module.
F21 Auxiliary voltage supply fuses
F22 Auxiliary circuit protection switch
T1 Drive module
R11 Common mode filter (option +E208 for frames R6 to R10). Standard for frame R11.
R12 du/dt filter (option +E205)
 Operation principle and hardware description 33

￭ General information on the cabinet layout

„ „

IP21 IP42
UL Type 1 UL Type 1
(option +B054)

￭ Cabinet layout – R6 and R7 (bottom entry and exit of cables)

The cabinet layout of frame R7 with dut/dt filter (option +E205) is shown below. Degree of
protection IP42 (option +B054). Frame R6 looks similar.
 „
34 Operation principle and hardware description

A B C

5
7

17
16
18
1
2
15

6 19
14

3 13
12
8 11 20

4
10
9
4

A Cabinet door closed 10 Auxiliary voltage transformer T21

B Cabinet door open 11 Motor cable connection terminals

Note:
For drives with no du/dt filter (option +E205), the
motor cables are connected to the drive module
terminals.

C Cabinet door open, mounting plate and cabinet 12 Input cable connection terminals
shrouds removed
1 Drive control panel 13 Main switch with AC fuses (Q1)
2 Operating switch 14 Main contactor (Q2, option +F250)
3 Main switch handle 15 Power cable connection terminals of the drive
module behind the shroud
4 Gratings for cooling air in 16 Drive module
5 Gratings for cooling air out 17 Additional I/O terminal block (option +L504)
6 Mounting plate, see section Mounting plate – R6 18 Drive control unit
to R9 (page 36)
7 Lifting lugs 19 Common mode filter (option +E208)
8 Cabinet door fan 20 du/dt filter (option +E205)
9 Power and control cable entries -

￭ Cabinet layout – R8 and R9 (bottom entry and exit of cables)

The cabinet layout of frame R9 with du/dt filter (option +E205) is shown below. Degree of
protection IP42 (option +B054). Frame R8 looks similar.
„
Operation principle and hardware description 35

A B C

5
7

17
16 18
1
2

15
6 19
14

13

3 12 20

11 21
8

4 10

9
4

A Cabinet door closed 10 Auxiliary voltage transformer T21

B Cabinet door open 11 Input cable connection terminals
C Cabinet door open, mounting plates and cabinet 12 Main switch-disconnector (Q1)
shrouds removed
1 Drive control panel 13 AC fuses
2 Operating switch 14 Main contactor (Q2, option +F250)
3 Main switch handle 15 Power cable connection terminals of the drive
module behind the shroud
4 Gratings for cooling air in 16 Drive module
5 Gratings for cooling air out 17 Additional I/O terminal block (option +L504)
6 Mounting plate, see section Mounting plate – R6 18 Drive control unit
to R9 (page 36)
7 Lifting lugs 19 Common mode filter (option +E208)
8 Cabinet door fan 20 du/dt filter (option +E205)
9 Power and control cable entries 21 Motor cable connection terminals

Note:
For drives with no du/dt filter (option +E205), the
motor cables are connected to the drive module
terminals.
36 Operation principle and hardware description

￭ Mounting plate – R6 to R9
The components and terminals on the mounting plate of frames R6 to R9 are shown below.
The layout of frames R6 and R7 is similar.

+G300 switch-disconnector and miniature circuit X3 External main contactor control

breaker for cabinet heater (option +G300)
A61 Emergency stop relay for options +Q951 X250 Indication of main contactor status5
and +Q963
Q95, F95 Switch-disconnector and miniature circuit X289 Indication of the status of the molded case
breaker for cabinet heater (option +G300) circuit breaker (option +F289)
F21 Auxiliary transformer fuses X300 Connection terminals for cabinet heater
(option +G300)
F22 Auxiliary transformer's secondary side X951 Connection of external emergency stop
miniature circuit breaker button (options +Q951 and Q963)
T22, C22 24VDC power supply and buffer with emer- X969 Connection of external Safe torque off but-
gency stop options (+Q951 and +Q963), ton
also with line contactor option (+F250).
X251, X4, X6, X56, X53, X51, X55, X18 and X19: for internal use.
 Operation principle and hardware description 37

X250
Terminals for

1 1 1 X250 Auxiliary contacts of line contactor (option +F250)

2 2 2 X289 Auxiliary contacts of molded case circuit breaker (op-
3 3 3 tion +F289)
4 4 4
X951 Push buttons for emergency stop option +Q951 or
PE PE PE +Q963. See section Connecting the emergency stop
push buttons (options +Q951 and +Q963) (page 109).

X969 External STO customer connection for safety option

+Q951 or +Q963. See section Connecting the Safe
- X289
torque off circuit (page 109).

1 1 1
2 2 2
3 3 3
4 4 4
5 5 5
6 6 6

„
38 Operation principle and hardware description

￭ Cabinet layout – R10 and R11 (bottom entry and exit of cables)

A B

1
10 10

2 3 9

11
7
12
4

13
5

14

A Cabinet door closed 7 Main switch-disconnector

B Cabinet door open 8 AC fuses
1 Gratings for cooling air out 9 Line contactor (option +F250)
2 Operating switch 10 Lifting lugs
3 Drive control panel 11 Drive control unit
4 Main switch handle 12 Mounting plate, see section Mounting
plate (page 39)
5 Gratings for cooling air in 13 Behind the shroud: Additional I/O terminal block
(option +L504)
6 "Door" fan at the back of the mounting plate. 14 Additional fan in IP54 cabinets (option +B055)
 Operation principle and hardware description 39

18

17
16

19

15

C Cabinet door open, mounting plates and cabinet 17 Input cable connection terminals
shrouds removed

15 Power and control cable entries 18 Drive module

16 Motor cable connection terminals 19 Auxiliary voltage transformer T21

Mounting plate
The components and terminals on the mounting plate of frames R10 and R11 are shown
below.
40 Operation principle and hardware description

A41 Drive control unit X289 Indication of the status of the molded case
circuit breaker (option +F289)
A61 Emergency stop relay for options +Q951 X300 Connection terminals for cabinet heater
and +Q963 (option +G300)
Q95, F95 Switch-disconnector and miniature circuit X951 Connection of external emergency stop
breaker for cabinet heater (option +G300) button (options +Q951 and Q963)
K26 Cabinet fan control relay X969 Connection of external Safe torque off but-
ton
F22 Auxiliary transformer's secondary side X504 Additional I/O terminal block (option +L504)
miniature circuit breaker
T22, C22 24VDC power supply and buffer with emer- K41.1 Ready pilot light control relay (option +G327)
gency stop options (+Q951 and +Q963),
also with line contactor option (+F250).
X3 External main contactor control K41.2 Run pilot light control relay (option+G328)
X250 Indication of main contactor status K41.3 Fault pilot light control relay (option +G329)
X251, X4, X6, X56, X53, X51, X55, X18 and X19: for internal use.
 Operation principle and hardware description 41

￭ Cooling air flow

The figure below shows cooling air flow in frames R6 to R9 (side view) and in frames R10
„ R11 (front view).
and

R6…R9 R10, R11

 42 Operation principle and hardware description

„ ￭ Overview of power and control connections

The diagram shows the power connections and control interfaces of the drive.

6
5 X12
... 4

.......... SLOT 1
..........
1

SLOT 2 ..........
..........
..........
..........
2
. . .
. . .

7 8

PE PE
L1 L1 U2

L2 L2 V2 M3~

9
L3 L3 W2

1 Option slot 1 for optional fieldbus adapter modules

2 Option slot 2 for optional I/O extension modules
3 Embedded fieldbus connector
4 Panel port
5 I/O terminal blocks. See section Layout (page 115) and section Default I/O connection diagram (page 117).
6 Control panel (page 43).
7 Connection terminals for options, see sections Mounting plate – R6 to R9 (page 36) and Mounting
plate (page 39).
8 Additional terminal block X504 (option +L504) (page 46).
9 du/dt filter (option +E205) (page 45).
 Operation principle and hardware description 43

￭ Door switches and

„ lights

1 2 3

4 5

Label in English Label in local Description

language
1 READY - Ready pilot light (option +G327)
2 RUN - Run pilot light (option+G328)
3 FAULT - Fault pilot light (option +G329)
4 MAIN CONT. - Operating switch with option +F250
OFF ON 0 Opens the main contactor (Q2) and disables starting of the drive
1 Closes the main contactor (Q2)

5 EMERGENCY - Emergency stop indication light and reset push button with options
STOP RESET +Q951 and +Q963
6 EMERGENCY - Emergency stop push button with options +Q951 and +Q963
STOP

Main switch-disconnector Q1
The switch-disconnector handle switches the main voltage to the drive on and off.

￭ Control panel
The control panel is the user interface of the drive. It provides the essential controls such
as Start/Stop/Direction/Reset/Reference, and the parameter settings for the control program.
One control panel can be used to control several drives through a panel link.
The control panel can be removed by pulling it forward from the top edge and disconnecting
the panel cable. The panel is reinstalled in reverse order. For the use of the control panel,
see the firmware manual or ACX-AP-x Assistant control panel user’s manual
(3AUA0000085685 [English]).
44 Operation principle and hardware description

Control by PC tools
There is a USB connector on the front of the panel that can be used to connect a PC to the
drive.
„ „When a PC is connected to the control panel, the control panel keypad is disabled.
￭ Common mode filter
The drive of frames R6 to R9 can be optionally equipped with a common mode filter. Frames
R10 and R11 are equipped with a common mode filter as standard. The filter contains ferrite
rings mounted around the drive AC conductors. The filter protects the motor bearings by
reducing the bearing currents.
More information on when the option is required: See section Examining the compatibility
of the motor and drive (page 64).

Descriptions of cabinet options

Note:
All options are not available for all drive types or do not coexist with certain other options.
Check actual availability with ABB.

￭ Degree of protection
Definitions
According to IEC/EN 60529, the degree of protection is indicated by an IP code where the
first numeral means protection against ingress of solid foreign objects, and the second
numeral protection against ingress of water. The IP codes of the standard cabinet and
options covered in this manual are defined below.

IP code The equipment is protected …

First numeral Second numeral
IP21 against ingress of solid foreign objects > 12.5 mm against dripping (vertically falling drops)
IP42 against ingress of solid foreign objects > 1 mm against dripping (15° tilting) water
IP54 dust-protected against splashing water
 Operation principle and hardware description 45

IP21
The degree of protection of the standard drive cabinet is IP21 (UL type 1). With doors open,
the degree of protection of the standard cabinet and all cabinet options is IP20. The live
parts inside the cabinet are protected against contact with clear plastic shrouds or metallic
gratings.

IP42 (option +B054)

This option provides the degree of protection of IP42 (UL type 1 Filtered). The air inlet
gratings are covered with a metallic mesh between the inner metallic grating and the outer
plastic grating.

IP54 (option +B055)

This option provides the degree of protection of IP54 (UL type 12). It provides the cabinet
air inlets with filter housings containing folded board air filter mats between the inner metallic
grating and the outer plastic grating. An additional fan on the cabinet roof is included.

￭ UL listed (option +C129)

The option includes factory inspection of the cabinet according to UL 508C and the following
accessories and features:
• US type main switch fuse
• US cable conduit entry (plain plate without ready-made holes)
• all components UL Listed/Recognized
• maximum supply voltage 480 V.
Related options: +H351 (top entry of cables), +H353 (top exit of cables) and +H358 (cable
conduit entry)

￭ Plinth height (options +C164 and +C179)

The standard height of the cabinet plinth is 50 mm. These options specify a plinth height of
100 mm (+C164) or 200 mm (+C179).

￭ Empty cubicles (options +C196 to +C201)

Note:
This option is available for US only.

These options add an empty cubicle to the drive cabinet: The cubicle is equipped with blank
power cable entries both at the top and the bottom.
• on the right-hand side of the converter cubicle (400 mm wide with option +C196, 600
mm wide with option +C197 and 800 mm wide with option +C198)
• on the left-hand side of the converter cubicle (400 mm wide with option +C199, 600 mm
wide with option +C200 and 800 mm wide with option +C201).

￭ du/dt filter (option +E205)

The du/dt filter protects the motor insulating system by reducing the voltage rise speed at
the motor terminals. The filter also protects the motor bearings by reducing the bearing
currents.
More information on when the option is required: See section Examining the compatibility
of the motor and drive (page 64).
46 Operation principle and hardware description

￭ Molded case circuit breaker (MCCB, option +F289)

This option replaces the standard main switch with a molded case circuit breaker. The
breaker has inbuilt protection functions against overload and short-circuit. It is operated with
a direct rotary handle on the cabinet door.
For US market only.

￭ Cabinet heater with external supply (option +G300)

The option contains:
• 50 W heating elements in the cubicles where needed
• load switch for providing electrical isolation during service
• miniature circuit breaker for overcurrent protection
• terminal block for external power supply.
The heater prevents humidity condensation inside the cabinet when the drive is not running.
The power output of the semiconductor-type heating elements depends on the environmental
temperature. The customer must switch the heating off when it is not needed by cutting the
supply voltage off.
The customer must supply the heater from an external 110…240 V AC power source.
See also
• Connecting external power supply wires for the cabinet heater (option +G300) (page 110)
• Auxiliary circuit power consumption (page 213)
• circuit diagrams delivered with drive for the actual wiring.

￭ Top cable entry/exit (options +H351 and +H353)

The default input and output cabling direction is through the bottom of the cabinet. The top
entry (+H351) and top exit (+H353) options provide power and control cable entries at the
roof of the cabinet. The entries are equipped with grommets and 360° grounding hardware.
The options add an additional 125 mm (4.92 in) wide cable channel to the cabinet width.

￭ Cable conduit entry (option +H358)

The option provides US/UK conduit plates (plain 3 mm [0.12"] thick steel plates without any
ready-made holes). US/UK conduit plates are provided as standard with option +C129
instead of the normal cable entries.

￭ Additional terminal block X504 (option +L504)

The standard terminal blocks of the drive control unit are wired to the additional terminal
block at the factory for customer control wiring. The terminals are spring loaded.
Cables accepted by the terminals:
• solid wire 0.2 to 2.5 mm2 (24 to 12 AWG)
• stranded wire with ferrule 0.25 to 2.5 mm2 (24 to 12 AWG)
• stranded wire without ferrule 0.2 to 2.5 mm2 (24 to 12 AWG).
Stripping length: 10 mm (0.5 in).
Note:
The option modules inserted in the slots of the control unit are not wired to the additional
terminal block. The customer must connect the option module control wires directly to the
modules.
 Operation principle and hardware description 47

Type designation label

The type designation label includes an IEC rating, appropriate markings, a type designation
and a serial number, which allow identification of each unit. The type designation label is
located on the front cover. An example label is shown below.

8
2
6

4
5 7 9

1 Type designation, see section Type designation key below.

2 Manufacturing address
3 Frame size
4 Cooling method
5 Degree of protection
6 Ratings, see section Ratings (page 171), Electrical power network specification (page 211) and Motor
connection data (page 211).
7 Short-circuit withstand strength, see section Electrical power network specification (page 211).
8 Valid markings
9 Serial number. The first digit of the serial number refers to the manufacturing plant. The next four digits
refer to the unit’s manufacturing year and week, respectively. The remaining digits complete the serial
number so that there are no two units with the same number.

Type designation key

The type designation contains information on the specifications and configuration of the
drive. The first digits from left express the basic configuration (eg, ACS580-07-0640A-4).
The optional selections are given thereafter, separated by plus signs, eg, +B055. The main
selections are described below. Not all selections are available for all types or with all options.
For more information, refer to ACX580-07 Ordering Information (3AXD10000485076 available
on request).

Code Description
Basic codes
ACS580 Product series
07 When no options are selected: cabinet-installed drive, IP21, main switch, AC fuses, ACS-AP-S as-
sistant control panel, for frames R6 to R9 EMC filtering for first environment TN grounded systems
(category C2), for frames R10 and R11 EMC filtering for second environment TN grounded systems
(category C3), input choke, common mode filter in frames R10 and R11, coated boards, ACS580
standard control program, EIA/RS-485 fieldbus connector, Safe torque off function, bottom entry
and exit of cables, multilingual device label sticker, USB memory stick containing all manuals.
Size
xxxx Refer to the rating tables, Ratings (page 171)
48 Operation principle and hardware description

Code Description
Voltage range
4 380…480 V. This is indicated in the type designation label as typical input voltage level 3~400/480
V AC.
Option codes (plus codes)
Degree of protection
B054 IP42 (UL Type 1)
B055 IP54 (UL Type 12)
Construction
C129 UL listed (option +C129) (page 45)
C164 Plinth 100 mm (3.94 in). Separate delivery.
C179 Plinth 200 mm (7.87 in). Separate delivery.
C196 Empty cabinet 400 mm on the right-hand side. For US market only. Not available for +H351 and
+H353. Not available with +C164 and +C179.
C197 Empty cabinet 600 mm on the right-hand side. For US market only. Not available for +H351 and
+H353. Not available with +C164 and +C179.
C198 Empty cabinet 800 mm on the right-hand side. For US market only. Not available with +C164 and
+C179. Not available with +C164 and +C179.
C199 Empty cabinet 400 mm on the left-hand side. For US market only. Not available with +C164 and
+C179. Not available with +C164 and +C179.
C200 Empty cabinet 600 mm on the left-hand side. For US market only. Not available with +C164 and
+C179. Not available with +C164 and +C179.
C201 Empty cabinet 800 mm on the left-hand side. For US market only. Not available with +C164 and
+C179. Not available with +C164 and +C179.
Filters
E205 du/dt filter (option +E205) (page 45)
E208 Common mode filter (page 44)
Line options
F250 Line contactor
F289 Molded case circuit breaker (MCCB) for US market only
Cabinet options
G300 Cabinet heater (external supply). See Cabinet heater with external supply (option +G300) (page 46).
G327 Ready pilot light, white
G328 Run pilot light, green
G329 Fault pilot light, red
Cabling
H351 Top entry of cables. Additional channel: 125 mm (4.92 in) in cabinet width.
H353 Top exit of cables, Additional channel: 125 mm (4.92 in) in cabinet width.
H358 Cable conduit entry (included with +C129). See Cable conduit entry (option +H358) (page 46).
Control panel
J429 ACS-AP-W Assistant control panel with Bluetooth interface
Fieldbus adapters
K451 FDNA-01 DeviceNet™ adapter module
K454 FPBA-01 PROFIBUS DP adapter module
K457 FCAN-01 CANopen adapter module
 Operation principle and hardware description 49

Code Description
K458 FSCA-01 RS-485 adapter module
K462 FCNA-01 ControlNet™ adapter module
K469 FECA EtherCat adapter module
K470 FEPL EtherPOWERLINK adapter module
K473 FENA-11 Ethernet adapter module for EtherNet/IP™, Modbus TCP and PROFINET IO protocols
K490 Ethernet/IP adapter module
K491 Modbus/TCP adapter module
K492 PROFINET IO adapter module
I/O extensions and feedback interfaces
L501 CMOD-01 external 24 V DC/AC and digital I/O extension module (two relay outputs and one digital
output)
L504 Additional I/O terminal block (Additional terminal block X504 (option +L504) (page 46))
L512 CHDI-01 115/230 V digital input extension module (six digital inputs and two relay outputs)
L523 CMOD-02 external 24 V and isolated PTC interface
L537 CPTC-02 ATEX-certified thermistor protection module
Specialties
P931 Extended warranty for 36 month from delivery
P932 Extended warranty for 60 month from delivery
P912 Seaworthy packing
P929 Container packing
Safety functions
Q951 Emergency stop of Category 0 with opening the main contactor or breaker
Q963 Emergency Stop, Category 0 without opening main contactor with safety relay
Q971 ATEX-certified Safe disconnection function, EX II (2) GD. Requires +L537
Printed documentation (manuals, dimensional drawings, circuit diagrams and manual language).

Note:
The delivered manual set may include manuals in English if the translation is not available.

R700 English
R701 German
R702 Italian
R703 Dutch
R704 Danish
R705 Swedish
R706 Finnish
R707 French
R708 Spanish
R709 Portuguese
R711 Russian
50
 Mechanical installation 51

4
Mechanical installation

Contents of this chapter

This chapter describes the mechanical installation procedure of the drive.
10
Examining the installation site
Examine the installation site:
• The installation site is sufficiently ventilated or cooled to remove heat from the drive.
See the technical data.
• The ambient conditions of the drive meet the specifications. See the technical data.
• There is enough free space above the drive to enable cooling, maintenance, and
operation of the pressure relief (if present).
• The floor that the drive cabinet is installed on is of non-flammable material, as smooth
as possible, and strong enough to support the weight of the unit. Check the floor flatness
with a spirit level. The maximum allowed deviation from the surface level is 5 mm in
every 3 meters. Level the installation site, if necessary, as the cabinet is not equipped
with adjustable feet.
52 Mechanical installation

Do not install the drive on an elevated platform or a recess. The module extraction/installation
ramp included with the drive is only suitable for a height difference of 50 mm maximum (ie.
the standard plinth height of the drive).

Necessary tools
The tools required for moving the unit to its final position, fastening it to the floor and wall
and tightening the connections are listed below:
• crane, fork-lift or pallet truck (check load capacity!), slate/spud bar, jack and rollers
• Pozidriv and Torx screwdrivers
• torque wrench
• set of wrenches or sockets.
 Mechanical installation 53

Moving and unpacking the drive

Move the drive in its original pallet in horizontal position, preferably in the original package
to installation site as shown below to avoid damaging the cabinet surfaces and door devices.
When you use a pallet truck, check its load capacity before you move the drive.
Horizontal package:

10
54 Mechanical installation

Vertical package:

2321

1
1088

A Lifting the transport package with slings.

1 Lifting points
B Lifting the transport package with forklift
 Mechanical installation 55

„￭ Unpacking the transport package

This drawing shows the layout of the horizontal transport package.

4
1
5

3
10
1

1 Bracket for attaching the drive to the wooden 5 Timber

pallet
2 Cardboard packing hood 6 Drive cabinet
3 Wooden pallet - -

Unpack the horizontal transport package as follows:

1. Cut the strips (4)
2. Remove the hood (2)
3. Undo the screws that attach the bracket (1) to the wooden pallet.
4. Remove the plastic wrapping.
5. After checking the delivery (see section Checking the delivery (page 55)), lift the drive
cabinet to its installation place (see section Lifting the cabinet (page 56)).
Unpack the vertical transport package as follows:
„1. Undo the screws that hold the wooden elements of the transport crate together.
2. Remove the elements.
3. Remove the clamps with which the drive cabinet is mounted onto the transport pallet
by undoing the fastening screws.
4. Remove the plastic wrapping.

￭ Checking the delivery

The drive delivery contains:
• drive cabinet
56 Mechanical installation

• option modules (if ordered) installed onto the control unit at the factory
• appropriate drive and option module manuals
• delivery documents.
Check that there are no signs of damage. Before attempting installation and operation,
check the information on the type designation labels of the drive to verify that the delivery
is of the correct type.

￭ Lifting the cabinet

„
Lift the drive cabinet up using its lifting lugs.

„
 Mechanical installation 57

„Lift the cabinet to its position. Maximum allowed angle of the lifting slings is 20° (10° for
frames R10 and R11, IP54).

Max. 20° Max. 10°

10

R10, R11 IP54

„￭ Moving the cabinet after unpacking

Move drive cabinet carefully in the upright position. Avoid tilting. The center of gravity of the
cabinet is high.

Moving on rollers

Lay the cabinet on the rollers and move it carefully

until close to its final location.
Remove the rollers by lifting the unit with a crane,
forklift, pallet truck or jack.
58 Mechanical installation

Final placement

Move the cabinet into its final position with an iron bar.
Place a wooden piece at the bottom edge of the cabinet
in order not to damage the cabinet frame with the iron
bar.

Attaching the cabinet to the floor and wall or roof

„
￭ General rules
• Install the drive cabinet in an upright vertical position with its back against a wall (a), or
back-to-back with another cabinet (b).
• Leave 400 mm (15.75 in) free space above the basic roof level of the cabinet for cooling.
IP54 (UL Type 12) fan replacement requires 320 mm (12.6 in) free space above.
• Leave some space at the side where the cabinet outmost hinges are to allow the doors
to open sufficiently (w). The doors must open 120° to allow the drive module replacement.

> 400 mm (15.75”)

b a w

120°
 Mechanical installation 59

Note 1: Make height adjustments before attaching the cabinet with metal shims between
the cabinet bottom and the floor.
Note 2: If you remove the lifting eyes, attach the bolts back to retain the degree of protection
of the cabinet.

￭ Attaching methods
„ the cabinet
Attach „ to the floor from the front and rear edge by using clamps delivered with
the drive, or bolt the cabinet to the floor through the holes inside if they are accessible.

Alternative 1 – Clamping
„ „
1. Insert the clamps into the twin slots along the front
and rear edges of the cabinet frame body and at-
tach them to the floor with a bolt. The recommen-
ded maximum distance between the clamps in the
front edge is 800mm (31.5").
2. If floor mounting from back is not possible, attach
the cabinet at the top to wall with L-brackets (not
10
included in the delivery) using the lifting lug attach-
ing holes.

M16
„

Clamp dimensions

„
 „
60 Mechanical installation

Alternative 2 – Using the holes inside the cabinet

„
1. Attach the cabinet to the floor through the bottom
attaching holes with M10 to M12 (3/8” to 1/2”) bolts.
The recommended maximum distance between
the front edge attaching points is 800 mm (31.5”).
2. If the back attaching holes are not accessible, at-
tach the cabinet at the top to wall with L-brackets
(not included in the delivery) using the lifting lug
attaching holes.

M16

Miscellaneous
￭ Cable duct in the floor below the cabinet
„
A cable duct can be constructed below the 500 mm wide middle part of the cabinet. The
cabinet weight lies on the two 50 mm wide transverse sections which the floor must carry.
Prevent the cooling air flow from the cable duct to the cabinet by bottom plates. To ensure
the degree of protection for the cabinet, use the original bottom plates delivered with the
„
unit. With user-defined cable entries, take care of the degree of protection, fire protection
and EMC compliance.
500 (19.68”)

50 (1.97”) 500 (19.68”) 50 (1.97”)

„￭ Arc welding
ABB does not recommend attaching the cabinet by arc welding. However, if arc welding is
the only option, connect the return conductor of the welding equipment to the cabinet frame
at the bottom within 0.5 meters (1’6”) of the welding point.
Note:
The thickness of the zinc plating of the cabinet frame is 100 to 200 micrometers (4 to 8 mil).

WARNING!
Make sure that the return wire is connected correctly. Welding current must not
return via any component or cabling of the drive. If the welding return wire is
 Mechanical installation 61

connected improperly, the welding circuit can damage electronic circuits in the
cabinet.

WARNING!
Do not inhale the welding fumes.

10
62
 Guidelines for planning the electrical installation 63

5
Guidelines for planning the electrical
installation

Contents of this chapter

This chapter contains instructions for planning the electrical installation of the drive. Some
instructions are mandatory to follow in every installation, others provide useful information
that only concerns certain applications.
11
Limitation of liability
The installation must always be designed and made according to applicable local laws and
regulations. ABB does not assume any liability whatsoever for any installation which breaches
the local laws and/or other regulations. Furthermore, if the recommendations given by ABB
are not followed, the drive may experience problems that the warranty does not cover.

Selecting the supply disconnecting device

The drive is equipped with a main switch-disconnector as standard. The disconnector can
be locked to the open position for installation and maintenance work.

Selecting the main contactor

The drive can be equipped with a line contactor (option +F250).
64 Guidelines for planning the electrical installation

Examining the compatibility of the motor and drive

Use asynchronous AC induction motors, permanent magnet synchronous motors, AC
induction servomotors or ABB synchronous reluctance motors (SynRM motors) with the
drive.
Select the motor size and drive type from the rating table on basis of the AC line voltage
and motor load. You can find the rating table in the appropriate drive or inverter unit hardware
manual. You can also use the DriveSize PC tool.
Make sure that the motor withstands the maximum peak voltage in the motor terminals. See
Requirements table (page 64). For basics of protecting the motor insulation and bearings
in drive systems, see Protecting the motor insulation and bearings (page 64).
Note:
• Consult the motor manufacturer before using a motor whose nominal voltage differs
from the AC line voltage connected to the drive input.
• The voltage peaks at the motor terminals are relative to the supply voltage of the drive,
not the drive output voltage.
• If the motor and drive are not of the same size, consider the operation limits of the drive
control program for the motor nominal voltage and current. See the appropriate
parameters in the firmware manual.

￭ Protecting the motor insulation and bearings

The drive employs modern IGBT inverter technology. Regardless of frequency, the drive
output comprises pulses of approximately the drive DC bus voltage with a very short rise
time. The pulse voltage can almost double at the motor terminals, depending on the
attenuation and reflection properties of the motor cable and the terminals. This can cause
additional stress on the motor and motor cable insulation.
Modern variable speed drives with their fast rising voltage pulses and high switching
frequencies can generate current pulses that flow through the motor bearings. This can
gradually erode the bearing races and rolling elements.
du/dt filters protect motor insulation system and reduce bearing currents. Common mode
filters mainly reduce bearing currents. Insulated N-end (non-drive end) bearings protect the
motor bearings.

￭ Requirements table
These tables show how to select the motor insulation system and when a drive du/dt and
common mode filters and insulated N-end (non-drive end) motor bearings are required.
Ignoring the requirements or improper installation may shorten motor life or damage the
motor bearings and voids the warranty.
 Guidelines for planning the electrical installation 65

This table shows the requirements when an ABB motor is in use.

Motor Nominal AC supply Requirement for

type voltage
Motor insula- ABB du/dt and common mode filters, insulated N-end
tion system motor bearings
PN < 100 kW 100 kW ≤ PN < 350 PN ≥ 350 kW
and frame kW or
size < or frame size ≥ IEC 400
IEC 315 IEC 315 ≤ frame size
< IEC 400
PN < 134 hp 134 hp ≤ PN < 469 hp PN ≥ 469 hp
and frame or or
size < NEMA 500 ≤ frame frame size >
NEMA 500 size ≤ NEMA 580 NEMA 580
Random- UN ≤ 500 V Standard - +N + N + CMF
wound
500 V < UN ≤ 600 V Standard + du/dt + N + du/dt + N + du/dt + CMF
M2_, M3_
and M4_ or
Reinforced - +N + N + CMF
600 V < UN ≤ 690 V Reinforced + du/dt + N + du/dt + N + du/dt + CMF
(cable length ≤
150 m)
600 V < UN ≤ 690 V Reinforced - +N + N + CMF
(cable length >
150 m)
Form- 380 V < UN ≤ 690 V Standard n.a. + N + CMF PN < 500 kW:
wound +N + CMF
HX_ and
PN ≥ 500 kW:
AM_
+N + du/dt + CMF

Old 1) 380 V < UN ≤ 690 V Check with the + N + du/dt with voltages over 500 V + CMF
form- motor manu-
wound facturer. 11
HX_ and
modular

Random- 0 V < UN ≤ 500 V Enamelled + N + CMF

wound 500 V < U ≤ 690 V wire with fiber + N + du/dt + CMF
N glass taping
HX_ and
AM_ 2)

HDP Consult the motor manufacturer.

1) manufactured before 1.1.1998

2) For motors manufactured before 1.1.1998, check for additional instructions with the motor manufacturer.
66 Guidelines for planning the electrical installation

This table shows the requirements when a non-ABB motor is in use.

Motor Nominal AC supply Requirement for

type voltage
Motor insula- ABB du/dt and common mode filters, insulated N-end
tion system motor bearings
PN < 100 kW 100 kW ≤ PN < 350 PN ≥ 350 kW
and frame kW or
size < or frame size ≥ IEC 400
IEC 315 IEC 315 ≤ frame size
< IEC 400
PN < 134 hp 134 hp ≤ PN < 469 hp PN ≥ 469 hp
and frame or or
size < NEMA 500 ≤ frame frame size >
NEMA 500 size ≤ NEMA 580 NEMA 580
Random- UN ≤ 420 V Standard: - + N or CMF + N + CMF
wound ÛLL = 1300 V
and form-
420 V < UN ≤ 500 V Standard: + du/dt + du/dt + (N or CMF) + N + du/dt + CMF
wound
ÛLL = 1300 V
or
Reinforced: - + N or CMF + N + CMF
ÛLL = 1600 V,
0.2 micro-
second rise
time
500 V < UN ≤ 600 V Reinforced: + du/dt + du/dt + (N or CMF) + N + du/dt + CMF
ÛLL = 1600 V
or
Reinforced: - + N or CMF + N + CMF
ÛLL = 1800 V
600 V < UN ≤ 690 V Reinforced: + du/dt + du/dt + N + N + du/dt + CMF
ÛLL = 1800 V

Reinforced: - + N + CMF + N + CMF

ÛLL = 2000 V,
0.3 micro-
second rise
time 1)

1) If the intermediate DC circuit voltage of the drive is increased from the nominal level due to long term resistor braking
cycles, check with the motor manufacturer if additional output filters are needed in the applied drive operation range.

The abbreviations used in the tables are defined below.

Abbr. Definition
UN Nominal AC line voltage
ÛLL Peak line-to-line voltage at motor terminals which the motor insulation must withstand
PN Motor nominal power
du/dt du/dt filter at the output of the drive
CMF Common mode filter
N N-end bearing: insulated motor non-drive end bearing
n.a. Motors of this power range are not available as standard units. Consult the motor manufacturer.
 Guidelines for planning the electrical installation 67

Availability of du/dt filter and common mode filter by drive or inverter type

Product type Availability of du/dt filter Availability of common mode filter

(CMF)
ACS580-07 +E205 +E208

Additional requirements for explosion-safe (EX) motors

If you will use an explosion-safe (EX) motor, follow the rules in the requirements table above.
In addition, consult the motor manufacturer for any further requirements.

Additional requirements for ABB motors of types other than M2_, M3_, M4_, HX_ and
AM_
Use the selection criteria given for non-ABB motors.

Additional requirements for braking applications

When the motor brakes the machinery, the intermediate circuit DC voltage of the drive
increases, the effect being similar to increasing the motor supply voltage by up to 20 percent.
Consider this voltage increase when specifying the motor insulation requirements if the
motor will be braking a large part of its operation time.
Example: Motor insulation requirement for a 400 V AC line voltage application must be
selected as if the drive were supplied with 480 V.

Additional requirements for the regenerative and low harmonics drives

It is possible to increase the intermediate circuit DC voltage from the nominal (standard)
level with a parameter in the control program. If you choose to do this, select the motor
insulation system which withstands the increased DC voltage level.

Additional requirements for ABB high-output and IP23 motors

The rated output power of high output motors is higher than what is stated for the particular
frame size in EN 50347 (2001).
11
This table shows the requirements for protecting the motor insulation and bearings in drive
systems for ABB random-wound motor series (for example, M3AA, M3AP and M3BP).

Nominal AC supply Requirement for

voltage
Motor insulation ABB du/dt and common mode filters, insulated N-end motor
system bearings
PN < 100 kW 100 kW ≤ PN < PN ≥ 200 kW
200 kW
PN < 140 hp 140 hp ≤ PN < PN ≥ 268 hp
268 hp
UN ≤ 500 V Standard - +N + N + CMF
500 V < UN ≤ 600 V Standard + du/dt + du/dt + N + du/dt + N + CMF
or
Reinforced - +N + N + CMF
600 V < UN ≤ 690 V Reinforced + du/dt + du/dt + N + du/dt + N + CMF

Additional requirements for non-ABB high-output and IP23 motors

The rated output power of high-output motors is higher than what is stated for the particular
frame size in EN 50347 (2001).
68 Guidelines for planning the electrical installation

If you plan to use a non-ABB high-output motor or an IP23 motor, consider these additional
requirements for protecting the motor insulation and bearings in drive systems:
• If motor power is below 350 kW: Equip the drive and/or motor with the filters and/or
bearings according to the table below.
• If motor power is above 350 kW: Consult the motor manufacturer.

Nominal AC supply Requirement for

voltage
Motor insulation system ABB du/dt and common mode filters, insulated N-
end motor bearings
PN < 100 kW or frame 100 kW < PN < 350 kW or
size < IEC 315 IEC 315 < frame size <
IEC 400
PN < 134 hp or frame size 134 hp < PN < 469 hp or
< NEMA 500 NEMA 500 < frame size <
NEMA 580
UN ≤ 500 V Standard: ÛLL = 1300 V + N or CMF + N or CMF
420 V < UN < 500 V Standard: ÛLL = 1300 V + du/dt + (N or CMF) + N + du/dt + CMF
or
Reinforced: ÛLL = 1600 V, + N or CMF + N or CMF
0.2 microsecond rise time
500 V < UN ≤ 600 V Reinforced: ÛLL = 1600 V + du/dt + (N or CMF) + N + du/dt + CMF
or
Reinforced: ÛLL = 1800 V + N or CMF + N + CMF
600 V < UN ≤ 690 V Reinforced: ÛLL = 1800 V + N + du/dt + N + du/dt + CMF

Reinforced: ÛLL = 2000 V, + N + CMF + N + CMF

0.3 microsecond rise
time 1)

1) If the intermediate DC circuit voltage of the drive is increased from the nominal level due to long term resistor braking
cycles, check with the motor manufacturer if additional output filters are needed in the applied drive operation range.

Additional data for calculating the rise time and the peak line-to-line voltage
The diagrams below show the relative peak line-to-line voltage and rate of change of voltage
as a function of the motor cable length. If you need to calculate the actual peak voltage and
voltage rise time considering the actual cable length, proceed as follows:
• Peak line-to line voltage: Read the relative ÛLL/UN value from the diagram below and
multiply it by the nominal supply voltage (UN).
• Voltage rise time: Read the relative values ÛLL/UN and (du/dt)/UN from the diagram
below. Multiply the values by the nominal supply voltage (UN) and substitute into equation
t = 0.8 · ÛLL/(du/dt).
 Guidelines for planning the electrical installation 69

3.0
A ÛLL/UN
2.5

2.0

1.5

1.0 du/dt
------------- (1/Ps)
UN
0.5

0.0
0 50 100 150 200 250 300 350
l (m)

B 5.0
du/dt
------------- (1/Ps)
UN
4.0

3.0
ÛLL/UN

2.0

1.0

1.0
0 50 100 150 200 250 300 350
l (m)
11
A Drive with du/dt filter
B Drive without du/dt filter
I Motor cable length
ÛLL/UN Relative peak line-to-line voltage
(du/dt)/UN Relative du/dt value

Additional note for common mode filters

Common mode filters are available as plus code option +E208.

Selecting the power cables

￭ General guidelines
Select the input power and motor cables according to local regulations.
• Current: Select a cable capable of carrying the drive (or motor) nominal current.
• Temperature: For an IEC installation, select a cable rated for at least 70 °C (90 °C for
IP55 [UL Type 12]) maximum permissible temperature of conductor in continuous use.
For North America, select a cable rated for at least 90 °C (194 °F).
• Voltage: 600 V AC cable is accepted for up to 500 V AC. 750 V AC cable is accepted
for up to 600 V AC. 1000 V AC cable is accepted for up to 690 V AC.
70 Guidelines for planning the electrical installation

To comply with the EMC requirements of the CE mark, use one of the preferred cable types.
See Preferred power cable types (page 71).
Symmetrical shielded cable reduces electromagnetic emission of the whole drive system
as well as the stress on motor insulation, bearing currents and wear.
Metal conduit reduces electromagnetic emission of the whole drive system.
The protective conductor must always have an adequate conductivity.
Unless local wiring regulations state otherwise, the cross-sectional area of the protective
conductor must agree with the conditions that require automatic disconnection of the supply
required in 411.3.2. of IEC 60364-4-41:2005 and be capable of withstanding the prospective
fault current during the disconnection time of the protective device. The cross-sectional area
of the protective conductor can either be selected from the table below or calculated according
to 543.1 of IEC 60364-5-54.
This table shows the minimum cross-sectional area of the protective conductor related to
the phase conductor size according to IEC 61800-5-1 when the phase conductor and the
protective conductor are made of the same metal. If this is not so, the cross-sectional area
of the protective earthing conductor shall be determined in a manner which produces a
conductance equivalent to that which results from the application of this table.

Cross-sectional area of the phase conductors Minimum cross-sectional area of the corresponding
S (mm2) protective conductor
Sp (mm2)
S ≤ 16 S 1) , 2)
16 < S ≤ 35 16
35 < S S/2

1) Drive safety standard IEC/EN 61800-5-1:

• use a protective earth conductor with a cross-section of at least 10 mm2 (8 AWG) Cu or 16 mm2 (6 AWG) Al, or
• use a second protective earth conductor of the same cross-sectional area as the original protective earthing conductor,
or
• use a device which automatically disconnects the supply if the protective earth conductor breaks.
2) Drive safety standard IEC/EN 61800-5-1: If the protective earth conductor is separate (ie, it does not form part of the input
power cable or the input power cable enclosure), the cross section must be at least:
• 2.5 mm2 (14 AWG) when the conductor is mechanically protected, or
• 4 mm2 (12 AWG) when the conductor is not mechanically protected.

￭ Typical power cable sizes

See the technical data of the drive (or unit).
 Guidelines for planning the electrical installation 71

„
￭ Power cable types
„
Preferred power cable types
This section presents the preferred cable types. Check with local/state/country electrical
codes for allowance.

Cable type Use as input power cabling Use as motor cabling

PE Yes Yes

Symmetrical shielded (or armored)

„ with three phase conductors
cable
and concentric PE conductor as
shield (or armor)

PE Yes Yes

Symmetrical shielded (or armored)

cable with three phase conductors
and symmetrically constructed PE
conductor and a shield (or armor)

Yes Yes

PE

Symmetrical shielded (or armored)

cable with three phase conductors 11
and a shield (or armor), and separ-
ate PE conductor/cable 1)

1) A separate PE conductor is required if the conductivity of the shield (or armor) is not sufficient for the PE use.

Alternate
„ power cable types

Cable type Use as input power cabling Use as motor cabling

„
Yes with phase conductor smaller Yes with phase conductor smaller
than 10 mm2 (8 AWG). than 10 mm2 (8 AWG), or motors up
PVC
to 30 kW (40 hp).
Note: Shielded or armored cable, or
Four-conductor cabling in PVC con- cabling in metal conduit is always
duit or jacket (three phase conduct- recommended to minimize radio fre-
ors and PE) quency interference.
Yes Yes with phase conductor smaller
than 10 mm2 (8 AWG) or motors up
EMT to 30 kW (40 hp)

Four-conductor cabling in metal

conduit (three phase conductors and
„
PE), eg, EMT, or four-conductor ar-
mored cable
72 Guidelines for planning the electrical installation

Cable type Use as input power cabling Use as motor cabling

Yes Yes with motors up to 100 kW
(135 hp). A potential equalization
between the frames of motor and
driven equipment is required.

Well-shielded (Al/Cu shield or ar-

mor) four-conductor cable (three
phase conductors and a PE)

Not allowed power cable types

Cable type Use as input power cabling Use as motor cabling

No No
PE

Symmetrical shielded cable with in-

dividual
„ shields for each phase
conductor

￭ Additional guidelines, North America

ABB recommends the use of conduit for power wiring to the drive and between the drive
and the motor(s). Due to the variety of application needs, metallic and non-metallic conduit
can be used. ABB prefers the use of metallic conduit.
The following table shows examples of various materials and methods for wiring the drive
in the intended application. See NEC 70 along with state and local codes for the appropriate
materials for your application.
In all applications, ABB prefers the use of symmetrical shielded VFD cable between drive
and motor(s).

Wiring method Notes

Conduit - Metallic 1) 2)
Electrical metallic tubing: Type EMT • Use separate conduit run for each motor.
Rigid metal conduit: Type RMC • Do not run power feed wiring and motor wiring in the
same conduit.
Liquid-tight flexible metal electrical conduit: Type LFMC

Conduit - Non-metallic2) 3)
Liquid-tight flexible non-metallic conduit: Type LFNC • Use separate conduit run for each motor.
• Do not run power feed wiring and motor wiring in the
same conduit.
Wireways2)
Metallic • Use output conductors require separation from motor
feed and other low voltage conductors.
• Do not run outputs of multiple drives in parallel.
Bundle each cable together and use separator where
possible.
 Guidelines for planning the electrical installation 73

Wiring method Notes

Free air2)
Enclosures, air handlers, etc. • Allowed internally in enclosures when in accordance
with UL.

1) Metallic conduit may be used as an additional ground path, provided this path is a solid path capable of handling ground
currents.
2) See 70 (NEC), UL, and local codes for your application.
3) Non-metallic conduit use underground is allowed; however, these installations inherently have an increased chance for
nuisance problems due to the potential for water/moisture in the conduit. Water/moisture in the conduit increases the
likelihood of VFD faults or warnings. Proper installation is required to ensure there is no intrusion of water/moisture.

Metal conduit
Couple separate parts of a metal conduit together: bridge the joints with a ground conductor
bonded to the conduit on each side of the joint. Also bond the conduits to the drive enclosure
and motor frame. Use separate conduits for input power, motor, brake resistor, and control
wiring.
Note:
Do not run motor wiring from more than one drive in the same conduit.

￭ Power cable shield

If the cable shield is used as the sole protective earth (PE) conductor, make sure that its
conductivity agrees with the PE conductor requirements.
„
To effectively suppress radiated and conducted radio-frequency emissions, the cable shield
conductivity must be at least 1/10 of the phase conductor conductivity. The requirements
are easily met with a copper or aluminum shield. The minimum requirement of the motor
cable shield of the drive is shown below. It consists of a concentric layer of copper wires
with an open helix of copper tape or copper wire. The better and tighter the shield, the lower
the emission level and bearing currents.
11
1 2 3 4 5

1 Insulation jacket
2 Helix of copper tape or copper wire
3 Copper wire screen
4 Inner insulation
5 Cable core

Selecting the control cables

￭ Shielding
Only use shielded control cables.
 74 Guidelines for planning the electrical installation

Use a double-shielded twisted pair cable for analog signals. This type of cable is
recommended for the pulse encoder signals also. Employ one individually shielded pair for
each signal. Do not use common return for different analog signals.
A double-shielded cable (figure a below) is the best alternative for low-voltage digital signals
but single-shielded (b) twisted pair cable is also acceptable.

a b

„￭ Signals in separate cables

Run analog and digital signals in separate, shielded cables. Do not mix 24 V DC and
115/230 V AC signals in the same cable.
„
￭ Signals that can be run in the same cable
If their voltage does not exceed 48 V, relay-controlled signals can be run in the same cables
as digital input signals. The relay-controlled signals should be run as twisted pairs.
„
￭ Relay cable type
The cable type with braided metallic screen (for example ÖLFLEX by LAPPKABEL, Germany)
„ has been tested and approved by ABB.
￭ Control panel to drive connection
Use EIA-485 with male RJ-45 connector, cable type Cat 5e or better. The maximum permitted
length of the cable is 100 m (328 ft).
 Guidelines for planning the electrical installation 75

Routing the cables

￭ General guidelines – IEC
• Route the motor cable away from other cables. Motor cables of several drives can be
run in parallel installed next to each other.
• Install the motor cable, input power cable and control cables on separate trays.
• Avoid long parallel runs of motor cables with other cables in order to decrease
electromagnetic interference caused by the rapid changes in the drive output voltage.
• Where control cables must cross power cables, make sure they are arranged at an
angle as near to 90 degrees as possible.
• Do not run extra cables through the drive.
• Make sure that the cable trays have good electrical bonding to each other and to the
grounding electrodes. Aluminum tray systems can be used to improve local equalizing
of potential.
This figure illustrates the cable routing guidelines with an example drive.
Note:
When motor cable is symmetrical and shielded and it has short parallel runs with other
cables (< 1.5 m / 5 ft), distances between the motor cable and other cables can be reduced
by half.

1
min. 300 mm (12 in)
2 4

4
11
min. 300 mm (12 in) *
2
3

90°
3 1
min. 200 mm (8 in)
*min. 500 mm (20 in)
2
3

1 Motor cable
2 Input power cable
3 Control cable
4 Brake resistor or chopper cable (if any)
76 Guidelines for planning the electrical installation

￭ General guidelines – North America

Make sure that the installation is in accordance with national and local codes. Obey these
general guidelines:
• Use separate conduits for the input power, motor, brake resistor (optional), and control
cabling.
• Use separate conduit for each motor cabling.
The drawing below illustrates general guidelines for routing input power and motor cabling
in conduits.

1 1 1 1

2 2 2 2

3 3
3

3
2

1 Input power cabling

2 Motor cabling
3 Conduit
 Guidelines for planning the electrical installation 77

￭ Continuous motor cable shield/conduit or enclosure for equipment

on the motor cable
To minimize the emission level when safety switches, contactors, connection boxes or
similar equipment are installed on the motor cable between the drive and the motor:
• Install the equipment in a metal enclosure.
• Use either a symmetrical shielded cable, or install the cabling in a metal conduit.
• Make sure that there is a good and continuous galvanic connection in the shield/conduit
between drive and motor.
• Connect the shield/conduit to the protective ground terminal of the drive and the motor.

￭ Separate control cable ducts

Lead 24 V DC and 230 V AC (120 V AC) control cables in separate ducts unless the 24 V DC
cable is insulated for 230 V AC (120 V AC) or insulated with an insulation sleeving for
230 V AC (120 V AC).

230 V AC 24 V DC
(120 V AC)
230 V AC
24 V DC (120 V AC)

11
Implementing thermal overload and short-circuit protection
￭ Protecting the input cabling and the drive upon a short-circuit
To protect the input cabling in short-circuit situations, install fuses or a suitable circuit breaker
at the supply side of the cabling.
The drive is equipped with internal AC fuses as standard. In case of a short-circuit inside
the drive, the AC fuses protect the drive, restrict drive damage, and prevent damage to
adjoining equipment.

￭ Protecting the motor and motor cable in short-circuits

The drive protects the motor cable and motor in a short-circuit situation when the motor
cable is sized according to the nominal current of the drive. No additional protection devices
are needed.

￭ Protecting the drive and the power cables against thermal overload
The drive protects itself and the input and motor cables against thermal overload when the
cables are sized according to the nominal current of the drive. No additional thermal protection
devices are needed.
78 Guidelines for planning the electrical installation

WARNING!
If the drive is connected to multiple motors, use a separate circuit breaker or fuses
for protecting each motor cable and motor against overload. The drive overload
protection is tuned for the total motor load. It may not trip due to an overload in
one motor circuit only.

￭ Protecting the motor against thermal overload

According to regulations, the motor must be protected against thermal overload and the
current must be switched off when overload is detected. The drive includes a motor thermal
protection function that protects the motor and switches off the current when necessary.
Depending on a drive parameter value, the function either monitors a calculated temperature
value (based on a motor thermal model) or an actual temperature indication given by motor
temperature sensors.
The motor thermal protection model supports thermal memory retention and speed sensitivity.
The user can tune the thermal model further by feeding in additional motor and load data.
The most common temperature sensors are:
• motor sizes IEC180…225: thermal switch, for example Klixon
• motor sizes IEC200…250 and larger: PTC or Pt100.
See the firmware manual for more information on the motor thermal protection function.

￭ Protecting the drive against ground faults

The drive is equipped with an internal ground fault protective function to protect the unit
against ground faults in the motor and motor cable. This function is not a personnel safety
or a fire protection feature. See the firmware manual for more information.

Residual current device compatibility

The drive is suitable to be used with residual current devices of Type B.
Note:
As standard, the drive contains capacitors connected between the main circuit and the
frame. These capacitors and long motor cables increase the ground leakage current and
may cause nuisance faults in residual current devices.

￭ Implementing the emergency stop function

You can order the drive with an emergency stop function.
See the appropriate manual for more information.

Option User’s manual Manual code

code (English)
+Q951 Emergency stop, stop category 0 (using main contactor/breaker) 3AUA0000119895
+Q963 Emergency stop, stop category 0 (using Safe torque off) 3AUA0000119908

￭ Implementing the Safe Torque Off function

See chapter The Safe torque off function on page 243.

￭ Implementing the Power loss ride-through function

Implement the power-loss ride-through function as follows:
 Guidelines for planning the electrical installation 79

• Check that the power-loss ride-through function of the drive is enabled with parameter
30.31.
• Set parameter 21.01 (in vector mode) or parameter 21.19 (in scalar mode) to make
flying start (starting into a rotating motor) possible. If the installation is equipped with a
main contactor, prevent its tripping at the input power break. For example, use a time
delay relay (hold) in the contactor control circuit.

WARNING!
Make sure that the flying restart of the motor will not cause any danger. If you are
in doubt, do not implement the Power-loss ride-through function.

￭ Using power factor compensation capacitors with the drive

Power factor compensation is not needed with AC drives. However, if a drive is to be
connected in a system with compensation capacitors installed, note the following restrictions.

WARNING!
Do not connect power factor compensation capacitors or harmonic filters to the
motor cables (between the drive and the motor). They are not meant to be used
with AC drives and can cause permanent damage to the drive or themselves.

If there are power factor compensation capacitors in parallel with the input of the drive:
1. Do not connect a high-power capacitor to the power line while the drive is connected.
The connection will cause voltage transients that may trip or even damage the drive.
2. If capacitor load is increased/decreased step by step when the AC drive is connected
to the power line, make sure that the connection steps are low enough not to cause
voltage transients that would trip the drive.
3. Check that the power factor compensation unit is suitable for use in systems with AC
drives, ie, harmonic generating loads. In such systems, the compensation unit should
typically be equipped with a blocking reactor or harmonic filter. 11
￭ Implementing a safety switch between the drive and the motor
ABB recommends that you install a safety switch between the permanent magnet motor
and the drive output. The switch is needed to isolate the motor during any maintenance
work on the drive.

￭ Using a contactor between the drive and the motor

Implementing the control of the output contactor depends on how you select the drive to
operate.
• For vector control mode and motor ramp stop, open the contactor as follows:
1. Give a stop command to the drive.
2. Wait until the drive decelerates the motor to zero speed.
3. Open the contactor.
• For vector control mode and motor coast stop, or scalar control mode, open the contactor
as follows:
1. Give a stop command to the drive.
2. Open the contactor.
80 Guidelines for planning the electrical installation

WARNING!
When the vector control mode is in use, never open the output contactor while the
drive controls the motor. The vector control operate extremely fast, much faster
than it takes for the contactor to open its contacts. When the contactor starts
opening while the drive controls the motor, the vector control will try to maintain
the load current by immediately increasing the drive output voltage to the maximum.
This will damage, or even burn the contactor completely.

￭ Implementing a bypass connection

If bypassing is required, employ mechanically or electrically interlocked contactors between
the motor and the drive and between the motor and the power line. Make sure with
interlocking that the contactors cannot be closed simultaneously. The installation must be
clearly marked as defined in IEC/EN 61800-5-1, subclause 6.5.3, for example, “THIS
MACHINE STARTS AUTOMATICALLY”.
Bypass connection is available as a factory-installed option for some cabinet-installed drive
types. Consult ABB for more information.

WARNING!
Never connect the drive output to the electrical power network. The connection
may damage the drive.

￭ Implementing the ATEX-certified Safe motor disconnection function

(option +Q971)
With option +Q971, the drive provides ATEX-certified safe motor disconnection without
contactor using the drive Safe torque off function. For more information, see
• ATEX-certified Safe disconnection function, Ex II (2) GD for ACS880 drives (+Q971)
Application guide (3AUA0000132231 [English]).
• FPTC-02 ATEX-certified thermistor protection module, Ex II (2) GD (option +L537+Q971)
for ACS880 drives user's manual (3AXD50000027782 [English]).
• CPTC-02 ATEX-certified thermistor protection module, Ex II (2) GD (option +L537+Q971)
user's manual (3AXD50000030058 [English]).

￭ Protecting the contacts of relay outputs

Inductive loads (relays, contactors, motors) cause voltage transients when switched off.
The relay contacts on the drive control unit are protected with varistors (250 V) against
overvoltage peaks. In spite of this, it is highly recommended that inductive loads are equipped
with noise attenuating circuits (varistors, RC filters [AC] or diodes [DC]) to minimize the
EMC emission at switch-off. If not suppressed, the disturbances may connect capacitively
or inductively to other conductors in the control cable and form a risk of malfunction in other
parts of the system.
Install the protective component as close to the inductive load as possible. Do not install
protective components at the relay outputs.
 Guidelines for planning the electrical installation 81

230 V AC

1 2

230 V AC

+ 24 V DC

1 Relay output
2 Varistor
3 RC filter
4 Diode

￭ Connecting motor temperature sensor to the drive via an option module

This table shows:
• the option module types that you can use for the motor temperature sensor connection
• the insulation or isolation level that each option module forms between its temperature
sensor connector and other connectors
• the temperature sensor types that you can connect to each option module
• the temperature sensor insulation requirement in order to form, together with the
insulation of the option module, a reinforced insulation between the motor live parts and
the drive control unit. 11
Option module Temperature sensor Temperature sensor insulation
type requirement

Type Insulation/Isolation PTC KTY Pt100,

Pt1000

FIO-11 Galvanic isolation between sensor - x x Reinforced insulation

connector and other connectors (in-
cluding drive control unit connector)

FEN-xx Galvanic isolation between sensor x x - Reinforced insulation

connector and other connectors (in-
cluding drive control unit connector)

FAIO-01 Basic insulation between sensor x x x Basic insulation. Connectors of op-

connector and drive control unit tion module other than sensor con-
connector. No insulation between nector must be left unconnected.
sensor connector and other I/O
connectors.

FPTC- Reinforced insulation between x - - No special requirement

xx 1) sensor connector and other connect-
ors (including drive control unit con-
nector).

1) Suitable for use in safety functions (SIL2 / PL c rated).

82 Guidelines for planning the electrical installation

Protecting the drive against ground faults

The drive is equipped with an internal ground fault protective function to protect the unit
against ground faults in the motor and motor cable. This function is not a personnel safety
or a fire protection feature. See the firmware manual for more information.

￭ Residual current device compatibility

The drive is suitable to be used with residual current devices of Type B.
Note:
As standard, the drive contains capacitors connected between the main circuit and the
frame. These capacitors and long motor cables increase the ground leakage current and
may cause nuisance faults in residual current devices.

Implementing the emergency stop function

The drive can be equipped with emergency stop function of stop category 0. For safety
reasons, install the emergency stop devices at each operator control station and at other
operating stations where emergency stop can be needed.
Note:
Pressing the stop key on the control panel of the drive, or turning the operating switch of
the drive from position "1" to "0" does not generate an emergency stop of the motor or
separate the drive from dangerous potential.
See the user’s manual for the wiring, start-up and operation instructions.

Option User’s manual Manual code (English)

code

+Q951 Emergency stop, stop category 0 (option +Q951) for ACS580-07, 3AXD50000171828
ACH580-07 and ACQ580-07 drives user's manual

+Q963 Emergency Stop, Category 0 (option +Q963) without opening main 3AXD50000171835
contactor with safety relay for ACS580-07, ACH580-07 and ACQ580-
07 drives user's manual

Implementing ATEX-certified thermistor protection

See CPTC-02 ATEX-certified thermistor protection module, Ex II (2) GD (+L537+Q971)
user's manual (3AXD50000030058 [English]).

Implementing the Safe torque off function

See chapter The Safe torque off function (page 243).

Implementing the ATEX-certified Safe motor disconnection

function (option +Q971)
With option +Q971, the drive provides ATEX-certified safe motor disconnection without
contactor using the drive Safe torque off function. For more information, see
• ATEX-certified Safe disconnection function, Ex II (2) GD for ACS880 drives (+Q971)
Application guide (3AUA0000132231 [English]).
 Guidelines for planning the electrical installation 83

• FPTC-02 ATEX-certified thermistor protection module, Ex II (2) GD (option +L537+Q971)

for ACS880 drives user's manual (3AXD50000027782 [English]).
• CPTC-02 ATEX-certified thermistor protection module, Ex II (2) GD (option +L537+Q971)
user's manual (3AXD50000030058 [English]).

Implementing the Power-loss ride-through function

Implement the power-loss ride-through function as follows:
• Check that the power-loss ride-through function of the drive is enabled with parameter
30.31 Undervoltage control.
• Set parameter 21.01 Vector start mode to Automatic (in vector mode) or parameter
21.19 Scalar start mode to Automatic (in scalar mode) to make flying start (starting
into a rotating motor) possible. If the installation is equipped with a main contactor,
prevent its tripping at the input power break. For example, use a time delay relay (hold)
in the contactor control circuit.

WARNING!
Make sure that the flying restart of the motor will not cause any danger. If you
are in doubt, do not implement the Power-loss ride-through function.

￭ Units with line contactor (option +F250)

The main contactor of the drive opens in a power-loss situation. When the power returns,
the contactor closes. However, if the power-loss situation lasts so long that the drive trips
on undervoltage, it must be reset and started again to continue operation. If the power-loss
situation lasts so long that the buffering module (C22) empties, the main contactor remains
open and the drive operates only after reset and a new start.

Supplying power for the auxiliary circuits

11
The drive is equipped with an auxiliary control voltage transformer which supplies control
voltage, for example, for the control devices and cabinet fan(s).
Supply this option from an external power source:
• +G300 Cabinet heaters (230 or 115 V AC; external fuse: 16 A gG).

Using power factor compensation capacitors with the drive

Power factor compensation is not needed with AC drives.

WARNING!
Do not connect power factor compensation capacitors or harmonic filters to the
motor cables (between the drive and the motor). They are not meant to be used
with AC drives and can cause permanent damage to the drive or themselves.

Implementing a safety switch between the drive and the

motor
ABB recommends to install a safety switch between the permanent magnet synchronous
motor and the drive output. The switch is needed to isolate the motor during any maintenance
work on the drive.
84 Guidelines for planning the electrical installation

Using a contactor between the drive and the motor

Implementing the control of the output contactor depends on how you select the drive to
operate. See also section Implementing a bypass connection (page 84).
When you have selected to use
• vector control mode and motor ramp stop,
open the contactor as follows:
1. Give a stop command to the drive.
2. Wait until the drive decelerates the motor to zero speed.
3. Open the contactor.
When you have selected to use
• vector control mode and motor coast stop; or scalar control mode,
open the contactor as follows:
1. Give a stop command to the drive.
2. Open the contactor.

WARNING!
When the vector control mode is in use, never open the output contactor while the
drive controls the motor. The vector control operates extremely fast, much faster
than it takes for the contactor to open its contacts. When the contactor starts
opening while the drive controls the motor, the vector control will try to maintain
the load current by immediately increasing the drive output voltage to the maximum.
This will damage, or even burn the contactor completely.

Implementing a bypass connection

If bypassing is required, employ mechanically or electrically interlocked contactors between
the motor and the drive and between the motor and the power line. Make sure with
interlocking that the contactors cannot be closed simultaneously. The installation must be
clearly marked as defined in IEC/EN 61800-5-1, subclause 6.5.3, for example, "THIS
MACHINE STARTS AUTOMATICALLY".

WARNING!
Never connect the drive output to the electrical power network. The connection
can damage the drive.

Protecting the contacts of relay outputs

Inductive loads (relays, contactors, motors) cause voltage transients when switched off.
ABB highly recommends to equip inductive loads with noise attenuating circuits (varistors,
RC filters [AC] or diodes [DC]) in order to minimize the EMC emission at switch-off. If not
suppressed, the disturbances can connect capacitively or inductively to other conductors
in the control cable and form a risk of malfunction in other parts of the system.
Install the protective component as close to the inductive load as possible. Do not install
protective components at the relay outputs.
 Guidelines for planning the electrical installation 85

230 V AC

1 2

230 V AC

+ 24 V DC

1) Relay outputs; 2) Varistor; 3) RC filter; 4) diode

Implementing a motor temperature sensor connection

WARNING!
IEC 60664 requires double or reinforced insulation between live parts and the
surface of accessible parts of electrical equipment which are either non-conductive
or conductive but not connected to the protective earth.

To connect a motor temperature sensor and other similar components to the drive, you
have four alternatives: 11
1. If there is double or reinforced insulation between the sensor and the live parts of the
motor, you can connect the sensor directly to the inputs of the drive.
2. If there is basic insulation between the sensor and the live parts of the motor, you can
connect the sensor to the inputs of the drive if all circuits connected to the drive’s digital
and analog inputs (typically extra-low voltage circuits) are protected against contact
and insulated with basic insulation from other low-voltage circuits. The insulation must
be rated for the same voltage level as the drive main circuit. Note that extra-low voltage
circuits (such as 24 V DC) typically do not meet these requirements.
3. You can connect the sensor to an extension module with reinforced insulation (eg,
CMOD-02) between the sensor connector and the other connectors of the module. See
the table below for the sensor insulation requirement. For sensor connection to the
extension module, see its manual.
4. You can connect a sensor to an external thermistor relay the insulation of which is rated
for the main circuit voltage of the drive.
See sections
• AI1 and AI2 as Pt100, Pt1000, Ni1000, KTY83 and KTY84 sensor inputs (X1) (page 123)
• CMOD-02 multifunction extension module (external 24 V AC/DC and isolated PTC
interface
• CPTC-02 ATEX-certified thermistor module (external 24 V AC/DC and isolated PTC
interface.
86 Guidelines for planning the electrical installation

This table shows what temperature sensor types you can connect to the drive I/O extension
modules as well as the insulation requirement for the sensor.

Extension module Temperature sensor type

Type Insulation PTC KTY Pt100, Pt1000

CMOD-02 Reinforced insulation between the sensor X - -

connector and the other connectors of the
CPTC-02 module (including drive control unit connect- X - -
or). –> No special requirements for the
thermistor insulation level.
(The drive control unit is PELV compatible
also when the module and a thermistor
protection circuit are installed.)
 Electrical installation 87

6
Electrical installation

Contents of this chapter

This chapter gives instructions on the wiring the drive.

Warnings
WARNING!
If you are not a qualified electrician do not do the installation work described in 11
this chapter. Obey the instructions in chapter Safety instructions. If you ignore
them, injury or death, or damage to the equipment can occur.

Attaching the device stickers on the cabinet door

A multilingual device label sticker is delivered with the drive. Attach the stickers in the local
language on the English texts, see section Door switches and lights (page 43).
88 Electrical installation

Layout of the cable entries (frames R6 to R9)

The layout of the input and motor cable connection terminals of frame R9 without du/dt filter
(option +E205) is shown below. The shrouds in front of the terminals are removed. The
layout is similar for the other frame sizes.

W2

V2

U2

L1 L2 L3

1
1 2
3

4 5

L1, L2, L3 Input power cable terminals

U2, V2, W2 Motor cable terminals
1 Strain relief
2 PE (ground) terminal
3 Emi-conductive cushion for grounding of the outer shields of the control cables
4 Power cable entry
5 Control cable entry
 Electrical installation 89

Layout of the cable entries (frames R10 and R11)

The layout of the input and motor cable connection terminals of frame R10 is shown below.
The shrouds in front of the terminals are removed. The layout is similar for frame R11.

L1 L2 L3

U2 V2 W2

2
1
3
4

11

5 6

L1, L2, L3 Input power cable terminals

U2, V2, W2 Motor cable terminals
1 Strain relief
2 Input power cable entry
3 PE (ground) terminal
4 Emi-conductive cushion for grounding of the outer shields of the control cables
5 Motor cable entry
6 Control cable entry
90 Electrical installation

Connecting the power cables

￭„ Connection diagram

8 L1/ L2/ L3/

~ U1 V1 W1

Q2
~
4

T1/ T2/ T3/

U2 V2 W2

5
*)

Q1 6

L1 L2 L3 U2 V2 W2 **)

PE

2 3

1a 1b

7
U1 V1 W1
(PE) PE (PE) L1 L2 L3 M
3~

1 Use a separate grounding PE cable (1a) or a cable with a separate PE conductor (1b) if the conductivity
of the shield does not meet the requirements for the PE conductor.
2 360-degree grounding is recommended if shielded cable is used. Ground the other end of the input cable
shield or PE conductor at the distribution board.
3 360-degree grounding is required.
4 Line contactor (option +F250)
5 Common mode filter (option +E208 for frames R6 to R9). Standard in frames R10 and R11.
6 du/dt filter (option +E205)
7 Use a separate grounding cable if the shield does not meet the requirements of IEC 61439-1 and there
is no symmetrically constructed grounding conductor in the cable.
8 Drive module

Note:
If there is a symmetrically constructed grounding conductor on the motor cable in addition to the conductive
shield, connect the grounding conductor to the grounding terminal at the drive and motor ends.
Do not use an asymmetrically constructed motor cable. Connecting its fourth conductor at the motor end in-
creases bearing currents and causes extra wear.
*) Switch-disconnector or molded case circuit breaker (option +F289) and separate fuses in frames R8 to R11.
**) Output terminals U2, V2 and W2 are included with option +E205 and in frames R10 and R11.
 Electrical installation 91

￭ Checking the insulation of the drive system

WARNING!
Do not make any voltage withstand or insulation resistance tests on any part of
the drive as testing can damage the drive. Every drive has been tested for insulation
between the main circuit and the chassis at the factory. Also, there are
voltage-limiting circuits inside the drive which cut down the testing voltage
automatically.

￭ Checking the insulation of the input cable

Before you connect the input power cable to the drive, check its insulation according to local
regulations.

￭ Checking the compatibility with IT (ungrounded), corner-grounded

delta, midpoint-grounded delta, and TT systems
Ground-to-phase varistor
A drive with the ground-to-phase varistor connected can be installed to a symmetrically
grounded TN-S system. If you install the drive to another system, you may need to disconnect
the varistor.

WARNING!
Do not install the drive with the ground-to-phase varistor connected to a system
that the varistor is not suitable for. If you do, the varistor circuit can be damaged.

When to disconnect the ground-to-phase varistor: TN-S, IT, corner-grounded delta

and midpoint-grounded delta systems

Frame Symmetrically grounded TN Corner-grounded (B1) and IT systems (ungrounded or

size systems (TN-S systems), ie. 11
midpoint-grounded delta (B2) high-resistance grounded [>30
center-grounded wye (A) systems ohms]) (C)
R6...R9 Do not disconnect EMC or VAR Do not disconnect EMC AC or Disconnect EMC screws (2 pcs)
screws. VAR screws. Disconnect EMC and VAR screw.
DC screw.
R10... Do not disconnect VAR wire. Do not disconnect VAR wire. Disconnect VAR wire.
R11
92 Electrical installation

Frame Symmetrically grounded TN Corner-grounded (B1) and IT systems (ungrounded or

size systems (TN-S systems), ie. midpoint-grounded delta (B2) high-resistance grounded [>30
center-grounded wye (A) systems ohms]) (C)

A B1 C
L1
L1 L1
L2

L2 L3
L2
L3
PE
L3
N
PE
Drive Drive

B2
Drive L1

L2
L3
PE

Drive

These are the EMC filter and varistor screws in different drive frame sizes.

Frame EMC filter (+E200) screws Ground-to-phase varistor screws

size
R6..R9 Two EMC screws VAR

Guidelines for installing the drive to a TT system

The drive can be connected to a TT system under these conditions:
1. Residual current device has been installed in the supply system.
2. This wire has been disconnected. Otherwise EMC filter and ground-to-phase varistor
capacitor leakage current will cause the residual current device to trip.

Frame EMC filter screws Ground-to-phase varistor screws

size
R6...R9 Two EMC screws VAR
R10, R11 - VAR
 Electrical installation 93

Frame EMC filter screws Ground-to-phase varistor screws

size

L1
L2
L3
N

Drive

Note:
• Because the varistor wire has been disconnected, ABB does not guarantee the EMC
category.
• ABB does not guarantee the functioning of the ground leakage detector built inside the
drive.
• In large systems the residual current device can trip without a real reason.

Identifying different types of electrical power systems

To identify the electrical power system type, find out the supply transformer connection. If
that is not possible, measure these voltages at the distribution board before you connect
power to the drive:
1. input voltage line to line (UL-L)
2. input voltage line 1 to ground (UL1-G)
3. input voltage line 2 to ground (UL2-G)
11
4. input voltage line 3 to ground (UL3-G).
The line-to-ground voltages in relation to the line-to-line voltage of the electrical power
system types are shown below

UL-L UL1-G UL2-G UL3-G Electrical power system type Connection diagram
X 0.58·X 0.58·X 0.58·X Symmetrically grounded L1
TN system (TN-S system)
L2

L3
N
PE

X 1.0·X 1.0·X 0 Corner-grounded delta system

L1
(nonsymmetrical)

L2
L3
PE
94 Electrical installation

UL-L UL1-G UL2-G UL3-G Electrical power system type Connection diagram
X 0.866·X 0.5·X 0.5·X Midpoint-grounded delta system
L1
(nonsymmetrical)

L2
L3
PE

X Varying Varying Varying IT systems (ungrounded or high-

level versus level versus level versus resistance-grounded [>30 ohms]) L1
time time time nonsymmetrical L2
L3

Disconnecting the EMC filter and ground-to-phase varistor (R6 to R9)

To disconnect the internal EMC filter or ground-to-phase varistor, do as follows:
1. Switch off the power from the drive.
2. Open the cover, if not already opened.
3. To disconnect the internal EMC filter, remove the two EMC screws.
4. To disconnect the ground-to-phase varistor, remove the varistor screw.

A EMC (DC)
B EMC (AC)
C VAR

Disconnecting the ground-to-phase varistor (R10 and R11)

Varistor (VAR) grounding wire is attached next to the control circuit compartment. Disconnect
it. Insulate the end and attach it.
Electrical installation 95

11
96 Electrical installation

￭ Connecting the motor cable at the motor end

Connect the power cables at the motor end.
For minimum radio-frequency interference, ground the cable shield 360 degrees at the cable
entry of the motor terminal box.

Checking the insulation of the motor and motor cable

WARNING!
Obey the safety instructions of the drive. If you ignore them, injury or death, or
damage to the equipment can occur.
If you are not a qualified electrician, do not do installation or maintenance work.

1. Stop the drive and do the steps in section Electrical safety precautions (page 20) before
you start the work.
2. Check that the motor cable is disconnected from the drive output terminals.
3. Measure the insulation resistance between the phase conductors and then between
each phase conductor and the protective earth conductor. Use a measuring voltage of
1000 V DC. The insulation resistance of an ABB motor must exceed 100 Mohm
(reference value at 25 °C [77 °F]). For the insulation resistance of other motors, consult
the manufacturer’s instructions.
Note:
Moisture inside the motor casing reduces the insulation resistance. If moisture is
suspected, dry the motor and repeat the measurement.

ohm
U1
M U1-V1, U1-W1, V1-W1
V1
1000 V DC, 3~ U1-PE, V1-PE, W1-PE
ohm W1
> 100 Mohm PE

￭ Connection procedure (IEC, frames R6 to R9)

1. Do the steps in section Electrical safety precautions (page 20) before you start the work.
2. Open the cabinet door.
3. For drives without option +E205: To remove the mounting plate, undo the mounting
screws and unplug the connectors on top of it:
• auxiliary voltage supply connectors X23, X22 and X21
• Contactor control connectors: X3, X6
 Electrical installation 97

• contactor feedback connector X250 with option +F250

• cabinet door fan supply connector X8 and control X505
• cabinet heater connector X300 with option +G300.
4. For drives without option +E205: Remove the shrouds (4a, 4b, 4c and 4d). To remove
the shroud on the power cable terminals, release the clips with a screwdriver and pull
the shroud out (4d). For drives with option +E205: Remove the shrouds 4a, 4b.

4c
4b

4a

4d

11

5. For drives without option +E205: Knock out holes in the shroud for the motor cable
conductors.
6. Peel off 3 to 5 cm of the outer insulation of the cables above the cable entries with the
conductive sleeves for the 360° high-frequency grounding.

7. Prepare the ends of the cables.

98 Electrical installation

WARNING!
Apply grease to stripped aluminum conductors before attaching them to
non-coated aluminum cable lugs. Obey the grease manufacturer’s instructions.
Aluminum-aluminum contact can cause oxidation in the contact surfaces.

PE PE

8. If fire insulation is used, make an opening in the mineral wool sheet according to the
diameter of the cable.
9. Put the cables through the bottom plate.
10. Remove rubber grommets from the bottom plate for the cables to be connected. Cut
adequate holes into the rubber grommets. Slide the grommets onto the cables. Slide
the cables through the bottom plate with the conductive sleeves and attach the grommets
to the holes.
11. Attach the conductive sleeves to the cable shields with cable ties. Tie up the unused
conductive sleeves with cable ties.

12. Seal the slot between the cable and mineral wool sheet (if used) with sealing compound
(eg, CSD-F, ABB brand name DXXT-11, code 35080082).
13. Connect the twisted shields of the motor cables to the ground bar and the phase
conductors to the U2, V2 and W2 terminals of the drive module. For drives with du/dt
 Electrical installation 99

filter (option +E205), connect the phase conductors to the T1/U2, T2/V2 and T3/W2
terminals of the cabinet with cable lugs.
14. Connect the twisted shields of the input cables and separate ground cable (if present)
to the PE terminal of the cabinet and the phase conductors to the L1, L2 and L3 terminals.

13

14

14
13

15. Tighten the power cable screws to the torque given in Terminal and entry data for the
power cables (page 182).
16. Reinstall the shrouds and mounting plate.
11
100 Electrical installation

￭ Connection procedure (IEC, frames R10 and R11)

1. Do the steps in section Electrical safety precautions (page 20) before you start the work.
2. Open the cabinet door.
3. Remove the shrouding:
• With bottom entry and bottom exit: Undo the mounting screws and pull the shroud
out.

• With top entry (option +H351) and bottom exit: Undo the mounting screws and pull
the shroud out.
Electrical installation 101

11
102 Electrical installation

• With top entry and top exit (options +H351 and +H353): Remove the shrouds and
door fan (see Replacing the door fan (frames R10 and R11) (page 141)). Undo the
mounting screws and pull the shrouds out.

4. Remove the door fan mounting plate. See section Replacing the door fan (frames R10
and R11) (page 141).
5. Peel off 3 to 5 cm of the outer insulation of the cables above the cable entries with the
conductive sleeves for the 360° high-frequency grounding.
 Electrical installation 103

6. Prepare the ends of the cables.

WARNING!
Apply grease to stripped aluminum conductors before attaching them to
non-coated aluminum cable lugs. Obey the grease manufacturer’s instructions.
Aluminum-aluminum contact can cause oxidation in the contact surfaces.

PE PE

7. If fire insulation is used, make an opening in the mineral wool sheet according to the
diameter of the cable.
8. Put the cables through the bottom plate.
9. Remove rubber grommets from the bottom plate for the cables to be connected. Cut
adequate holes into the rubber grommets. Slide the grommets onto the cables. Slide
the cables through the bottom plate with the conductive sleeves and attach the grommets
to the holes.
10. Attach the conductive sleeves to the cable shields with cable ties. Tie up the unused 11
conductive sleeves with cable ties.

11. Seal the slot between the cable and mineral wool sheet (if used) with sealing compound
(eg, CSD-F, ABB brand name DXXT-11, code 35080082).
104 Electrical installation

12. Connect the twisted shields of the motor cables to the ground bar and the phase
conductors to the U2, V2 and W2 terminals of the drive module.
13. Connect the twisted shields of the input cables and separate ground cable (if present)
to the PE terminal of the cabinet and the phase conductors to the L1, L2 and L3 terminals.

14. Tighten the power cable screws to the torque given in Terminal and entry data for the
power cables (page 182).
15. Reinstall the shrouds and mounting plate.

Connecting the control cables

See chapter Control unit (page 115) for the default I/O connections of the drive control
program. The default I/O connections can be different with some hardware options, see the
circuit diagrams delivered with the drive for the actual wiring.
Connect the cables as described under Overview of control cable connection
procedure (page 104).

￭ Overview of control cable connection procedure

WARNING!
Obey the instructions in chapter Safety instructions. If you ignore them, injury or
death, or damage to the equipment can occur.

1. Stop the drive and do the steps in section Electrical safety precautions (page 20) before
you start the work.
2. Run the control cables to the inside the cabinet as described in section Grounding the
outer shields of the control cables at the cabinet entry (page 105).
3. Route the control cables as described in section Routing the control cables inside the
cabinet (page 107).
4. Connect the control cables as described in sections
• Connecting external wiring to the control unit or optional I/O terminal block (page 108)
• Connecting the emergency stop push buttons (options +Q951 and +Q963) (page 109)
• Connecting the Safe torque off circuit (page 109)
 Electrical installation 105

• Connecting external power supply wires for the cabinet heater (option
+G300) (page 110)

￭ Grounding the outer shields of the control cables at the cabinet entry
Ground the outer shields of all control cables 360 degrees at the EMI conductive cushions
as follows (example constructions are shown below, the actual hardware may vary):
1. Loosen the tightening screws of the EMI conductive cushions and pull the cushions
apart.
2. Cut adequate holes to the rubber grommets in the entry plate and put the cables through
the grommets and the cushions.
3. Strip off the cable plastic sheath above the entry plate just enough to ensure proper
connection of the bare shield and the EMI conductive cushions.
4. Tighten the two tightening screws so that the EMI conductive cushions press tightly
round the bare shield.

4 3

4 4

1 1 11

Note 1: Keep the shields continuous as close to the connection terminals as possible.
Secure the cables mechanically at the entry strain relief.
Note 2: If the outer surface of the shield is non-conductive:
• Cut the shield at the midpoint of the bare part. Be careful not to cut the conductors or
the grounding wire (if present).
• Turn the shield inside out to expose its conductive surface.
• Cover the turned shield and the stripped cable with copper foil to keep the shielding
continuous.
106 Electrical installation

A B C
A Stripped cable

B Conductive surface of the shield exposed

C Stripped part covered with copper foil

2 2 1 Cable shield
1
3
2 Copper foil
4
3 Shielded twisted pair

4 Grounding wire
5

Note for top entry of cables: When each cable has its own rubber grommet, sufficient IP
and EMC protection can be achieved. However, if very many control cables come to one
cabinet, plan the installation beforehand as follows:
1. Make a list of the cables coming to the cabinet.
2. Sort the cables going to the left into one group and the cables going to the right into
another group to avoid unnecessary crossing of cables inside the cabinet.
3. Sort the cables in each group according to size.
4. Group the cables for each grommet as follows ensuring that each cable has a proper
contact to the cushions on both sides.

Cable diameter in mm Max. number of cables per grommet

≤ 13 4
≤ 17 3
< 25 2 Electrical installation 99
≥ 25 1

5. Arrange the bunches according to size from thickest to the thinnest between the EMI
5. Arrange the bunches
conductive according to size from thickest to the thinnest between the EMI
cushions.
conductive cushions.

6. If more than one cable go through a grommet, seal the grommet by applying Loctite
6. 5221 (catalogue
If more than number 25551)
one cable go inside
throughthe agrommet.
grommet, seal the grommet by applying Loctite
5221 (catalogue number 25551) inside the grommet.

Routing the control cables inside the cabinet

Use the existing trunking in the cabinet wherever possible. Use sleeving if cables are laid
against sharp edges. When running cables to or from the swing-out frame, leave enough
slack at the hinge to allow the frame to open fully.

Connecting to the inverter control unit (A41)

 Electrical installation 107

￭ Routing the control cables inside the cabinet

The route of the control cables is shown below in frame R9. The route is similar frames R6,
R7 and R8.

X504 (+L504)

11

The route of the control cables for frames R10 and R11 is shown below.
108 Electrical installation

X504 (+L504)

￭ Connecting external wiring to the control unit or optional I/O terminal

block
Note:
Keep any signal wire pairs twisted as close to the terminals as possible. Twisting the wire
with its return wire reduces disturbances caused by inductive coupling.

Note:
Leave slack to the control wires to make it possible to lift the control unit mounting plate a
little when the drive module is replaced.

Ground the pair-cable shields and all grounding wires to the grounding clamp.
 Electrical installation 109

Leave the other ends of the control cable shields unconnected or ground them indirectly
via a high-frequency capacitor with a few nanofarads, eg, 3.3 nF / 630 V. The shield can
also be grounded directly at both ends if they are in the same ground line with no significant
voltage drop between the end points.
Connect the conductors to the appropriate terminals (see Default I/O connection
diagram (page 117)) of the control unit or with option +L504 to the detachable terminal block
„ X504.
￭ Connecting the emergency stop push buttons (options +Q951 and
+Q963)
See the circuit diagrams delivered with the drive for connecting the emergency stop circuit
„ the user manuals of the options.
and

Internal connections
X951
1 Emergency stop push button on the cabinet door
1 1
2 Emergency stop push button on the cabinet door
2 2
1 3 Emergency stop circuit
3*
3 4* 4 Emergency stop reset button on the cabinet door 11
6
2 5*
5 Emergency stop indication on the cabinet door
3 6*
Customer connections
7
4 7
8 6 Customer external emergency stop button
9
5 7 Customer external emergency stop reset
10
* Remove bridges 3–4 and 5–6 if there is an external
emergency stop button. When the bridge connec-
tions are installed only the cabinet door push button
is in use.

„
￭„ Connecting the Safe torque off circuit
Connect the customer Safe torque off circuit as described in chapter .
For drives with options +Q951, +Q963 and +Q971, connect the Safe torque off circuit to
terminal block X969 – not to the control unit STO terminals.:
 110 Electrical installation

Internal Customer * Remove bridges 1–2 and 3–4 if there is an external

X969 Safe torque off function
connections connections

STO OUT1 1* STO OUT1

STO IN1 2* STO IN1

STO IN2 3* STO IN2

STO OUT2 4* STO OUT2

STO INTERNAL 5

„
￭ Connecting external power supply wires for the cabinet heater (option
+G300)
„ Connect the external power supply wires for the cabinet heater to terminal block X300 at
the back of the mounting plate.

Frames R6...R9

X300

N 1
L 2 1 Internal wiring of the cabinet heater: heater off/fault
= contact open.
PE PE

4
1
5

Frames R10...R11 1 Internal wiring of the cabinet heater: heater off/fault

= contact open.

Q95
L 1
N 3

X300
PE XPE95
1 1
2
 Electrical installation 111

Setting the voltage range of the auxiliary control voltage

transformer (T21)
Connect the power supply wires of the auxiliary control voltage transformer according to
the power network voltage.

Connecting a PC
A PC (with eg, the Drive composer PC tool) can be connected as follows:
1. Connect an ACx-AP-x control panel to the unit either
• by inserting the control panel into the panel holder or platform (if present), or
• by using an Ethernet (eg, Cat 5e) networking cable.
2. Remove the USB connector cover on the front of the control panel.
3. Connect an USB cable (Type A to Type Mini-B) between the USB connector on the
control panel (3a) and a free USB port on the PC (3b).
4. The panel will display an indication whenever the connection is active.
11

USB connected 4
2
?

Stop Loc/Rem Start

Stop Loc/Rem Start

2 3a 3b

5. See the documentation of the PC tool for setup instructions.

112 Electrical installation

Installing option modules

WARNING!
Obey the instructions in chapter Safety instructions. If you ignore them, injury or
death, or damage to the equipment can occur.

1. Stop the drive and do the steps in section Electrical safety precautions (page 20) before
you start the work.

￭ Option slot 2 (I/O extension modules)

1. Put the module carefully into its position on the control unit.
2. Tighten the mounting screw.
3. Tighten the grounding screw (CHASSIS) to 0.8 N·m. The screw grounds the module.
It is necessary for fulfilling the EMC requirements and for correct operation of the module.

2
 Electrical installation 113

￭ Option slot 1 (fieldbus adapter modules)

1. Put the module carefully into its position on the control unit.
2. Tighten the mounting screw (CHASSIS) to 0.8 N·m. The screw tightens the connections
and grounds the module. It is necessary for fulfilling the EMC requirements and for
correct operation of the module.

11

￭ Wiring the optional modules

See the appropriate optional module manual or for I/O options chapter Optional I/O extension
modules for specific installation and wiring instructions.
114
 Control unit 115

7
Control unit

Contents of this chapter

This chapter contains the default I/O connection diagram, descriptions of the terminals and
technical data for the drive control unit (CCU-24).

Layout
The layout of the external control connection terminals on the drive module control unit is
shown below.
116 Control unit

SLOT 1
SLOT 1
X15 Option slot 1 (fieldbus adapter modules)
ANALOG IN/OUT
1...3 Analog input 1
1…3, AI1 AI1 Current/Voltage selection switch
for
4…6, AI2 analog input 1
4...6 Analog input 2
7…9, AO1 AI2 Current/Voltage selection switch
for analog input 2
10…12 EFB 7...9 Analog outputs
AO1 Current/Voltage selection switch
13…15 for analog output 1

10...12 Auxiliary voltage output

16…18
DIGITAL IN

34…38 13...18 Digital inputs

40, 41 STO
34...38 Safe torque off connection.
19…21 Reserved for internal use with op-
tions +Q951, +Q963 and +Q971.
22…24 AIR IN Internal air temperature NTC
TEMP sensor connection
X12 25…27 FAN2 Internal fan 2 connection
FAN1 Internal fan 1 connection
X12 Panel port (control panel connec-
tion, wired at the factory to the
AIR IN TEMP control panel)
SLOT 2
X15 Reserved to internal use.
FAN 2, FAN 1
BIAS S101 EFB
EIA/RS-485 fieldbus connector
TERM S100
BIAS Bias resistor switch
S101
TERM End termination switch
S100
29...31 Connection terminals
SLOT 2
Option slot 2 (I/O extension modules)

40, 41 24 V AC/DC external power input

RO1 … RO3
19...21 Relay output 1 (RO1)
22...24 Relay output 2 (RO2)
25...27 Relay output 3 (RO3)
 Control unit 117

Default I/O connection diagram

The default I/O connections of the ABB Standard macro are shown below.
XI Reference voltage and analog inputs and outputs
1 SCR Signal cable shield (screen)
1…10 kohm 2 AI1 Output frequency reference: 0…10 V 1)
3 AGND Analog input circuit common
4 +10V Reference voltage 10 V DC
5 AI2 Not configured
6 AGND Analog input circuit common
max. 7 AO1 Output frequency: 0…20 mA
500 ohm 8 AO2 Motor current: 0…20 mA
9 AGND Analog output circuit common
7) X2 & X3 Aux. voltage output and programmable digital inputs
10 +24V Aux. voltage output +24 V DC, max. 250 mA 2)
11 DGND Auxiliary voltage output common
5)
12 DCOM Digital input common for all
13 DI1 Stop (0) / Start (1)
14 DI2 Forward (0) / Reverse (1)
6)
15 DI3 Constant frequency selection3)
16 DI4 Constant frequency selection 3)
17 DI5 Ramp set 1 (0) / Ramp set 2 (1) 4)
18 DI6 Not configured 7)
X6, X7, X8 Relay outputs
19 RO1C Ready run
20 RO1A 250 V AC / 30 V DC
21 RO1B 2A
22 RO2C Running
23 RO2A 250 V AC / 30 V DC
24 RO2B 2A
25 RO3C Fault (-1)
26 RO3A 250 V AC / 30 V DC
27 RO3B 2A
X5 EIA-485 Modbus RTU
29 B+
30 A- Embedded Modbus RTU (EIA-485).
31 DGND
S4 TERM Serial data link termination switch
S5 BIAS Serial data link bias resistors switch
X4 Safe torque off
34 OUT1 Safe torque off. Factory connection. Both
35 OUT2 circuits must be closed for the drive to start.
5)
5) 36 SGND See chapter Safe torque off function and
37 IN1 section Connecting the Safe torque off circuit
38 IN2 on page 84.
X10 24 V AC/DC

See the notes on 40 24 V AC/DC+ i Ext. 24V AC/DC input to power up the control unit
the next page.
41 24 V AC/DC- in when the main supply is disconnected.

Total load capacity of the Auxiliary voltage output +24V (X2:10) is 6.0 W (250 mA / 24 V DC).
Terminal sizes: 0.14…2.5 mm2 (all terminals)
Tightening torques: 0.5…0.6 N·m (0.4 lbf·ft)
Notes:
1. Current [0(4)…20 mA, Rin = 100 ohm] or voltage [0(2)…10 V, Rin >200 kohm]. Change
of setting requires changing the corresponding parameter.
118 Control unit

2. Total load capacity of the Auxiliary voltage output +24V (X2:10) is 6.0 W (250 mA / 24 V)
minus the power taken by the option modules installed on the board.
3. In scalar control (default): See Menu - Primary settings - Start, stop, reference -
Constant frequencies or parameter group 28 Frequency reference chain.
In vector control: See Menu - Primary settings - Start, stop, reference - Constant
speeds or parameter group Speed reference selection

DI3 DI4 Operation/Parameter

0 0 Set frequency through AI1
1 0 28.26 Constant frequency 1
0 1 28.27 Constant frequency 2
1 1 28.28 Constant frequency 3

4. See Menu - Primary settings - Ramps or parameter group 28 Frequency reference

chain.

DI5 Ramp set Parameters

0 1 28.72 Freq acceleration time 1
28.73 Freq deceleration time 1
1 2 28.74 Freq acceleration time 2
28.75 Freq deceleration time 2

5. Connected with jumpers at the factory.

6. Ground the outer shield of the cable 360 degrees under the grounding clamp on the
grounding shelf for the control cables.
7. With option +E202 in frames R10 and R11, digital input DI6 is reserved for internal
overtemperature supervison of the cabinet. See section Option +E205 in frames R10
and R11: DI6 internal overtemperature supervision (page 118)

￭ Option +E205 in frames R10 and R11: DI6 internal overtemperature

supervision
With option +E205, digital input DI6 is used by default for the internal overtemperature
supervision of the cabinet in frames R10 and R11. The I/O connection is shown below.
X2 & X3
10 +24V
11 DGND
12 DCOM
13 DI1
14 DI2
15 DI3
16 DI4
17 DI5
X4 *)
18 DI6

*) Internal overtemperature supervision of the cabinet is connected between DI6 and +24V
auxiliary voltage supply. If DI6 is to be used for another purpose, see section Changing
internal overtemperature supervision from DI6 to another digital input (page 120)

Power supply connections for PNP with option +L504

Internal and external +24 V power supply connections with option +L504 for PNP
configuration are shown below.
 Control unit 119

Internal +24 V power supply External +24 V power supply

PNP connection (source) PNP connection (source)

X503:1 X503:1
10 +24V 10 +24V
11 DGND 0 V DC 11 DGND
12 DCOM 12 DCOM
+24 V DC
13 DI1 13 DI1
14 DI2 14 DI2
15 DI3 15 DI3
16 DI4 16 DI4
17 DI5 17 DI5
18 DI6 18 DI6
X504:18 X504:18

Power supply connections for NPN with option +L504

Internal and external +24 V power supply connections for NPN configuration are shown
below.

Internal +24 V power supply External +24 V power supply

NPN connection (sink) NPN connection (sink)

X503:1 X503:1
10 +24V 10 +24V
11 DGND +24 V DC 11 DGND
12 DCOM 0 V DC 12 DCOM
13 DI1 13 DI1
14 DI2 14 DI2
15 DI3 15 DI3
16 DI4 16 DI4
17 DI5 17 DI5
18 DI6 18 DI6
X504:18 X504:18

Power supply connections for PNP without option +L504

Internal and external +24 V power supply connections without option +L504 for PNP
configuration are shown below.

Internal +24 V power supply External +24 V power supply

PNP connection (source) PNP connection (source)

10 +24V 10 +24V
11 DGND 0 V DC 11 DGND
12 DCOM 12 DCOM
+24 V DC
13 DI1 13 DI1
14 DI2 14 DI2
15 DI3 15 DI3
16 DI4 16 DI4
17 DI5 17 DI5
18 DI6 18 DI6
X4 X4

Power supply connections for NPN without option +L504

Internal and external +24 V power supply connections without option +L504 for NPN
configuration are shown below.
120 Control unit

Internal +24 V power supply External +24 V power supply

NPN connection (sink) NPN connection (sink)

10 +24V 10 +24V
11 DGND +24 V DC 11 DGND
12 DCOM 0 V DC 12 DCOM
13 DI1 13 DI1
14 DI2 14 DI2
15 DI3 15 DI3
16 DI4 16 DI4
17 DI5 17 DI5
18 DI6 18 DI6
X4 X4

Changing internal overtemperature supervision from DI6 to another digital input

With option +E205 in frames R10 and R11, by default, digital input DI6 is used for the internal
overtemperature supervision of the drive cabinet. If it is required to use DI6 for an other
purpose, change the overtemperature supervision wiring from DI6 to another free digital
input either on the control unit or on the CMOD-01 multifunction extension module. Activate
the overtemperature supervision in the new digital input with these parameter settings:
1. Select the correct digital input from parameter 31.01 External event 1 source.
2. Check that parameter 31.02 External event 1 type is set to Fault = 0.
For more information, see the firmware manual.

WARNING!
Always connect the internal overtemperature supervision of the drive cabinet to a
free digital input or to CMOD-01 multifunction extension module if disconnected
from digital input DI6. Activate the change. Disconnection of overtemperature
supervision leads to overtemperature and can damage the drive.

￭ Switches

Switch Description Position

TERM EFB link termination. Must be set ON Bus not terminated (default)
to the terminated (ON) position
when the drive (or another device) TERM
is the first or last unit on the link.
ON Bus terminated

TERM

BIAS Switches on the biasing voltages ON Bias off (default)

to the bus. One (and only one)
device, preferably at the end of the BIAS
bus must have the bias on.
ON Bias on

BIAS

￭ PNP configuration for digital inputs (X2 & X3)

Internal and external +24 V power supply connections for PNP configuration are shown in
the figure below.
 Control unit 121

Internal +24 V power supply External +24 V power supply

PNP connection (source) PNP connection (source)

X2 & X3 X2 & X3
10 +24V 10 +24V
11 DGND +24 V DC 11 DGND
12 DCOM 0 V DC 12 DCOM
13 DI1 13 DI1
14 DI2 14 DI2
15 DI3 15 DI3
16 DI4 16 DI4
17 DI5 17 DI5
18 DI6 18 DI6

WARNING!
Do not connect the +24 V AC cable to the control unit ground when the control
unit is powered from an external 24 V AC supply.

￭ NPN configuration for digital inputs (X2 & X3)

Internal and external +24 V power supply connections for NPN configuration are shown in
the figure below.

Internal +24 V power supply External +24 V power supply

NPN connection (sink) NPN connection (sink)

X2 & X3 X2 & X3
10 +24V 10 +24V
11 DGND +24 V DC 11 DGND
12 DCOM 0 V DC 12 DCOM
13 DI1 13 DI1
14 DI2 14 DI2
15 DI3 15 DI3
16 DI4 16 DI4
17 DI5 17 DI5
18 DI6 18 DI6

WARNING!
Do not connect the +24 V AC cable to the control unit ground when the control
unit is powered from an external 24 V AC supply.

￭ Connection for obtaining 0…10 V from analog output 2 (AO2)

To obtain 0…10 V from analog output AO2, connect a 500 ohm resistor (or two 1 kohm
resistors in parallel) between analog output AO2 and analog common ground AGND.
Examples are shown in the figure below.
122 Control unit

X1

8 AO2 Analog output 2. Default output 0…20 mA.

0…10 V

500 ohm
Analog common ground. Internally connected to chassis
9 AGND
through a 2 Mohm resistor.

X1

8 AO2 Analog output 2. Default output 0…20 mA.

0…10 V

1 kohm 1 kohm
Analog common ground. Internally connected to chassis
9 AGND
through a 2 Mohm resistor.

￭ Connection examples of two-wire and three-wire sensors to analog

input (AI2)
Hand/Auto, Hand/PID, and PID macros use analog input AI2.
Note:
The maximum capability of the auxiliary voltage output (24 V DC [250 mA]) must not be
exceeded.

An example of a two-wire sensor/transmitter supplied by the drive auxiliary voltage output

is shown below. Set the input signal to 4…20 mA, not 0…20 mA.

X1
P
- 4…20 mA
5 AI2 Process actual value measurement or reference,
I + 6 AGND 0(4)…20 mA, Rin = 100 ohm
…
10 +24V Auxiliary voltage output, non-isolated,
11 DGND +24 V DC, max. 250 mA

An example of a three-wire sensor/transmitter supplied by the drive auxiliary voltage output

is shown below.The sensor is supplied through its current output and the drive feeds the
supply voltage (+24 V DC). Thus the output signal must be 4…20 mA, not 0…20 mA.

X1
OUT (0)4…20 mA
P 5 AI2 Process actual value measurement or reference,
-
I 6 AGND 0(4)…20 mA, Rin = 100 ohm
+ …
10 +24V Auxiliary voltage output, non-isolated,
11 DGND +24 V DC, max. 250 mA

￭ DI6 as frequency input

If DI6 is used as a frequency input, see the firmware manual for how to set parameters
accordingly.

￭ DI6 as PTC input

If DI6 is used as a PTC input, see firmware manual for how to set parameters accordingly.
The wiring and the PTC sensor need to be double isolated. Otherwise the CMOD-02 I/O
extension module must be used.
 Control unit 123

"0" > kohm

10 "1" < 1.5 kohm
Imax = 5 mA
18
T
PTC

￭ AI1 and AI2 as Pt100, Pt1000, Ni1000, KTY83 and KTY84 sensor inputs
(X1)
One, two or three Pt100 sensors; one, two or three Pt1000 sensors; or one Ni1000, KTY83
or KTY84 sensor for motor temperature measurement can be connected between an analog
input and output as shown below. Leave the other end of the shield unconnected or ground
it indirectly via a few nanofarads high-frequency capacitor, for example, 3.3 nF / 630 V. The
shield can also be grounded directly at both ends if they are in the same ground line with
no significant voltage drop between the end points.

1...3 x (Pt100 or Pt100) or

1 x (Ni1000 or KTY83 or KTY84)
XAI
AIn 1)
AGND

T T T XAO
2)
AOn
AGND

1. Set the input type to voltage with switch S1 for analog input AI1or with S2 for analog input AI2. Set the
appropriate analog input unit to V (volt) in parameter group 12 Standard AI.
2. Select the excitation mode in parameter group 13 Standard AO.

WARNING!
As the inputs pictured above are not insulated according to IEC 60664, the
connection of the motor temperature sensor requires double or reinforced insulation
between motor live parts and the sensor.
If the assembly does not fulfill this requirement, the I/O board terminals must be
protected against contact and must not be connected to other equipment or the
temperature sensor must be isolated from the I/O terminals.

￭ Safe torque off (X4)

For the drive to start, both connections (+24 V DC to IN1 and +24 V DC to IN2) must be
closed. By default, the terminal block has jumpers to close the circuit.
Remove the jumpers before connecting an external Safe torque off circuitry to the drive.
See also chapter The Safe torque off function (page 243).
124 Control unit

Note:
Only 24 V DC can be used for STO. Only PNP input configuration can be used.
 Control unit 125

Technical data
External power supply Maximum power: 36 W, 1.50 A at 24 V AC/DC ±10% as standard
Term. 40, 41 Terminal size: 0.14…2.5 mm2

+24 V DC output Total load capacity of this outputs is 6.0 W (250 mA / 24 V) minus the power
(Term. 10) taken by the option modules installed on board.
Terminal size: 0.14…2.5 mm2

Digital inputs DI1…DI6 Input type: NPN/PNP

(Term. 13…18) Terminal size: 0.14…2.5 mm2
DI1…DI5 (Term.13…17)
12/24 V DC logic levels: "0" < 4 V, "1" > 8 V
Rin: 3 kohm
Hardware filtering: 0.04 ms, digital filtering: 2 ms sampling
DI5 (Term.17)
Can be used as a digital or frequency input.
12/24 V DC logic levels: "0" < 3 V, "1" > 8 V
Rin: 3 kohm
Max. frequency 16 kHz
Symmetrical signal (duty cycle D = 0.50)
DI6 (Term.18)
Can be used as a digital or frequency input.
12/24 V DC logic levels: "0" < 3 V, "1" > 8 V
Rin: 3 kohm
Max. frequency 16 kHz
Symmetrical signal (duty cycle D = 0.50)
Hardware filtering: 0.04 ms, digital filtering: 2 ms sampling

Note:
DI6 is not supported in the NPN configuration.
PTC mode – PTC thermistor can be connected between DI6 and +24VDC:
< 1.5 kohm = ‘1’ (low temperature), > 4 kohm = ‘0’ (high temperature), open
circuit = ‘0’ (high temperature).
DI6 is not a reinforced/double insulated input. Connecting the motor PTC
sensor to this input requires usage of a reinforced/double insulated PTC
sensor inside the motor

Relay outputs RO1…RO3 250 V AC / 30 V DC, 2 A Terminal size: 0.14…2.5 mm2

(Term. 19…27)
See section Isolation areas (page 126).

Analog inputs AI1 and AI2 Current/voltage input mode selected with a parameter, see AI1 and AI2 as
(Term. 2 and 5) Pt100, Pt1000, Ni1000, KTY83 and KTY84 sensor inputs (X1) (page 123).
Current input: 0(4)…20 mA, Rin: 100 ohm
Voltage input: 0(2)…10 V, Rin: > 200 kohm
Terminal size: 0.14…2.5 mm2
Inaccuracy: typical ±1%, max. ±1.5% of full scale
Inaccuracy for Pt100 sensors: 10 °C (50 °F)

Analog outputs AO1 and AO2 Current/voltage output mode for AO1 selected with a parameter, see Connec-
(Term. 7 and 8) tion for obtaining 0…10 V from analog output 2 (AO2) (page 121).
Current output: 0…20 mA, Rload: < 500 ohm
Voltage input: 0…10 V, Rload: > 100 kohm (AO1 only)
Terminal size: 0.14…2.5 mm2
Inaccuracy: ±1% of full scale (in voltage and current modes)

Reference voltage output for Max. 20 mA output Inaccuracy: ±1%

analog inputs +10 V DC (Term.
4)
126 Control unit

Safe torque off (STO) inputs 24 V DC logic levels: "0" < 5 V, "1" > 13 V
IN1 and IN2 (Term. 37 and 38) Rin: 2.47 kohm
Terminal size: 0.14…2.5 mm2

Embedded fieldbus (X5) Connector pitch 5 mm, wire size 2.5 mm2
Physical layer: EIA-485
Cable type: Shielded twisted pair cable with twisted pair for data and a wire
or pair for signal ground, nominal impedance 100…165 ohms, for example
Belden 9842
Transmission rate: 9.6…115.2 kbit/s
Termination by switch

Control panel - drive EIA-485, male RJ-45 connector, max. cable length 100 m (328 ft)
connection

Control panel - PC USB Type Mini-B, max. cable length 2 m (7 ft)

connection

Isolation areas
SLOT 1
Fieldbus module

1…3
AI1
4…6
Power unit
AI2
connection
7…8
AO
10…12
24 V
GND
13…15
DI

16…18
DI EFB
34…38 EIA/R5-485
STO connection
40, 41
Ext. 24 V
19…21
RO1
22…24
SLOT 2
RO2
I/O extension
module 25…27
Panel port RO3

Reinforced insulation (IEC/EN 61800-5-1:2007)

Functional insulation (IEC/EN 61800-5-1:2007)

The terminals on the control board fulfill the Protective Extra Low Voltage
(PELV) requirements (EN 50178): There is reinforced insulation between the
user terminals which only accept ELV voltages and terminals that accept
higher voltages (relay outputs).

Note:
There is functional insulation also between the individual relay outputs.

Note:
There is reinforced insulation on the power unit.
 Control unit 127

Ground isolation diagram

X1 Slot 1 Slot 2
1 SCR
2 AI1
3 AGND
4 +10V
5 AI2
6 AGND
7 AO1
8 AO2
9 AGND
X2 & X3
10 +24V
*)
11 DGND
12 DCOM
13 DI1
14 DI2
15 DI3
16 DI4
17 DI5
18 DI6
X6, X7, X8
19 RO1C
20 RO1A
21 RO1B
22 RO2C
23 RO2A
24 RO2B
25 RO3C
26 RO3A
27 RO3B
X5
29 B+
30 A-
31 DGND
X4
34 OUT1
35 OUT2
36 SGND
37 IN1
38 IN2
X10
40 24VAC/DC+in
41 24VAC/DC-in

Ground
*) Jumper installed at factory
128
 Installation checklist of the drive 129

8
Installation checklist of the drive

Contents of this chapter

This chapter contains a checklist of the mechanical and electrical installation of the drive.

Checklist
Examine the mechanical and electrical installation of the drive before start-up. Go through
the checklist together with another person.

WARNING!
Obey the safety instructions of the drive. If you ignore them, injury or death, or
damage to the equipment can occur.
If you are not a qualified electrician, do not do installation or maintenance work.

WARNING!
Stop the drive and do the steps in section Electrical safety precautions (page 20)
before you start the work.

Make sure that …

The ambient operating conditions meet the drive ambient conditions specification, and enclosure rating
(IP code or UL enclosure type).
The supply voltage matches the nominal input voltage of the drive. See the type designation label.
The drive cabinet has been attached to floor, and if necessary due to vibration etc, also by its top to
the wall or roof.
The cooling air flows freely in and out of the drive.
If the drive is connected to a network other than a symetrically grounded TN-S system: Check the
compatibility. See the electrical installation instructions.
130 Installation checklist of the drive

Make sure that …

There is an adequately sized protective earth (ground) conductor between the drive and the switchboard,
the conductor has been connected to appropriate terminal, and the terminal has been tightened to the
proper torque. Proper grounding has also been measured according to the regulations.
The input power cable has been connected to the appropriate terminals, the phase order is right, and
the terminals have been tightened to the proper torque.
There is an adequately sized protective earth (ground) conductor between the motor and the drive,
and the conductor has been connected to appropriate terminal, and the terminal has been tightened
to the proper torque. (Pull on the conductors to check.). Proper grounding has also been measured
according to the regulations.
The motor cable has been connected to the appropriate terminals, the phase order is right, and the
terminals have been tightened to the proper torque.
The motor cable has been routed away from other cables.
No power factor compensation capacitors have been connected to the motor cable.
The control cables have been connected to the appropriate terminals, and the terminals have been
tightened to the proper torque.
The voltage setting of the auxiliary voltage transformers (if any) is correct. See the electrical installation
instructions.
If a drive bypass connection will be used: The direct-on-line contactor of the motor and the drive output
contactor are either mechanically and/or electrically interlocked, ie, cannot be closed simultaneously.
A thermal overload device must be used for protection when bypassing the drive. Refer to local codes
and regulations.
There are no tools, foreign objects or dust from drilling inside the drive.
The area in front of the drive is clean: the drive cooling fan cannot draw any dust or dirt inside.
Cover(s) of the motor connection box are in place. Cabinet shrouds are in place and doors are closed.
The motor and the driven equipment are ready for start.
 Start-up 131

9
Start-up

Contents of this chapter

This chapter contains the start-up procedure of the drive. The default device designations
(if any) are given in brackets after the name, for example "main switch-disconnector (Q1)".
The same device designations are also used in the circuit diagrams, typically.

Start-up procedure
Action

Safety

WARNING! 12
Obey the safety instructions during the start-up procedure. See chapter Safety instruc-
tions (page 15).

Checks/Settings with no voltage connected

Check the mechanical and electrical installation of the drive. See Installation checklist of the
drive (page 129).

Powering up the drive

Close the cabinet doors.

Make sure that it is safe to connect voltage. Ensure that:

• cabinet doors are closed
• nobody is working on the drive or circuits that have been wired from outside into the drive cabinet
• cover of the motor terminal box is on.

Close the main switch-disconnector (Q1).

Setting up the drive parameters, and performing the first start

132 Start-up

Action

Setup the drive control program. See Quick start-up guide for ACS580 drives with standard control program
(3AXD50000048035 [English])

Drives with main contactor (Q2, option +F250): Close the main contactor by turning the operating switch
on the cabinet door from OFF into ON position.

Perform the first start of the drive and motor.

Stop the motor and drive.

Drives with a fieldbus adapter module (optional): Set the fieldbus parameters. Activate the appropriate
assistant in the control program, or see the user’s manual of the fieldbus adapter module, and the drive
firmware manual. Not all control programs include assistants.
Check that the communication works between the drive and the PLC.

On-load checks

Check that the cooling fans rotate freely in the right direction, and the air flows upwards. A paper sheet
set on the intake (door) gratings stays. The fans run noiselessly.

Check that the motor starts. stops and follows the speed reference in right direction when controlled with
the control panel.

Check that the motor starts. stops and follows the speed reference in right direction when controlled
through the customer-specific I/O or fieldbus.

Drives in which the Safe torque off control circuit is connected: Test and validate the operation of the
Safe torque off function. See chapter The Safe torque off function (page 243).

Drives with an emergency stop circuit (options +Q951 and +Q963): Test and validate the operation of
the emergency-stop circuit. Implementing the emergency stop function (page 82).
 Fault tracing 133

10
Fault tracing

Contents of this chapter

This chapter describes the fault tracing possibilities of the drive.

Warning and fault messages

See the firmware manual for the descriptions, causes and remedies of the drive control
program warning and fault messages.
134
 Maintenance 135

11
Maintenance

Contents of this chapter

This chapter contains preventive maintenance instructions.

Maintenance intervals
The table below shows the maintenance tasks which can be done by the end user. The
complete maintenance schedule is available on the Internet
(www.abb.com/drivesservices).For more information, consult your local ABB Service
representative (www.abb.com/searchchannels).
The maintenance and component replacement intervals are based on the assumption that
the equipment is operated within the specified ratings and ambient conditions. ABB
recommends annual drive inspections to ensure the highest reliability and optimum
performance.
Note:
Long term operation near the specified maximum ratings or ambient conditions may require
shorter maintenance intervals for certain components. Consult your local ABB Service
representative for additional maintenance recommendations.

￭ Descriptions of symbols
Action Description
I Visual inspection and maintenance action if needed
P Performance of on/off-site work (commissioning, tests, measurements or other work)
R Replacement of component
136 Maintenance

￭ Recommended annual maintenance actions by the user.

Action Target
I IP42 air inlet and outlet meshes on the cabinet doors
R IP54 air filters on the cabinet doors
P Quality of supply voltage
I Spare parts
P Capacitor reforming, spare modules and spare capacitors
I Tightness of terminals
I Dustiness, corrosion or temperature
I Heat sink cleaning

￭ Recommended maintenance intervals after start-up

Component Years from start-up
3 6 9 12 15 18
Cooling
Main cooling fans
Main cooling fans (frames R6 to R11) R R
Auxiliary cooling fans
Auxiliary cooling fan for circuit boards (frames R6 to R9) R R
Second auxiliary cooling fan (frames R8 to R9) R R
Circuit board compartment cooling fans (frames R10 and R11) R R
Cabinet cooling fans
Cabinet cooling fan, door (frames R6 to R9) R R
Cabinet cooling fan, 50 Hz, internal/door/IP54 (frames R10 to R11) R R
Cabinet cooling fan, 60 Hz, internal/IP54 (frames R10 to R11) R R R
Cabinet cooling fan, 60 Hz, door (frames R10 to R11) R R
Aging
Control panel battery (real-time clock) R R

4FPS10000309652

Cleaning the interior of the cabinet

WARNING!
Obey the instructions in chapter Safety instructions. If you ignore them,
injury or death, or damage to the equipment can occur.

WARNING!
Use a vacuum cleaner with an antistatic hose and nozzle. Using a normal vacuum
cleaner creates static discharges which can damage circuit boards.

1. Stop the drive and do the steps in section Electrical safety precautions (page 20) before
you start the work.
2. When necessary, clean the interior of the cabinet with a soft brush and a vacuum cleaner.
„
Maintenance 137

3. Check the air inlet and outlet meshes/filters of the cabinet. Clean when necessary.
For IP42 (UL Type 1 Filtered) drives: see section Cleaning the air inlet (door) meshes
(IP42 / UL Type 1 Filtered) below.
For IP54 (UL Type 12) drives: see section Cleaning the air inlet (door) meshes (IP42 /
UL Type 1 Filtered).

Cleaning the air inlet (door) meshes (IP42 / UL Type 1

Filtered)
WARNING!
Use a vacuum cleaner with an antistatic hose and nozzle. Using a normal vacuum
cleaner creates static discharges which can damage circuit boards.

Check the dustiness of the air inlet meshes. If the dust cannot be removed by vacuum
cleaning from outside through the grating holes with a small nozzle, proceed as follows:
1. Stop the drive and do the steps in section Electrical safety precautions (page 20) before
„ you start the work.
2. Remove the fasteners at the top of the grating.
3. Lift the grating and pull it away from the door.
4. Vacuum clean the mesh.
5. Reinstall the mesh and grating in reverse order.

Replacing the air filters (IP54 / UL Type 12)

Check the air filters and replace if necessary (see Materials (page 214) for the correct filter
types).

￭ Inlet (door) filters (IP54 / UL Type 12)

1. Stop the drive and do the steps in section Electrical safety precautions (page 20) before
you start the work.
2. Remove the fasteners at the top of the grating.
3. Lift the grating and pull it away from the door.
4. Remove the air filter mat.
5. Place the new filter mat in the grating the metal wire side facing the door.
6. Reinstall the grating in reverse order.
138 Maintenance

„
￭ Outlet (roof) filters (IP54 / UL Type 12)
1. Remove the front and back gratings of the fan cubicle by lifting them upwards
2. Remove the air filter mat.
„
3. Place the new filter mat in the grating.
4. Reinstall the grating in reverse order.

Heatsink
The drive module heatsink fins pick up dust from the cooling air. The drive runs into
overtemperature warnings and faults if the heatsink is not clean. When necessary, clean
the heatsink as follows.

WARNING!
Obey the instructions in chapter Safety instructions. If you ignore them,
injury or death, or damage to the equipment can occur.

WARNING!
Use a vacuum cleaner with antistatic hose and nozzle. Using a normal vacuum
cleaner creates static discharges which can damage circuit boards.

1. Stop the drive and do the steps in section Electrical safety precautions (page 20) before
you start the work.
 Maintenance 139

2. Remove the drive module from the cabinet. See section Replacing the drive module
(frames R6 to R9) (page 148)
3. Undo the attaching screws of the handle plate of the drive module.
4. Remove the handle plate.
5. Vacuum the interior of the heatsink from the opening.
6. Blow clean compressed air (not humid or oily) upwards from the opening and, at the
same time, vacuum from the top of the drive module.
7. Reinstall the handle plate.
8. Install the drive module back into the cabinet.

Fans
The lifespan of the cooling fans of the drive depends on the running time, ambient
temperature and dust concentration. See the firmware manual for the actual signal which
indicates the running time of the cooling fan. Reset the running time signal after fan
replacement.
Replacement fans are available from ABB. Do not use other than ABB specified spare parts.

￭ Replacing the door fan (frames R6 to R9)

Applicability: For drives with option +F250, +L537, +B055, +Q951, +Q963, Q971 or +G300.

WARNING!
Obey the instructions in chapter Safety instructions. If you ignore them, injury or
death, or damage to the equipment can occur.

1. Stop the drive and do the steps in section Electrical safety precautions (page 20) before
you start the work.
2. Open the cabinet door.
3. Unplug the power supply wires.
4. Undo the two mounting screws of the fan.
5. Install the new fan in reverse order.
140 Maintenance

3
4

￭ Replacing the cabinet fan (frames R6 to R9)

Applicability: For drives without any of these options +F250, +L537, +B055, +Q951, +Q963,
+Q971 and +G300

WARNING!
Obey the instructions in chapter Safety instructions. If you ignore them, injury or
death, or damage to the equipment can occur.

1. Stop the drive and do the steps in section Electrical safety precautions (page 20) before
you start the work.
2. Open the cabinet door.
3. Unplug the power supply wires.
4. Remove the shroud.
5. Undo the mounting screws and nuts of the fan.
6. Install the new fan in reverse order.
 Maintenance 141

3
3

￭ Replacing the door fan (frames R10 and R11)

WARNING!
Obey the instructions in chapter Safety instructions. If you ignore them, injury or
death, or damage to the equipment can occur.

1. Stop the drive and do the steps in section Electrical safety precautions (page 20) before
you start the work.
2. Open the cabinet door.
3. Unplug the connector of the fan power supply at the front of the mounting plate.
4. Pull the mounting plate outwards somewhat and unplug the connectors at the back of
the mounting plate.
5. Remove the mounting plate.
6. Undo the fan assembly mounting screws.
7. Remove the fan and the fan grating from the mounting plate.
8. Install the new fan in reverse order.
142 Maintenance
 Maintenance 143

￭ Replacing the cabinet fan (frames R10 and R11, IP54)

WARNING!
Obey the instructions in chapter Safety instructions. If you ignore them, injury or
death, or damage to the equipment can occur.

1. Stop the drive and do the steps in section Electrical safety precautions (page 20) before
you start the work.
2. Open the cabinet door.
3. Undo the fastening screws (a) of the fan mounting plate.
4. Pull the mounting plate outwards and unplug the power supply cable (b) of the fan
behind the mounting plate.
5. Remove the fan mounting plate.
6. Undo the mounting screws and nuts of the fan, and take it out of the mounting plate.
7. Install the new fan in reverse order.
144 Maintenance

a 3

￭ Replacing the drive module main fans (frames R6 to R8)

WARNING!
Obey the instructions in chapter Safety instructions. If you ignore them, injury or
death, or damage to the equipment can occur.

1. Stop the drive and do the steps in section Electrical safety precautions (page 20) before
you start the work.
2. Open the cabinet door.
3. Remove the drive module from the cabinet as described in section Replacing the drive
module (frames R6 to R9) (page 148).
4. Remove the two mounting screws of the fan mounting plate at the bottom of the drive
module.
5. Unplug the fan power supply wires from the drive.
6. Pull the fan mounting plate down from the side edge.
7. Unplug the fan power supply wires from the drive.
8. Lift the fan mounting plate off.
9. Remove the fan from the mounting plate.
 Maintenance 145

10. Install the new fan in reverse order.

11. Reset the fan on-time counter in parameter group 5 of the drive control program.

￭ Replacing the drive module main fans (frame R9)

WARNING!
Obey the instructions in chapter Safety instructions. If you ignore them,
„
„„ injury or death, or damage to the equipment can occur.

1. Stop the drive and do the steps in section Electrical safety precautions (page 20) before
you start the work.
2. Open the cabinet door.
3. Remove the drive module from the cabinet as described in section Replacing the drive
module (frames R6 to R9) (page 148).
4. Undo the two mounting screws of the fan mounting plate at the bottom of the drive
module.
5. Turn the mounting plate downwards.
6. Unplug the fan power supply wires from the drive.
7. Remove the fan mounting plate.
8. Remove the fans by removing the two mounting screws.
9. Install the new fans in reverse order.
10. Reset the fan on-time counter in parameter group 5 of the drive control program.

6
5

8
4
8
146 Maintenance
„

￭ Replacing the drive module main fans (frames R10 and R11)
WARNING!
Obey the instructions in chapter Safety instructions. If you ignore them, injury or
death, or damage to the equipment can occur.

1. Stop the drive and do the steps in section Electrical safety precautions (page 20) before
you start the work.
2. Open the cabinet door.
3. Remove the drive module out of the cabinet as described in section Replacing the drive
module (frames R10 and R11) (page 154).
4. Open the support legs of the pedestal.
5. Undo the two screws that fasten the fan assembly plate.
6. Tilt the fan assembly plate down.
7. Disconnect the power supply wires of the fans.
8. Remove the fan assembly from the drive module.
9. Undo the fastening screws of the fan(s) and remove the fan(s) from the assembly plate.
10. Install the new fan(s) in reverse order.
11. Reset the fan on-time counter in parameter group 5 of the drive control program.

5 6

8
4 4

3 3
 Maintenance 147

￭ Replacing the auxiliary cooling fan of the drive module (frames R6 to

R9)
WARNING!
Obey the instructions in chapter Safety instructions. If you ignore them,
injury or death, or damage to the equipment can occur.

1. Stop the drive and do the steps in section Electrical safety precautions (page 20) before
you start the work.
2. Open the cabinet door.
3. Unplug fan power supply wires from the drive.
4. Release the retaining clips.
5. Lift the fan off.
6. Install the new fan in reverse order.
Note:
Make sure that the arrow on the fan points up.

￭ Replacing the circuit board compartment cooling fans (frames R10

and R11)
WARNING!
Obey the instructions in chapter Safety instructions. If you ignore them,
injury or death, or damage to the equipment can occur.

1. Stop the drive and do the steps in section Electrical safety precautions (page 20) before
you start the work.
2. Open the cabinet door.
3. Remove the drive module out of the cabinet as described in section Replacing the drive
module (frames R10 and R11) (page 154).
4. Undo the fastening screw of the fan enclosure.
5. Unplug the power supply cable of the fan.
6. Install the new fan in reverse order.
148 Maintenance

Replacing the drive module (frames R6 to R9)

This replacing procedure requires: preferably two persons, a set of screw drivers with
extension bar and a torque wrench, chains for securing the module during the installation.
The drawings below show a cabinet of frame size R7. The procedure is the same for the
other frame sizes.

WARNING!
Obey the instructions in chapter Safety instructions. If you ignore them,
injury or death, or damage to the equipment can occur.
Handle the drive module carefully:
• Use safety shoes with a metal toe cap to avoid foot injury.
• Lift the drive module only by the lifting lugs.

1. Stop the drive and do the steps in section Electrical safety precautions (page 20) before
you start the work.
2. Open the cabinet door.
3. To attach the sliding rails:
3 a) Remove the sliding rails (2 pcs) from the left-hand side cabinet frame.
3 b) Undo the four screws from the top horizontal studs.
3 c) Attach the left-hand side sliding rail to the horizontal stud with the removed screws
3 d) Attach the right-hand side sliding rail to the horizontal stud with the removed screws.

WARNING!
Check that the stopping screws (3e) at the ends of the studs are in place, so
that the drive module cannot slide off the rail.
 Maintenance 149

3b

3a

Tap screw M6x16 T30 (hex) Torx M6x16

3d
3e 3c 3e

Torx M6x16 Torx M6x16

4. Unplug the wires connected to the mounting plate connectors (if present).
5. Remove the mounting plate (four screws).
6. Remove the shroud (two screws).
7. Remove the shroud on the power cable connection terminals.
150 Maintenance

6
6

5 5

5 5

8. Disconnect the option modules from the control unit.

9. For drives with additional I/O terminal block (option +L504), disconnect the upper
terminals and remove any fastening. Move the wires aside before you lift the module
out. Note: Mark the wires for reconnection!
 Maintenance 151

10. For drives without additional I/O terminal block (option +L504), disconnect the
customer-installed wires from the control unit. Note: Mark the wires for reconnection!
11. For drives with line contactor (option +F250), disconnect the input power cables from
the output of the contactor.

12. Disconnect the input power cable conductors and motor cable conductors from the drive
module terminals.
152 Maintenance

13. Secure the drive module with chains from the lifting eyes.
14. Undo the mounting screws of the flange.
15. Slide the drive module forwards along the sliding bars.
16. Lift the module out of the cabinet with a lifting device.

13

15

16

14
 Maintenance 153

17. Remove the flange.

Combiscrew M6×25 T25

M6 nut, 6 N·m M6 nut, 6 N·m

M6×10 T30, 6 N·m

18. Install the new module in reverse order.

154 Maintenance

Replacing the drive module (frames R10 and R11)

WARNING!
Obey the instructions in chapter Safety instructions. If you ignore them, injury or
death, or damage to the equipment can occur.

This replacing procedure requires: preferably two persons, installation ramp, a set of screw
drivers and a torque wrench with an extension bar of 500 mm (20 in), chains for securing
the module during the installation.
The drawings show frame R10. The details in frame R11 are slightly different.
1. Stop the drive and do the steps in section Electrical safety precautions (page 20) before
you start the work.
2. Open the cabinet door.
3. Remove the shrouds.
4. Unplug the quick connectors at the top and bottom of the control unit mounting plate.
5. Disconnect the PE conductor of the auxiliary control voltage transformer.
6. Remove the mounting plate.
 Maintenance 155

5
156 Maintenance

7. Disconnect the drive module input busbars with a torque wrench withn an extension
bar of 500 mm (20 in). Combi screw M12, 70 N·m (52 lbf·ft).
 Maintenance 157

8. Disconnect the drive module output busbars. M12, 70 N·m (52 lbf·ft).

8
158 Maintenance

9. Remove the shroud. Undo the screws that attach the drive module to the cabinet at the
top and behind the front support legs.
 Maintenance 159

10. Attach the extraction ramp to the cabinet base with two screws.

11. Attach the drive module lifting lugs to the cabinet lifting lug with chains.
12. Pull the drive module carefully out of the cabinet preferably with help from another
person.
160 Maintenance

13. Install the new module in reverse order.

11

13

12

Replacing the drive module (frames R10 and R11, IP54)

WARNING!
Obey the instructions in chapter Safety instructions. If you ignore them, injury or
death, or damage to the equipment can occur.

This replacing procedure requires: preferably two persons, installation ramp, a set of screw
drivers and a torque wrench with an extension bar of 500 mm (20 in), chains for securing
the module during the installation.
The drawings show frame R10. The details in frame R11 are slightly different.
1. Stop the drive and do the steps in section Electrical safety precautions (page 20) before
you start the work.
2. Open the cabinet door.
3. Remove the shrouds and the additional IP54 fan.
4. Unplug the quick connectors at the top and bottom of the control unit mounting plate.
5. Disconnect the PE conductor of the auxiliary control voltage transformer.
6. Remove the mounting plate.
 Maintenance 161

5
162 Maintenance

7. Disconnect the drive module input busbars with a torque wrench withn an extension
bar of 500 mm (20 in). Combi screw M12, 70 N·m (52 lbf·ft).
 Maintenance 163

8. Disconnect the drive module output busbars. M12, 70 N·m (52 lbf·ft).

8
164 Maintenance

9. Remove the shroud. Undo the screws that attach the drive module to the cabinet at the
top and behind the front support legs.
 Maintenance 165

10. Attach the extraction ramp to the cabinet base with two screws.

11. Attach the drive module lifting lugs to the cabinet lifting lug with chains.
12. Pull the drive module carefully out of the cabinet preferably with help from another
person.
166 Maintenance

13. Install the new module in reverse order.

11

13

12

Capacitors
The DC circuit of the power modules of the drive contain several electrolytic capacitors.
Their lifespan depends on the operating time of the drive, loading and ambient temperature.
Capacitor life can be prolonged by lowering the ambient temperature.
Capacitor failure is usually followed by damage to the unit and an input cable fuse failure,
or a fault trip. Contact ABB if capacitor failure is suspected. Replacements are available
from ABB. Do not use other than ABB specified spare parts. Contact an ABB service
representative for spare parts and repair services.

￭ Reforming the capacitors

The capacitors must be reformed if the drive has not been powered (either in storage or
unused) for a year or more. The manufacturing date is on the type designation label. For
information on reforming the capacitors, see Converter module capacitor reforming
instructions (3BFE64059629 [English]) in the ABB Library (https://library.abb.com/en).
If the drive module has been stored for one to three years, turn on the mains power for 30
minutes without load, then continue as usual.
If the drive module has been stored for less than a year, continue as usual.

Fuses
￭ Replacing AC fuses (frames R6 and R7)
WARNING!
Obey the instructions in chapter Safety instructions. If you ignore them, injury or
death, or damage to the equipment can occur.
 Maintenance 167

1. Stop the drive and do the steps in section Electrical safety precautions (page 20) before
you start the work.
2. Open the cabinet door.
3. Remove the shrouding from in front of the switch fuse.
4. Replace the fuses with the fuse handle which is in the cabinet.
5. Reinstall the shrouding removed earlier and close the cabinet door.

￭ Replacing AC fuses
WARNING!
Obey the instructions in chapter Safety instructions. If you ignore them, injury or
death, or damage to the equipment can occur.

1. Stop the drive and do the steps in section Electrical safety precautions (page 20) before
you start the work.
2. Open the cabinet door.
3. Remove the shrouding from in front of the fuses.
4. Slacken the nuts of the headless screws of the fuses so that you can slide out the fuse
blocks. Make a note of the order of the washers on the screws.
5. Remove the screws, nuts and washers from the old fuses and attach them to the new
fuses. Make sure to keep the washers in the original order.

6. Insert the new fuses into their slots in the cabinet.

7. Tighten the screws to torque 5 N·m (3 lbf·ft) maximum.
8. Tighten the nuts to torque as follows:
• Cooper-Bussmann fuses: 50 N·m (37 lbf·ft) if size 3; 40 N·m (30 lbf·ft) if size 2
• Mersen (Ferraz-Shawmut): 46 N·m (34 lbf·ft) if size 33; 26 N·m (19 lbf·ft) if size 32
• Other fuses: Refer to the fuse manufacturer's instructions.
9. Reinstall the shrouding removed earlier and close the cabinet door.

„
168 Maintenance

Control panel
￭ Cleaning the control panel
Use a soft damp cloth to clean the control panel. Avoid harsh cleaners which could scratch
the display window.

￭ Replacing the battery in the assistant control panel

A battery is only used in assistant control panels that have the clock function. The battery
keeps the clock operating during power interruptions.
The expected life for the battery is greater than ten years.
Note:
The battery is NOT required for any control panel or drive functions, except the clock.

1. To remove the control panel from the drive, press the retaining clip at the top and pull
it forward from the top edge.
2. Disconnect the panel cable.
3. To remove the battery, use a coin to rotate the battery cover on the back of the control
panel.
4. Replace the battery with type CR2032. Dispose the old battery according to local disposal
rules or applicable laws.
5. To reinstall the control panel, press the retaining clip at the top (5a) and push the control
panel in at the top edge (5b)
 Maintenance 169

CR2032

5a

5b
170
 Technical data 171

12
Technical data

Contents of this chapter

This chapter contains the technical specifications of the drive, for example, the ratings, sizes
and technical requirements, provisions for fulfilling the requirements for CE and other
markings.

Ratings
The nominal ratings for the drives with 50 Hz and 60 Hz supply are given below. The symbols
are described in section Definitions (page 173).

IEC RATINGS
Drive type Frame Input Output ratings
ACS580-07- size rating
No-overload use Light-overload Heavy-overload
use use
I1 Imax I2 SN PN ILd PLd IHd PHd
A A A kVA kW A kW A kW
UN = 400 V
0145A-4 R6 145 178 145 100 75 138 75 105 55
0169A-4 R7 169 247 169 117 90 161 90 145 75
0206A-4 R7 206 287 206 143 110 196 110 169 90
0246A-4 R8 246 350 246 170 132 234 132 206 110
0293A-4 R8 293 418 293 203 160 278 160 246* 132
0363A-4 R9 363 498 363 251 200 345 200 293 160
0430A-4 R9 430 542 430 298 250 400 200 363** 200
0505A-4 R10 505 560 505 350 250 485 250 361 200
0585A-4 R10 585 730 585 405 315 575 315 429 250
172 Technical data

IEC RATINGS
Drive type Frame Input Output ratings
ACS580-07- size rating
No-overload use Light-overload Heavy-overload
use use
I1 Imax I2 SN PN ILd PLd IHd PHd
A A A kVA kW A kW A kW
0650A-4 R10 650 730 650 450 355 634 355 477 250
0725A-4 R11 725 1020 725 502 400 715 400 566 315
0820A-4 R11 820 1020 820 568 450 810 450 625 355
0880A-4 R11 880 1100 880 610 500 865 500 725*** 400

3AXD10000451709

NEMA RATINGS
Drive type Frame Input rat- Max. cur- App. Output ratings
ACS580-07- size ing rent power
Light-overload use Heavy-overload use
I1 Imax SN ILd PLd IHd PHd
A A kVA A hp A hp
UN = 480 V
0145A-4 R6 124 178 123 124 100 96 75
0169A-4 R7 156 247 171 156 125 124 100
0206A-4 R7 180 287 199 180 150 156 125
0246A-4 R8 240 350 242 240 200 180 150
0293A-4 R8 260 418 290 260 200 240* 150
0363A-4 R9 361 498 345 361 300 302 250
0430A-4 R9 414 542 376 414 350 361** 300
0505A-4 R10 483 560 388 483 400 361 300
0585A-4 R10 573 730 506 573 450 414 350
0650A-4 R10 623 730 506 623 500 477 400
0725A-4 R11 705 850 589 705 600 566 450
0820A-4 R11 807 1020 707 807 700 625 500
0880A-4 R11 807 1020 707 807 700 625 500

￭ NEC ratings
NEC RATINGS
Drive type Frame Input rat- Max. cur- App. Output ratings
ACS580-07- size ing rent power
Light-overload use Heavy-overload use
I1 Imax SN ILd PLd IHd PHd
A A kVA A hp A hp
UN = 480 V
0124A-4 R6 124 178 100 124 100 96 75
0156A-4 R7 156 247 117 156 125 124 100
0180A-4 R7 180 287 143 180 150 156 125
 Technical data 173

NEC RATINGS
Drive type Frame Input rat- Max. cur- App. Output ratings
ACS580-07- size ing rent power
Light-overload use Heavy-overload use
I1 Imax SN ILd PLd IHd PHd
A A kVA A hp A hp
0240A-4 R8 240 350 170 240 200 180 150
0260A-4 R8 260 418 203 260 200 240* 150
0361A-4 R9 361 542 251 361 300 302 250
0414A-4 R9 414 542 298 414 350 361** 300

￭ Definitions

UN Nominal voltage of the drive. For the input voltage range, see section Electrical power network specific-
ation (page 211).

I1 Nominal rms input current

I2 Nominal output current (available continuously with no over-loading)

S Apparent power (no overload)

PN Typical motor power in no-overload use

ILd Continuous rms output current allowing 10% overload for 1 minute every 5 minutes.

PLd Typical motor power in light-overload use

Imax Maximum output current. Available for two seconds at start, then as long as allowed by drive temperature.

IHd Continuous rms output current allowing 50% overload for 1 minute every 10 minutes.
* Continuous rms output current allowing 30% overload for 1 minute every 10 minutes.
** Continuous rms output current allowing 25% overload for 1 minute every 10 minutes.

PHd Typical motor power in heavy-duty use

Note 1: The ratings apply at an ambient temperature of 40 °C (104 °F).

Note 2: To achieve the rated motor power given in the table, the rated current of the drive
must be higher than or equal to the rated motor current.
The DriveSize dimensioning tool available from ABB is recommended for selecting the drive,
motor and gear combination.

Output derating
￭ Ambient temperature derating
Drive types other than ACS580-0414A-4 and ACS580-0430A-4
In the temperature range +40…50 °C (+104…122 °F), the rated output current is derated
by 1% for every added 1 °C (1.8 °F). The output current can be calculated by multiplying
the current given in the rating table by the derating factor (k):
„
„

174 Technical data

1.00

0.90

0.80
+40 °C +50 °C T
+104 °F +122 °F

For example:

Temperature Derated current

40 ºC (104 ºF) ILd IHd

45 ºC (113 ºF) 0.95 · ILd 0.95 · Id

50 ºC (122 ºF) 0.90 · ILd 0.90 · IHd

Drive types ACS580-0414A-4 and ACS580-0430A-4

In the temperature range +35…50 °C (+95…122 °F), the rated output current is derated by
1% for every added 1 °C (1.8 °F). The output current can be calculated by multiplying the
current given in the rating table by the derating factor (k):
k

1.00

0.95
0.90
0.85

0.80
+35 °C +40 °C +50 °C T
„ +95 °F +104 °F +122 °F

„
￭ Altitude derating
At altitudes from 1000 to 2000 m (3300 to 6561 ft) above sea level, the derating is 1% for
every 100 m (328 ft). Multiply the output current given in Ratings (page 171) by the coefficient
value given in this table.

Frame Coeffficient

1000 m 2000 m 3000 m 4000 m

3281 ft 6562 9842 ft 13123 ft

R6 1.00 0.90 0.80 0.70

R7 1.00 0.90 0.80 0.70

R8 1.00 0.90 0.80 0.70

R9 1.00 0.90 0.80 0.70

R10 1.00 0.90 0.80 0.70

 Technical data 175

Frame Coeffficient

1000 m 2000 m 3000 m 4000 m

3281 ft 6562 9842 ft 13123 ft

R11 1.00 0.90 0.80 0.70

If ambient temperature is below +40 °C (+104 .°F), the derating can be reduced by 1.5%
for every 1 °C reduction in temperature. Curves with derating factors from 1.00 to 0.80 are
shown below. For a more accurate derating, use the DriveSize PC tool. A few altitude
derating curves are shown below.

Installation site altitude

4000 m
13123 ft
0.80
3500 m
11429 ft
0.85

3000 m 0.90
9842 ft

2500 m 0.95
8202 ft

1.00
2000 m
6562 ft

1500 m
4921 ft

1000 m
3300 ft
+20 °C +25 °C +30 °C +35 °C +40 °C
+68 °F +77 °F +86 °F +95 °F +104 °F

Ambient temperature

￭ Deratings for special settings in the drive control program

If you change the minimum switching frequency with parameter 97.02 Minimum switching
frequency, multiply the output current given in Ratings (page 171) by the coefficient value
given in this table.

Frame size 1.5 kHz 2 kHz 4kHz 8 kHz

R6 1.00 0.97 0.84 0.66

R7 1.00 0.98 0.89 0.71

R8 1.00 0.96 0.82 0.61

R9 1.00* 0.95* 0.79* 0.58*

R10 1.00 0.92 0.78 0.58

R11 1.00 0.92 0.78 0.58

176 Technical data

Frame size 1.5 kHz 2 kHz 4kHz 8 kHz

R11 1.00 0.92 0.78 0.58

R11 1.00 0.92 0.78 0.58

* current derating for -0414A-4 and -0430A-4 at 35 C

Note:
Changing the value of parameter 97.01 Switching frequency reference does not require
derating.

Fuses (IEC)
The standard drive is equipped with aR fuses listed below.

Drive type Input cur- Ultrarapid (aR) fuses (one fuse per phase)
ACS580-07- rent
(A) (A) A2s V Type Type Size
(Buss- (Mersen)
mann)

UN = 400 V

0145A-4 145 250 31000 690 170M3816D J320375C 1

0169A-4 169 250 31000 690 170M3816D J320375C 1

0206A-4 206 315 52000 690 170M3817D N320379C 1

0246A-4 246 400 79000 690 170M5408 H300065A 2

0293A-4 293 500 155000 690 170M5410 S1046930K 2

0363A-4 363 630 210000 690 170M6410 X300078C 3

0430A-4 430 700 300000 690 170M6411 Y300079C 3

0505A-4 505 800 465000 690 170M6412 W1046956F 3

0585A-4 585 900 670000 690 170M6413 X1046957F 3

0650A-4 650 1000 945000 690 170M6414 Y1046958F 3

0725A-4 725 1250 1950000 690 170M6416 A1046960F 3

0820A-4 820 1250 1950000 690 170M6416 A1046960F 3

0880A-4 880 1400 2450000 690 170M6417 B1046961F 3

Note 1: See also Implementing the emergency stop function (page 82).
Note 2: Fuses with higher current rating than the recommended ones must not be used.
Fuses with lower current rating can be used.
Note 3: Fuses from other manufacturers can be used if they meet the ratings and the melting
curve of the fuse does not exceed the melting curve of the fuse mentioned in the table.
 Technical data 177

Fuses (UL)
The drive with option +C129 and option +F289 is equipped with standard fuses listed below
for internal circuit protection. The fuses restrict drive damage and prevent damage to adjoining
equipment in case of a short-circuit inside the drive. The drive also requires external fuses
for branch circuit protection per NEC, see section Fuses for branch circuit
protection (page 178).

Drive type Input Fuse (one fuse per phase)

ACS580-07- current
A A V Type Type UL Type with op- Size
(Bussmann) (Mersen) class / tion +F289 (op-
Size tion
+F289)

UN = 480 V - NEMA types

0145A-4 124 250 600 DFJ-250 B235889A (HSJ J 170M3416 1

250)

0169A-4 156 300 600 DFJ-300 C235890A (HSJ J 170M3416 1

300)

0206A-4 180 300 600 DFJ-300 C235890A (HSJ J 170M4410 1

300)

0246A-4 240 400 690 170M5408 H300065A 2 170M5408 2

0293A-4 260 500 690 170M5410 S1046930K 2 170M5410 2

0363A-4 361 630 690 170M6410 X300078C 3 170M6410 3

0430A-4 414 700 690 170M6411 Y300079C 3 170M6411 3

0505A-4 483 800 690 170M6412 W1046956F 3 170M6412 3

0585A-4 573 900 690 170M6413 X1046957F 3 170M6413 3

0650A-4 623 1000 690 170M6414 Y1046958F 3 170M6414 3

0725A-4 705 1250 690 170M6416 A1046960F 3 170M6416 3

0820A-4 807 1250 690 170M6416 A1046960F 3 170M6416 3

0880A-4 807 1400 690 170M6417 B1046961F 3 170M6417 3

UN = 480 V - NEC types

0124A-4 124 250 600 DFJ-250 B235889A (HSJ J

250)

0156A-4 156 300 600 DFJ-300 C235890A (HSJ J

300)

0180A-4 180 300 600 DFJ-300 C235890A (HSJ J

300)

0240A-4 240 400 690 170M5408 H300065A 2

0260A-4 260 500 690 170M5410 S1046930K 2

0361A-4 361 630 690 170M6410 X300078C 3

0414A-4 414 700 690 170M6411 Y300079C 3

178 Technical data

The drive with option +F289 is equipped with standard fuses listed below for internal circuit
protection. The fuses restrict drive damage and prevent damage to adjoining equipment in
case of a short-circuit inside the drive. The drive also requires external fuses for branch
circuit protection per NEC, see section Fuses for branch circuit protection (page 178).

Drive type Input current Fuse (one fuse per phase) with option +F289
ACS580-07- A
A Manufacturer Type Size

UN = 480 V

0145A-4 124 250 Bussmann 170M3416 1

0169A-4 156 250 Bussmann 170M3416 1

0206A-4 180 315 Bussmann 170M4410 1

0246A-4 240 400 Bussmann 170M5408 2

0293A-4 260 500 Bussmann 170M5410 2

0363A-4 361 630 Bussmann 170M6410 3

0430A-4 414 700 Bussmann 170M6411 3

Note 1: See also Implementing the emergency stop function (page 82).
Note 2: Fuses with higher current rating than the recommended ones must not be used.
Fuses with lower current rating can be used.
Note 3: Fuses from other manufacturers can be used if they meet the ratings and the melting
curve of the fuse does not exceed the melting curve of the fuse mentioned in the table.
Note 4: Circuit breakers must not be used without fuses.

Fuses for branch circuit protection

The drive is suitable for use on a circuit capable of delivering not more than 100,000 rms
symmetrical amperes at 480 V maximum when the input cable is protected with UL class
T or L fuses. The fuses for branch circuit protection per NEC must be selected according
to the table below. Fast acting class T and L or faster are recommended in the USA. Obey
local regulations.

Drive type Input Fuse (one fuse per phase) NEC type
ACS580-07- current
A A V Manufacturer Type UL
class

UN = 460 V

0145A-4 124 200 600 Bussmann JJS-200 T 0124A-4

0169A-4 156 225 600 Bussmann JJS-225 T 0156A-4

0206A-4 180 300 600 Bussmann JJS-300 T 0180A-4

0246A-4 240 350 600 Bussmann JJS-350 T 0240A-4

0293A-4 260 400 600 Bussmann JJS-400 T 0260A-4

0363A-4 361 500 600 Bussmann JJS-500 T 0361A-4

0430A-4 414 600 600 Bussmann JJS-600 T 0414A-4

 Technical data 179

Drive type Input Fuse (one fuse per phase) NEC type
ACS580-07- current
A A V Manufacturer Type UL
class

0505A-4 483 600 600 Bussmann JJS-600 T

0585A-4 573 800 600 Ferraz A4BY800 L

0650A-4 623 800 600 Ferraz A4BY800 L

0725A-4 705 800 600 Ferraz A4BY800 L

0820A-4 807 900 600 Ferraz A4BY900 L

0880A-4 807 1000 600 Ferraz A4BY1000 L

Note 1: See also Implementing the emergency stop function (page 82).
Note 2: Fuses with higher current rating than the recommended ones must not be used.
Fuses with lower current rating can be used.
Note 3: Fuses from other manufacturers can be used if they meet the ratings and the melting
curve of the fuse does not exceed the melting curve of the fuse mentioned in the table.

Dimensions and weights

Drive type Height Width Depth Weight
ACS580-07-
mm in. mm in. mm in. kg lb
R6 2145 84.43 430 16.93 673 26.50 210 463
R7 2145 84.43 430 16.93 673 26.50 220 485
R8 2145 84.43 530 20.87 673 26.50 255 562
R9 2145 84.43 530 20.87 673 26.50 275 606
R10 IP21/IP42 2145 84.43 830 32.68 698 27.48 410 904
R10 IP54 2315 91.14 830 32.68 698 27.48 410 904
R11 IP21/IP42 2145 84.43 830 32.68 698 27.48 440 970
R11 IP54 2315 91.14 830 32.68 698 27.48 440 970

Free space requirements

Free space requirements for cooling are given below.

Front Side Above *

mm in. mm in. mm in.

150 5.91 - - 400 15.75

* measured from the base plate of the cabinet top.

> 400 mm (15.75”)

180 Technical data

Free space for door opening:

R6, R7: 400 mm (15.75”) in)

R8, R9: 500 mm (19.68 in)
R10. R11: 800 mm (31.50 in)

Maximum allowed plinth height for the

extraction/installation ramp
The maximum plinth height for the extraction/installation ramp delivered with the drive is 50
mm (1.97 in).

Typical power cable sizes

The table below gives typical copper and aluminum cable types with concentric copper
shield for the drives with nominal current. For the cable sizes accepted by the drive cabinet
cable entries and connection terminals, see Terminal and entry data for the power
cables (page 182).

Drive type ACS580-07- Frame IEC 1) US 2)

size
Cu cable type Al cable type Cu cable type
mm2 mm2 AWG/kcmil per phase
UN = 400 V
0145A-4 R6 3×95 3×120 3/0
0169A-4 R7 3×120 3×150 250 MCM
0206A-4 R7 3×150 3×240 300 MCM
0246A-4 R8 2×(3×70) 2×(3×95) 2×2/0
0293A-4 R8 2×(3×95) 2×(3×120) 2×3/0
0363A-4 R9 2×(3×120) 2×(3×185) 2×250 MCM
0430A-4 R9 2×(3×150) 2×(3×240) 2×300 MCM
0505A-4 R10 3x(3x95) 3x(3x150) 2×500 MCM or 3×250
MCM
0585A-4 R10 3x(3x120) 4×(3x150) 3x300 MCM
0650A-4 R10 3x(3x150) 4×(3x150) 3x300 MCM
0725A-4 R11 3x(3x185) 4x(3x185) 3×500 MCM or 4×300
MCM
0820A-4 R11 3x(3x240) 4x(3x240) 3×600 MCM or 4×400
MCM
0880A-4 R11 3x(3x240) 4x(3x240) 3×600 MCM or 4×400
MCM
UN = 480 V
0124A-4 R6 3x95 3x120 3/0
 Technical data 181

Drive type ACS580-07- Frame IEC 1) US 2)

size
Cu cable type Al cable type Cu cable type
mm2 mm2 AWG/kcmil per phase
0156A-4 R7 3x120 3x150 250 MCM
0180A-4 R7 3x150 3x240 300 MCM
0240A-4 R8 2x(3x70) 2x(3x95) 2x2/0
0260A-4 R8 2x(3x95) 2x(3x120) 2x3/0
0361A-4 R9 2x(3x120) 2x(3x185) 2x250 MCM
0414A-4 R9 2x(3x150) 2x(3x240) 2x300 MCM

1. The cable sizing is based on max. 9 cables laid on a cable ladder side by side, three ladder type trays one on top of the
other, ambient temperature 30 °C, PVC insulation, surface temperature 70 °C (EN 60204-1and IEC 60364-5-52/2001).
For other conditions, size the cables according to local safety regulations, appropriate input voltage and the load current
of the drive.
2. The cable sizing is based on NEC Table 310-16 for copper wires, 75 °C (167 °F) wire insulation at 40 °C (104 °F) ambient
temperature.Not more than three current-carrying conductors in raceway or cable or earth (directly buried). For other
conditions, size the cables according to local safety regulations, appropriate input voltage and the load current of the
drive.

Losses, cooling data and noise

Drive type ACS580-07- Air flow Heat dissipa- Noise
tion
IP21, IP42 (UL Type 1) IP54 (UL Type 12)
m3/h ft3/min m3/h ft3/min W dB(A)
UN = 480 V
0145A-4 685 403 585 344 2487 67
0169A-4 700 412 600 353 2497 67
0206A-4 700 412 600 353 3314 67
0246A-4 800 471 700 412 3806 65
0293A-4 800 471 700 412 4942 65
0363A-4 1400 824 1300 765 5868 68
0430A-4 1400 824 1300 765 7600 68
0505A-4 1900 1118 1900 1118 8353 72
0585A-4 1900 1118 1900 1118 9471 72
0650A-4 1900 1118 1900 1118 11200 72
0725A-4 2400 1413 2400 1413 11386 72
0820A-4 2400 1413 2400 1413 13725 72
0880A-4 2620 1542 2620 1542 15300 71
UN = 480 V - NEC types
0124A-4 685 403 585 344 2487 67
0156A-4 700 412 600 353 2497 67
0180A-4 700 412 600 353 3314 67
0240A-4 800 471 700 412 3806 65
0260A-4 800 471 700 412 4942 65
0361A-4 1400 824 1300 765 5868 68
0414A-4 1400 824 1300 765 7600 68
182 Technical data

Terminal and entry data for the power cables

There are two (in frames R6 to R9) or four (in frames R10 and R11) 60 mm (2.36 in) diameter
holes in the entry plate for the input power cables and two (in frames R6 to R9) or four (in
frames R10 and R11) 60 mm (2.36 in) diameter holes for the motor cables.

￭ IEC – Standard configuration

Input and motor cable terminal bolt sizes, accepted wire sizes (per three phases) and
tightening torques are given below.

Frame Input and motor cable connection terminals PE (grounding) termin-

size als
L1, L2, L3 T1/U2, T2/V2, T3/W2

Max. wire Bolt size Tighten- Min. wire Max. wire Tighten- Bolt size Tighten-
size ing torque size 1) size ing torque mm2 ing torque
mm2 N·m mm2 mm2 N·m N·m

R6 3×150 M10 20…40 3×25 3×150 30 M10 30…44

R7 2×(3×240) M10 20…40 2×(3×95) 2×(3×240) 40 M10 30…44

R8 2×(3×150) M10 20…40 2×(3×50) 2×(3×150) 40 M10 30…44

R9 2×(3×240) M12 50…75 2×(3×95) 2×(3×240) 70 M10 30…44

R10 4×(3×150) M12 50…75 - 4×(3×150) 50…75 M10 30…44

R11 4×(3×240) M12 50…75 - 4×(3×240) 50…75 M10 30…44

1) Note: Minimum wire size does not necessarily have enough current capability for full load.
Make sure the installation complies with local laws and regulations.

￭ IEC – With option +E205

Input and motor cable terminal bolt sizes, maximum accepted wire sizes (per three phases)
and tightening torques are given below.

Frame size L1, L2, L3, U2, V2, W2 PE (grounding)

Max. wire size Bolt size Tightening Bolt size Tightening
mm2 torque mm2 torque
N·m N·m
R6 3×120 M10 20…40 M10 30…44
R7 3×240 M10 20…40 M10 30…44
R8 2×(3×120) M10 20…40 M10 30…44
R9 2×(3×240) M12 50…75 M10 30…44
R10 4×(3×150) M12 50…75 M10 30…44
R11 4×(3×240) M12 50…75 M10 30…44

￭ US – Standard configuration
Input and motor cable terminal bolt sizes, accepted wire sizes (per three phases) and
tightening torques are given below.
 Technical data 183

Frame L1, L2, L3 T1/U2, T2/V2, T3/W2 PE (grounding)

size
Max. wire Bolt size Tighten- Min. wire Max. wire Tighten- Bolt size Tighten-
size ing torque size 1) size ing torque ing torque
AWG lbf·ft AWG AWG lbf·ft lbf·ft

R6 3×300 M10 (3/8") 22.1 3 3×300 22.1 M10 (3/8") 29.5

MCM MCM

R7 3×500 M10 (3/8") 22.1 3/0 3×500 22.1 M10 (3/8") 29.5
MCM MCM

R8 2×(3×300 M10 (3/8") 22.1 2×1/0 / 2×(3×300 22.1 M10 (3/8") 29.5
MCM) 2×3/0 2) MCM)

R9 2×(3×500 M12 51.6 2×3/0 2×(3×500 51.6 M10 (3/8") 29.5

MCM) (7/16") MCM)

R10 4×(3×300 M12 51.6 - 4×(3×300 51.6 M10 (3/8") 29.5

MCM) (7/16") MCM)

R11 4×(3×500 M12 51.6 - 4×(3×500 51.6 M10 (3/8") 29.5

MCM) (7/16") MCM)

1) Note: Minimum wire size does not necessarily have enough current capability for full load.
Make sure the installation complies with local laws and regulations.
2) -01-246A-4: 2×1/0, -01-293A-4: 2×3/0

￭ US – With option +E205

Input and motor cable terminal bolt sizes, maximum accepted wire sizes (per three phases)
and tightening torques are given below.

Frame size L1, L2, L3, U2, V2, W2 PE (grounding)

Max. wire size Bolt size Tightening Bolt size Tightening

mm2 torque mm2 torque
N·m N·m

R6 3×300 MCM M10 (3/8") 22.1 M10 30…44

R7 3×500 MCM M10 (3/8") 22.1 M10 30…44

R8 2×(3×300 MCM) M12 (7/16") 51.6 M10 30…44

R9 2×(3×500 MCM) M12 (7/16") 51.6 M10 30…44

R10 4×(3×300 MCM) M12 (7/16") 51.6 M10 30…44

R11 4×(3×500 MCM) M12 (7/16") 51.6 M10 30…44

184 Technical data

„Connection drawings
Frame R6: Input and motor cable terminal dimensions (bottom entry and exit, switch fuse OS250)

DET A
 Technical data 185

Frame R6: Input and motor cable terminal dimensions (bottom entry and exit, switch fuse OS400)

DET A
186 Technical data

Frame R6: Input and motor cable terminal dimensions (option +F289)

DET A
 Technical data 187

Frames R6 and R7: Input and motor cable terminal dimensions (bottom entry and exit, switch fuse OS250,
du/dt filter [option +E205])
188 Technical data

Frames R6 and R7: Input and motor cable terminal dimensions (bottom entry and exit, switch fuse OS400,
du/dt filter [option +E205])
 Technical data 189

Frames R6 and R7: Input and motor cable terminal dimensions (bottom entry and exit, options +F289 and
+E205)
190 Technical data

Frame R7: Input and motor cable terminal dimensions (bottom entry and exit, switch fuse OS250)

DET A
 Technical data 191

Frame R7: Input and motor cable terminal dimensions (bottom entry and exit, switch fuse OS400)

DET A
192 Technical data

Frame R7: Input and motor cable terminal dimensions (bottom entry and exit, option +F289)
 Technical data 193

Frames R6 and R7: Input and motor cable terminal dimensions (top entry and exit, options +H351 and +H353)
194 Technical data

Frame R8: Input and motor cable terminal dimensions (bottom entry and exit, switch-disconnector OT400)

DET A
 Technical data 195

Frame R8: Input and motor cable terminal dimensions (bottom entry and exit, switch-disconnector OT400,
du/dt filter [option +E205])
196 Technical data

Frame R8: Input and motor cable terminal dimensions (bottom entry and exit, option +F289)
 Technical data 197

Frame R9: Input and motor cable terminal dimensions (bottom entry and exit, switch-disconnector OT630)

DET A
198 Technical data

Frame R9: Input and motor cable terminal dimensions (bottom entry and exit, switch-disconnector OT630,
du/dt filter [option +E205])
 Technical data 199

Frames R8 and R9: Input and motor cable terminal dimensions (top entry and exit, options +H351 and +H353)
200 Technical data

Frames R8 and R9: Input and motor cable terminal dimensions (bottom entry and exit, options +F289 and
+E205)
 Technical data 201

Frame R9: Input and motor cable terminal dimensions (option +F289)
202 Technical data

Frame R10: Input and motor cable terminal dimensions (bottom entry and exit)
 Technical data 203

Frame R10: Input and motor cable terminal dimensions (bottom entry and exit, option +E205)
204 Technical data

Frame R10: Input and motor cable terminal dimensions (top entry and exit)
 Technical data 205

Frame R10: Input and motor cable terminal dimensions (top entry and exit, option +F289)
206 Technical data

Frame R11: Input and motor cable terminal dimensions (bottom entry and exit)
 Technical data 207

Frame R11: Input and motor cable terminal dimensions (bottom entry and exit, option +E205)
208 Technical data

Frame R11: Input and motor cable terminal dimensions (top entry and exit)
 Technical data 209

Frame R11: Input and motor cable terminal dimensions (top entry and exit, option +F289)
210 Technical data

Terminal and connection data for auxiliary control circuits

Maximum acceptable voltage and current values and wire sizes in terminal blocks are given
below.

Terminal block Maximum acceptable voltage and current values and wire sizes

X250 230V AC / 24V DC, 2A

• Solid wire 0,14...4 mm2 (28...12 AWG)
• Stranded wire 0,08...2,5 mm2 (28...14 AWG)

X289 230V AC / 24V DC, 2A

• Solid wire 0,14...4 mm2 (28...12 AWG)
• Stranded wire 0,08...2,5 mm2 (28...14 AWG)

X290 230V AC / 24V DC, 2A

• Solid wire 0,14...4 mm2 (28...12 AWG)
• Stranded wire 0,08...2,5 mm2 (28...14 AWG)

X300 230V AC, 4A

• Solid wire 0,14...4 mm2 (28...12 AWG)
• Stranded wire 0,08...2,5 mm2 (28...14 AWG)

X951 24V DC
• Solid wire 0,14...4 mm2 (28...12 AWG)
• Stranded wire 0,08...2,5 mm2 (28...14 AWG)

X969 24V DC
• Solid wire 0,14...4 mm2 (28...12 AWG)
• Stranded wire 0,08...2,5 mm2 (28...14 AWG)

X3 24V DC
• Solid wire 0,14...4 mm2 (28...12 AWG)
• Stranded wire 0,08...2,5 mm2 (28...14 AWG)

X504 230V AC / 24V DC, 2A

• Solid wire 0,25...2,5mm2 (24...12 AWG)
• Stranded wire 0,25...2,5 mm2 (24...14 AWG)

X601.1 480V AC, 20A

• Solid wire 0,75...16 mm2 (18...6 AWG)
• Stranded wire 0,75...16 mm2 (18...6 AWG)

X601.1 230V AC / 24V DC, 2A

• Solid wire 0,2...2,5 mm2 (24...14 AWG)
• Stranded wire 0,2...2,5 mm2 (24...14 AWG)
 Technical data 211

Electrical power network specification

Voltage (U1) ACS580-07-xxxxx-4 drives: 380…480 VAC 3-phase ±10%. This is indicated in the
type designation label as typical input voltage levels 3~400/480 V AC.

Network type TN (grounded) and IT (ungrounded) systems

Short-circuit withstand Maximum allowable prospective short-circuit current is 65 kA when the input cable
strength (IEC 61439-1) is protected with gG type fuses (IEC 60269) having maximum operating time of
0.1 seconds and maximum current rating:
• 400 A for frames R6 to R8
• 630 A for frame R9
• 1000 A for R10
• 1250 A for R11

Short-circuit current The drive is suitable for use on a circuit capable of delivering not more than 100,000
protection (UL 508C) rms symmetrical amperes at 480 V maximum when the input cable is protected
with UL class T or L fuses. For selection of fuses for branch circuit protection, see
section Fuses for branch circuit protection (page 178). Fast acting class T and L or
faster are recommended in the USA. Obey local regulations.

Frequency (f1) 50/60 Hz. Variation ±5% of nominal frequency.

Imbalance Max. ± 3% of nominal phase to phase input voltage

Fundamental power 0.98 (at nominal load)

factor (cos phi1)

Motor connection data

Motor types Asynchronous AC induction motors, permanent magnet synchronous motors

Voltage (U2) 0 to U1, 3-phase symmetrical. This is indicated in the type designation label as
typical output voltage level 3 ~ 0...U1. Umax at the field weakening point.

Frequency (f2) 0…500 Hz

For drives with du/dt filter: 500 Hz

Current See section Ratings (page 171).

Switching frequency 3 kHz (typically)

Maximum recommended 300 m (984 ft).

motor cable length Longer cables cause a motor voltage decrease which limits the available motor
power. The decrease depends on the motor cable length and characteristics. Note
that a sine filter (optional) at the drive output also causes a voltage decrease.
Contact ABB for more information.

Note:
With motor cables longer than 100 m (328 ft), the EMC Directive requirements
may not be fulfilled.

Control unit connection data

See chapter Control unit (page 115).

Efficiency
Approximately 98% at nominal power level
212 Technical data

Protection classes
Degrees of protection IP21 (standard), IP42 (option +B054), IP54 (option +B055)
(IEC/EN 60529) , IP54 (option +B055)
Enclosure types (UL50) UL Type 1 (standard), UL Type 1 (option +B054), UL Type 12 (option +B055). For
indoor use only.
Overvoltage category III, except for auxiliary power connections (fan, control, heating, lighting, cooling
(IEC/EN 60664-1) unit pump etc) which are category II.
Protective class I
(IEC/EN 61800-5-1)
 Technical data 213

Ambient conditions
Environmental limits for the drive are given below. The drive is to be used in a heated,
indoor, controlled environment.

Operation Storage Transportation

installed for stationary use in the protective package in the protective package

Installation site altitude 0 to 2000 m (6561 ft) - -

above sea level. For alti-
tudes over 2000 m, con-
tact ABB.
Output derated above
1000 m (3281 ft). See
section Output derating

Air temperature -0 to +50 °C (32 to 122 -40 to +70 °C (-40 to +158 -40 to +70 °C (-40 to +158
°F). No condensation al- °F) °F)
lowed. Output derated in
the range +40 … +50 °C
(+104 … +122 °F). See
section Output derating

Relative humidity 5 to 95% Max. 95% Max. 95%

No condensation allowed. Maximum allowed relative humidity is 60% in the pres-

ence of corrosive gases.

Contamination IEC/EN 60721-3-3:2002 IEC 60721-3-1:1997 IEC 60721-3-2:1997

(IEC 60721-3-x)

Chemical gases Class 3C2 Class 1C2 Class 2C2

Solid particles Class 3S2. No conductive Class 1S3. (packing must Class 2S2
dust allowed. support this, otherwise
1S2)

Atmospheric pressure 70 to 106 kPa 0.7 to 1.05 70 to 106 kPa 0.7 to 1.05 60 to 106 kPa 0.6 to 1.05
atmospheres atmospheres atmospheres

Vibration IEC/EN 60721-3-3:2002 IEC/EN 60721-3-1:1997 IEC/EN 60721-3-2:1997

IEC 61800-5-1 10…57 Hz: max. 0.075 10…57 Hz: max. 0.075 2…9 Hz: max. 3.5 mm
IEC 60068-2-6:2007, mm amplitude 57…150 mm amplitude 57…150 amplitude 9…20 Hz: 10
Hz: 1 g Hz: 1 g m/s2 (32.8 ft/s2)
EN 60068-2-6:2008
Environmental testing Part
2: Tests –Test Fc: Vibra-
tion (sinusoidal)

Shock Not allowed With packing max. 100 With packing max. 100
IEC 60068-2-27:2008, m/s2 (330 ft./s2), 11 ms m/s2 (330 ft./s2), 11 ms
EN 60068-2-27:2009
Environmental testing -
Part 2-27: Tests - Test Ea
and guidance: Shock

Auxiliary circuit power consumption

Cabinet heater (option 100 W
+G300)
214 Technical data

Materials
Cabinet Hot-dip zinc coated 1.5 mm thick steel sheet (thickness of coating approximately
20 micrometers). Polyester thermosetting powder coating (thickness approximately
80 micrometers) on visible surfaces, color RAL 7035 and RAL 9017.

Busbars Tin-plated copper

Air filters of IP54 drives Inlet (door): airComp 300-50 240 mm x 286 mm (ABB code 3AXD50000037880)

Fire safety of materials Insulating materials and non-metallic items mostly self-extinctive
(IEC 60332-1)

Package Standard package:

• plywood, wet strength heavy duty cardboard, polyethylene sheet (thickness0.15
mm), stretch film (thickness 0.023 mm), PP tape, PET strap,sheet metal (steel)
• for land and air transport when planned storage time is less than 2 months or
when storage can be arranged in clean and dry conditionsless than 6 months
Seaworthy package:
• plywood, wet strength heavy duty cardboard (or plywood with specialrequest),
VCI sheet film (PE, thickness 0.10 mm), VCI stretch film(PE, thickness 0.04
mm), VCI emitter bags, PP tape, PET strap, sheetmetal (steel)
• for sea transport in containers
• recommended for land and air transport when storage time prior to installation
exceeds 6 months or storage is arranged in partially weather-protected conditions
Plywood package on special request
Cabinets are attached to the pallet with screws and braced from the bottom end
to prevents swaying inside the package.
Transportation packaging:
• R6...R9 cabinets can be stacked (2 pieces) and transported horizontally.
• R10...R11 cabinets are transported vertically.
For drives with empty cabinet (options +C196 to +C201)
Standard package:
• timber, polyethylene sheet (thickness 0.15 mm), stretch film (thickness 0.023
mm),PP tape, PET strap, sheet metal (steel)
• for land and air transport when planned storage time is less than 2 months or
when storage can be arranged in clean and dry conditions less than 6 months
• can be used when products will not be exposed to corrosive atmosphere during
transport or storage
Seaworthy package:
• timber, plywood, VCI sheet film (PE, thickness 0.10 mm), VCI stretchfilm (PE,
thickness 0.04 mm), VCI emitter bags, PP tape, PET strap,sheet metal (steel)
• for sea transport with or without containerization
• for long storage periods in environments where roofed and humidity-controlled
storagecannot be arranged
For handling the packages, see section Moving and unpacking the drive (page 53).

Disposal
The main parts of the drive can be recycled to preserve natural resources and
energy. Product parts and materials should be dismantled and separated.
Generally all metals, such as steel, aluminum, copper and its alloys, and precious
metals can be recycled as material. Plastics, rubber, cardboard and other packaging
material can be used in energy recovery. Printed circuit boards and large electro-
lytic capacitors need selective treatment according to IEC 62635 guidelines. To
aid recycling, plastic parts are marked with an appropriate identification code.
Contact your local ABB distributor for further information on environmental aspects
and recycling instructions for professional recyclers. End of life treatment must
follow international and local regulations.
 Technical data 215

Applicable standards
The drive complies with the standards below. The compliance with the European Low
Voltage Directive is verified according to standard EN 61800-5-1.

European electrical safety requirements product standards

EN 61800-5-1:2007 Adjustable speed electrical power drive systems. Part 5-1: Safety requirements –
electrical, thermal and energy

IEC 60146-1-1:2009 Semiconductor converters – General requirements and line commutated converters
EN 60146-1-1:2010 – Part 1-1: Specification of basic requirements

IEC 60204-1:2005 Safety of machinery. Electrical equipment of machines. Part 1: General require-
+A1:2008 ments.
EN 60204-1:2006 Provisions for compliance: The final assembler of the machine is responsible for
+AC:2010 installing emergency-stop device.

IEC 60529:1989 Degrees of protection provided by enclosures (IP code)

EN 60529:1991

IEC/EN 60664-1:2007 Insulation coordination for equipment within low-voltage systems. Part 1: Principles,
requirements and tests

IEC/EN 61439-1:2011 Low-voltage switchgear and control gear assemblies -- Part 1: General rules

UL 50:2015 Enclosures for Electrical Equipment, Non-Environmental Considerations, 13th

edition

UL 508C: 2016 UL Standard for Safety, Power Conversion Equipment, fourth edition

CSA C22.2 No. 14-13: Industrial control equipment

2013

CSA 22.2 No. 274-13: Adjustable Speed Drives

2013

EMC performance

IEC 61800- Adjustable speed electrical power drive systems. Part 3: EMC requirements and
3:2004/A1:2011 specific test methods
EN 61800-3/A1:2012
216 Technical data

Markings
CE mark
Product complies with the applicable European Union legislation. For fulfilling the EMC requirements,
see the additional information concerning the drive EMC compliance (IEC/EN 61800-3).

UL listed mark for USA and Canada

Product has been tested and evaluated against the relevant North American standards by the Un-
derwriters Laboratories.

RCM mark
Product complies with Australian and New Zealand requirements specific to EMC, telecommunica-
tions and electrical safety. For fulfilling the EMC requirements, see the additional information con-
cerning the drive EMC compliance (IEC/EN 61800-3).

EAC (Eurasian Conformity) mark

Product complies with the technical regulations of the Eurasian Customs Union. EAC mark is required
in Russia, Belarus and Kazakhstan.

Electronic Information Products (EIP) green mark

The product complies with the People’s Republic of China Electronic Industry Standard (SJ/T 11364-
2014). The product does not contain toxic and hazardous substances or elements above the max-
imum concentration values, and it is an environmentally-friendly product which can be recycled.

CE marking
A CE mark is attached to the drive to verify that the drive complies with the provisions of
the European Low Voltage and EMC Directives. The CE marking also verifies that the drive,
in regard to its safety functions (such as Safe torque off), conforms with the Machinery
Directive as a safety component.

￭ Compliance with the European Low Voltage Directive

The compliance with the European Low Voltage Directive has been verified according to
standard EN 61800-5-1.

￭ Compliance with the European EMC Directive

The EMC Directive defines the requirements for immunity and emissions of electrical
equipment used within the European Union. The EMC product standard (EN 61800-3:2004)
covers requirements stated for drives. See section Compliance with the EN 61800-3:2004
„
below.

￭ Compliance with the European Machinery Directive

The drive is an electronic product which is covered by the European Low Voltage Directive.
However, the drive includes the Safe torque off function and can be equipped with other
safety functions for machinery which, as safety components, are in the scope of the
Machinery Directive. These functions of the drive comply with European harmonized
standards such as EN 61800-5-2. The declaration of conformity is shown below.
 Technical data 217

Declaration of Conformity
218 Technical data
 Technical data 219

￭ Compliance with the EN 61800-3:2004

Definitions
EMC stands for Electromagnetic Compatibility. It is the ability of electrical/electronic
equipment to operate without problems within an electromagnetic environment. Likewise,
the equipment must not disturb or interfere with any other product or system within its locality.
First environment includes establishments connected to a low-voltage network which supplies
buildings used for domestic purposes.
Second environment includes establishments connected to a network not supplying domestic
premises.
Drive of category C3: drive of rated voltage less than 1000 V and intended for use in the
second environment and not intended for use in the first environment.
Drive of category C4: drive of rated voltage equal to or above 1000 V, or rated current equal
to or above 400 A, or intended for use in complex systems in the second environment.

Category C2
The drive frames R6 to R9 comply with the standard with the following provisions:
1. The motor and control cables are selected as specified in the hardware manual.
2. The drive is installed according to the instructions given in the hardware manual.
3. Maximum motor cable length is 150 meters.

WARNING!
The drive may cause radio interference if used in a residential or domestic
environment. The user is required to take measures to prevent interference, in
addition to the requirements for CE compliance listed above, if necessary.

Note:
Do not install a drive equipped with EMC filter on IT (ungrounded) systems. The supply
network becomes connected to ground potential through the EMC filter capacitors which
may cause danger or damage the unit.

Category C3
The drive complies with the standard with the following provisions:
1. The motor and control cables are selected as specified in the hardware manual.
2. The drive is installed according to the instructions given in the hardware manual.
3. Maximum motor cable length is 100 meters.

WARNING!
A drive of category C3 is not intended to be used on a low-voltage public network
which supplies domestic premises. Radio frequency interference is expected if
the drive is used on such a network.

Category C4
If the provisions under Category C3 cannot be met, the requirements of the standard can
be met as follows:
1. It is ensured that no excessive emission is propagated to neighboring low-voltage
networks. In some cases, the natural suppression in transformers and cables is sufficient.
220 Technical data

If in doubt, the supply transformer with static screening between the primary and
secondary windings can be used.

1
7

2 8

4 4

5 9

6 6

1 Medium voltage network 6 Equipment

2 Neighboring network 7 Supply transformer

3 Point of measurement 8 Static screen

4 Low voltage 9 Drive

5 Equipment (victim)

2. An EMC plan for preventing disturbances is drawn up for the installation. A template is
available in Technical guide No. 3 EMC compliant installation and configuration for a
„
power drive system (3AFE61348280 (English)).
3. The motor and control cables are selected as specified in the hardware manual.
4. The drive is installed according to the instructions given in the hardware manual.

WARNING!
A drive of category C4 is not intended to be used on a low-voltage public network
which supplies domestic premises. Radio frequency interference is expected if
the drive is used on such a network.

UL marking
The drive is cULus listed with option +C129. The approval is valid with rated voltages up to
480 V.
UL checklist

WARNING!
Operation of this drive requires detailed installation and operation instructions
provided in the hardware and software manuals. The manuals are provided in
electric format in the drive package or on the Internet. Retain the manuals with
the drive at all times. Hard copies of the manuals can be ordered through the
manufacturer.

• Make sure that the drive type designation label includes the cULus Listed marking.
• DANGER - Risk of electric shock. After disconnecting the input power, always wait
for 5 minutes to let the intermediate circuit capacitors discharge before you start working
on the drive, motor or motor cable.
 Technical data 221

• The drive is to be used in a heated, indoor controlled environment. The drive must be
installed in clean air according to the enclosure classification. Cooling air must be clean,
free from corrosive materials and electrically conductive dust.
• The maximum ambient air temperature is 40 °C (104 °F) at rated current. The current
is derated for 40 to 50 °C (104 to 122 °F).
• The drive is suitable for use in a circuit capable of delivering not more than 100,000 rms
symmetrical amperes, 480 V maximum when protected by the UL fuses given elsewhere
in this chapter. The ampere rating is based on tests done according to the appropriate
UL standard.
• The cables located within the motor circuit must be rated for at least 75 °C (167 °F) in
UL-compliant installations.
• The input cable must be protected with fuses. The fuses must provide branch circuit
protection in accordance with the national regulations (National Electrical Code (NEC)
or Canadian Electrical Code). Obey also any other applicable local or provincial codes.
Note:
Circuit breakers must not be used without fuses in the USA. For suitable circuit breakers,
contact your local ABB representative.

WARNING!
The opening of the branch-circuit protective device may be an indication that
a fault current has been interrupted. To reduce the risk of fire or electric shock,
current-carrying parts and other components of the device should be examined
and replaced if damaged.

• The drive is equipped with UL classified fuses which provide branch circuit protection
in accordance with the National Electrical Code (NEC) and Canadian Electrical Code.
The fuses are listed elsewhere in this chapter.
• The drive provides motor overload protection. For adjustments, see the firmware manual.
• The drive overvoltage category according to IEC 60664-1 is III, except for auxiliary
power connections (fan, control, heating, lighting, cooling unit pump etc) which are of
category II.
222 Technical data

Disclaimers
￭ Generic disclaimer
The manufacturer shall have no obligation with respect to any product which (i) has been
improperly repaired or altered; (ii) has been subjected to misuse, negligence or accident;
(iii) has been used in a manner contrary to the manufacturer’s instructions; or (iv) has failed
as a result of ordinary wear and tear.

￭ Cybersecurity disclaimer
This product is designed to be connected to and to communicate information and data via
a network interface. It is Customer's sole responsibility to provide and continuously ensure
a secure connection between the product and Customer network or any other network (as
the case may be). Customer shall establish and maintain any appropriate measures (such
as but not limited to the installation of firewalls, application of authentication measures,
encryption of data, installation of anti-virus programs, etc) to protect the product, the network,
its system and the interface against any kind of security breaches, unauthorized access,
interference, intrusion, leakage and/or theft of data or information. ABB and its affiliates are
not liable for damages and/or losses related to such security breaches, any unauthorized
access, interference, intrusion, leakage and/or theft of data or information.
 Dimension drawings 223

13
Dimension drawings
Example dimension drawings are shown below.
224 Dimension drawings

Frames R6 and R7 (IP21, UL Type 1)

 Dimension drawings 225

Frames R6 and R7 (+B054: IP42, UL Type 1)

226 Dimension drawings

Frames R6 and R7 (+B055: IP54, UL Type 12)

 Dimension drawings 227

Frames R6 and R7 (+H351 and +H353: top entry and exit)

228 Dimension drawings

Frames R6 and R7 (+F289)

 Dimension drawings 229

Frames R6 and R7 (+F289, +H351, +H353)

230 Dimension drawings

Frames R8 and R9 (IP21)

 Dimension drawings 231

Frames R8 and R9 (+B054: IP42, UL Type 1)

232 Dimension drawings

Frames R8 and R9 (+B055: IP54, UL Type 12)

 Dimension drawings 233

Frames R8 and R9 (+H351 and +H353: top entry and exit)

234 Dimension drawings

Frames R8 and R9 (+F289)

 Dimension drawings 235

Frames R8 and R9 (+F289, +H351, +H353)

236 Dimension drawings

Frames R10 and R11 (IP21)

 Dimension drawings 237

Frames R10 and R11 (+B054: IP42, UL Type 1)

238 Dimension drawings

Frames R10 and R11 (+B055: IP54, UL Type 12)

 Dimension drawings 239

Frames R10 and R11 (+F289)

T
240 Dimension drawings

Frames R10 and R11 (+H351, +H353)

 Dimension drawings 241

Frames R10 and R11 (+B054: IP42, UL type 1, +H351, +H353)

T
242 Dimension drawings

Frames R10 and R11 (+B055: IP54, UL type 12, +H351,

+H353)

T
 The Safe torque off function 243

14
The Safe torque off function

Contents of this chapter

This chapter describes the Safe torque off (STO) function of the drive and gives instructions
for its use.

Description
The Safe torque off function can be used, for example, to as the final actuator device of
safety circuits that stop the drive in case of danger (such as an emergency stop circuit).
Another typical application is a prevention of unexpected start-up function that enables
short-time maintenance operations like cleaning or work on non-electrical parts of the
machinery without switching off the power supply to the drive.
When activated, the Safe torque off function disables the control voltage of the power
semiconductors of the drive output stage (A, see the diagrams below), thus preventing the
drive from generating the torque required to rotate the motor. If the motor is running when
Safe torque off is activated, it coasts to a stop.
The Safe torque off function has a redundant architecture, that is, both channels must be
used in the safety function implementation. The safety data given in this manual is calculated
for redundant use, and does not apply if both channels are not used.
The Safe torque off function complies with these standards:

Standard Name

IEC 60204-1:2016 Safety of machinery – Electrical equipment of machines – Part 1: General

EN 60204-1:2006 + A1:2009 + requirements
AC:2010

IEC 61000-6-7:2014 Electromagnetic compatibility (EMC) – Part 6-7: Generic standards – Im-
munity requirements for equipment intended to perform functions in a
safety-related system (functional safety) in industrial locations
244 The Safe torque off function

Standard Name

IEC 61326-3-1:2017 Electrical equipment for measurement, control and laboratory use – EMC
requirements – Part 3-1: Immunity requirements for safety-related systems
and for equipment intended to perform safety-related functions (functional
safety) – General industrial applications

IEC 61508-1:2010 Functional safety of electrical/electronic/programmable electronic safety-

related systems – Part 1: General requirements

IEC 61508-2:2010 Functional safety of electrical/electronic/programmable electronic safety-

related systems – Part 2: Requirements for electrical/electronic/program-
mable electronic safety-related systems

IEC 61511-1:2016 Functional safety – Safety instrumented systems for the process industry
sector

IEC 61800-5-2:2016 Adjustable speed electrical power drive systems – Part 5-2: Safety require-
EN 61800-5-2:2007 ments – Functional

IEC 62061:2005 + A1:2012 + Safety of machinery – Functional safety of safety-related electrical, elec-
A2:2015 tronic and programmable electronic control systems
EN 62061:2005 + AC:2010 +
A1:2013 + A2:2015

EN ISO 13849-1:2015 Safety of machinery – Safety-related parts of control systems – Part 1:

General principles for design

EN ISO 13849-2:2012 Safety of machinery – Safety-related parts of control systems – Part 2:

Validation

The function also corresponds to Prevention of unexpected start-up as specified by

EN ISO 14118:2018 (ISO 14118:2017), and Uncontrolled stop (stop category 0) as specified
in EN/IEC 60204-1.

￭ Compliance with the European Machinery Directive

See the technical data.
The Declaration of conformity is shown at the end of this chapter.
 The Safe torque off function 245

Wiring
For the electrical specifications of the STO connection, see the technical data of the control
unit.

￭ Connection principle
Connection with internal power supply

1
K STO 2
OUT1 34
+ 24 V DC
OUT2 35
+ 24 V DC
SGND 36
IN1 37
IN2 38 UDC+

A
4
3

UDC-

1 Drive
2 Control unit
3 Control logic
4 To motor
K Activation switch
246 The Safe torque off function

Connection with external power supply

24 V DC 1
- +
STO 2

K OUT1 34
+ 24 V DC
OUT2 35
+ 24 V DC
SGND 36
IN1 37
IN2 38 UDC+

A
4
3

UDC-

1 Drive
2 Control unit
3 Control logic
4 To motor
K Activation switch

￭ Wiring examples
Wiring with internal power supply

1 2
STO
34 OUT1 OUT
35 OUT2
13 23 31 Y1 Y2

36 SGND
K

14 24 32 A1 A2
37 IN1
38 IN2
GND

1 Drive
2 Safety PLC
K Safety relay
 The Safe torque off function 247

Wiring with external power supply

1 24 V DC 2
STO - +
34 OUT1 OUT
35 OUT2
13 23 31 Y1 Y2

36 SGND
K

14 24 32 A1 A2
37 IN1
38 IN2
GND

1 Drive
2 Safety PLC
K Safety relay

￭ Activation switch
In the wiring diagrams, the activation switch has the designation [K]. This represents a
component such as a manually operated switch, an emergency stop push button switch, or
the contacts of a safety relay or safety PLC.
• In case a manually operated activation switch is used, the switch must be of a type that
can be locked out to the open position.
• The contacts of the switch or relay must open/close within 200 ms of each other.
• A CPTC-02 thermistor protection module can also be used. For more information, see
the module documentation.

￭ Cable types and lengths

• Double-shielded twisted-pair cable is recommended.
• Maximum cable lengths:
• 300 m (1000 ft) between activation switch [K] and drive control unit
• 60 m (200 ft) between multiple drives or inverter units
• 60 m (200 ft) between external power supply and first control unit

Note:
A short-circuit in the wiring between the switch and an STO terminal causes a dangerous
fault. Therefore, it is recommended to use a safety relay (including wiring diagnostics) or a
wiring method (shield grounding, channel separation) which reduces or eliminates the risk
caused by the short-circuit.

Note:
The voltage at the STO input terminals of the drive must be at least 13 V DC to be interpreted
as “1”.
The pulse tolerance of the input channels is 1 ms.
248 The Safe torque off function

￭ Grounding of protective shields

• Ground the shield in the cabling between the activation switch and the control unit at
the control unit only.
• Ground the shield in the cabling between two control units at one control unit only.
 The Safe torque off function 249

Operation principle
1. The Safe torque off activates (the activation switch is opened, or safety relay contacts
open).
2. The STO inputs of the drive control unit de-energize.
3. The control unit cuts off the control voltage from the output IGBTs.
4. The control program generates an indication as defined by parameter 31.22 (see the
firmware manual of the drive).
The parameter selects which indications are given when one or both STO signals are
switched off or lost. The indications also depend on whether the drive is running or
stopped when this occurs.
Note:
This parameter does not affect the operation of the STO function itself. The STO function
will operate regardless of the setting of this parameter: a running drive will stop upon
removal of one or both STO signals, and will not start until both STO signals are restored
and all faults reset.

Note:
The loss of only one STO signal always generates a fault as it is interpreted as a
malfunction of STO hardware or wiring.

5. The motor coasts to a stop (if running). The drive cannot restart while the activation
switch or safety relay contacts are open. After the contacts close, a reset may be needed
(depending on the setting of parameter 31.22). A new start command is required to start
the drive.
250 The Safe torque off function

Start-up including acceptance test

To ensure the safe operation of a safety function, validation is required. The final assembler
of the machine must validate the function by performing an acceptance test. The acceptance
test must be performed
• at initial start-up of the safety function
• after any changes related to the safety function (circuit boards, wiring, components,
settings, etc.)
• after any maintenance work related to the safety function.

￭ Competence
The acceptance test of the safety function must be carried out by a competent person with
adequate expertise and knowledge of the safety function as well as functional safety, as
required by IEC 61508-1 clause 6. The test procedures and report must be documented
and signed by this person.

￭ Acceptance test reports

Signed acceptance test reports must be stored in the logbook of the machine. The report
shall include documentation of start-up activities and test results, references to failure reports
and resolution of failures. Any new acceptance tests performed due to changes or
maintenance shall be logged into the logbook.

￭ Acceptance test procedure

After wiring the Safe torque off function, validate its operation as follows.
Note:
If the drive is equipped with safety option +Q951 or +Q953, do the procedure shown in the
documentation of the option.

Note:
If a CPTC-02 module is installed, refer to its documentation.

Action

WARNING!
Follow the safety instructions. If you ignore them, injury or death, or damage to the equipment
can occur.

Ensure that the drive can be run and stopped freely during start-up.

Stop the drive (if running), switch the input power off and isolate the drive from the power line using a
disconnector.

Check the STO circuit connections against the wiring diagram.

Close the disconnector and switch the power on.

 The Safe torque off function 251

Action

Test the operation of the STO function when the motor is stopped.
• Give a stop command for the drive (if running) and wait until the motor shaft is at a standstill.
Ensure that the drive operates as follows:
• Open the STO circuit. The drive generates an indication if one is defined for the 'stopped' state in
parameter 31.22 (see the firmware manual).
• Give a start command to verify that the STO function blocks the drive's operation. The drive generates
a warning. The motor should not start.
• Close the STO circuit.
• Reset any active faults. Restart the drive and check that the motor runs normally.

Test the operation of the STO function when the motor is running.
• Start the drive and ensure the motor is running.
• Open the STO circuit. The motor should stop. The drive generates an indication if one is defined for
the 'running' state in parameter 31.22 (see the firmware manual).
• Reset any active faults and try to start the drive.
• Ensure that the motor stays at a standstill and the drive operates as described above in testing the
operation when the motor is stopped.
• Close the STO circuit.
• Reset any active faults. Restart the drive and check that the motor runs normally.

Test the operation of the failure detection of the drive. The motor can be stopped or running.
• Open the 1st channel of the STO circuit (wire coming to IN1). If the motor was running, it should
coast to a stop. The drive generates a FA81 Safe Torque Off 1 loss fault indication (see the firmware
manual).
• Give a start command to verify that the STO function blocks the drive's operation. The motor should
not start.
• Close the STO circuit.
• Reset any active faults. Restart the drive and check that the motor runs normally.
• Open the 2nd channel of the STO circuit (wire coming to IN2). If the motor was running, it should
coast to a stop. The drive generates a FA82 Safe Torque Off 2 loss fault indication (see the firmware
manual).
• Give a start command to verify that the STO function blocks the drive's operation. The motor should
not start.
• Close the STO circuit.
• Reset any active faults. Restart the drive and check that the motor runs normally.

Document and sign the acceptance test report which verifies that the safety function is safe and accepted
for operation.
252 The Safe torque off function

Use
1. Open the activation switch, or activate the safety functionality that is wired to the STO
connection.
2. The STO inputs on the drive control unit de-energize, and the control unit cuts off the
control voltage from the output IGBTs.
3. The control program generates an indication as defined by parameter 31.22 (see the
firmware manual of the drive).
4. The motor coasts to a stop (if running). The drive will not restart while the activation
switch or safety relay contacts are open.
5. Deactivate the STO by closing the activation switch, or reseting the safety functionality
that is wired to the STO connection.
6. Reset any faults before restarting.

WARNING!
The Safe torque off function does not disconnect the voltage of the main and
auxiliary circuits from the drive. Therefore maintenance work on electrical parts of
the drive or the motor can only be carried out after isolating the drive from the
supply and all other voltage sources.

WARNING!
(With permanent magnet or synchronous reluctance [SynRM] motors only)
In case of a multiple IGBT power semiconductor failure, the drive can produce an
alignment torque which maximally rotates the motor shaft by 180/p degrees (with
permanent magnet motors) or 180/2p degrees (with synchronous reluctance
[SynRM] motors) regardless of the activation of the Safe torque off function. p
denotes the number of pole pairs.

Notes:
• If a running drive is stopped by using the Safe torque off function, the drive will cut off
the motor supply voltage and the motor will coast to a stop. If this causes danger or is
not otherwise acceptable, stop the drive and machinery using the appropriate stop mode
before activating the Safe torque off function.
• The Safe torque off function overrides all other functions of the drive.
• The Safe torque off function is ineffective against deliberate sabotage or misuse.
• The Safe torque off function has been designed to reduce the recognized hazardous
conditions. In spite of this, it is not always possible to eliminate all potential hazards.
The assembler of the machine must inform the final user about the residual risks.
• The Safe torque off diagnostics are not available during power outages, or when the
drive is only powered by a CMOD-xx multifunction extension module.
 The Safe torque off function 253

Maintenance
After the operation of the circuit is validated at start-up, the STO function shall be maintained
by periodic proof testing. In high demand mode of operation, the maximum proof test interval
is 20 years. In low demand mode of operation, the maximum proof test interval is 5 or 2
years; see section Safety data (page 255). It is assumed that all dangerous failures of the
STO circuit are detected by the proof test. To perform the proof test, do the Acceptance test
procedure (page 250).
Note:
See also the Recommendation of Use CNB/M/11.050 (published by the European
co-ordination of Notified Bodies) concerning dual-channel safety-related systems with
electromechanical outputs:
• When the safety integrity requirement for the safety function is SIL 3 or PL e (cat. 3 or
4), the proof test for the function must be performed at least every month.
• When the safety integrity requirement for the safety function is SIL 2 (HFT = 1) or PL d
(cat. 3), the proof test for the function must be performed at least every 12 months.

The STO function of the drive does not contain any electromechanical components.
In addition to proof testing, it is a good practice to check the operation of the function when
other maintenance procedures are carried out on the machinery.
Include the Safe torque off operation test described above in the routine maintenance
program of the machinery that the drive runs.
If any wiring or component change is needed after start up, or the parameters are restored,
follow the test given in section Acceptance test procedure (page 250).
Use only spare parts approved by ABB.
Record all maintenance and proof test activities in the machine logbook.

￭ Competence
The maintenance and proof test activities of the safety function must be carried out by a
competent person with adequate expertise and knowledge of the safety function as well as
functional safety, as required by IEC 61508-1 clause 6.
254 The Safe torque off function

Fault tracing
The indications given during the normal operation of the Safe torque off function are selected
by drive control program parameter 31.22.
The diagnostics of the Safe torque off function cross-compare the status of the two STO
channels. In case the channels are not in the same state, a fault reaction function is
performed and the drive trips on an “STO hardware failure” fault. An attempt to use the STO
in a non-redundant manner, for example activating only one channel, will trigger the same
reaction.
See the firmware manual of the drive control program for the indications generated by the
drive, and for details on directing fault and warning indications to an output on the control
unit for external diagnostics.
Any failures of the Safe torque off function must be reported to ABB.
 The Safe torque off function 255

Safety data
The safety data for the Safe torque off function is given below.
Note:
The safety data is calculated for redundant use, and does not apply if both STO channels
are not used.

PFH
SIL/ SFF PFDavg PFDavg MTTFD DC TM
Frame size PL (T1 = 20 a) Cat. SC HFT CCF
SILCL (%) (T1 = 2 a) (T1 = 5 a) (a) (%) (a)
(1/h)

R6
3 e >99 3.92E-09 3.44E-05 8.58E-05 9380 ≥90 3 3 1 80 20
R7
R8
3 e >99 4.22E-09 3.69E-05 8.84E-05 8792 ≥90 3 3 1 80 20
R9
R10
3 e 99.60 4.15E-09 3.63E-05 9.08E-05 17544 ≥90 3 3 1 80 20
R11
3AXD10000015777 K, 3AXD10000410558 D

• The following temperature profile is used in safety value calculations:

• 670 on/off cycles per year with ΔT = 71.66 °C
• 1340 on/off cycles per year with ΔT = 61.66 °C
• 30 on/off cycles per year with ΔT = 10.0 °C
• 32 °C board temperature at 2.0% of time
• 60 °C board temperature at 1.5% of time
• 85 °C board temperature at 2.3% of time.
• Relevant failure modes:
• The STO trips spuriously (safe failure)
• The STO does not activate when requested
• A fault exclusion on the failure mode “short circuit on printed circuit board” has been
made (EN 13849-2, table D.5). The analysis is based on an assumption that one
failure occurs at one time. No accumulated failures have been analyzed.
• STO response times:
• STO reaction time (shortest detectable break): 1 ms
• STO response time: 2 ms (typical), 5 ms (maximum)
• Fault detection time: Channels in different states for longer than 200 ms
• Fault reaction time: Fault detection time + 10 ms
• Indication delays:
• STO fault indication (parameter 31.22) delay: < 500 ms
• STO warning indication (parameter 31.22) delay: < 1000 ms

￭ Abbreviations
Abbr. Reference Description
Cat. EN ISO 13849-1 Classification of the safety-related parts of a control system in respect
of their resistance to faults and their subsequent behavior in the fault
condition, and which is achieved by the structural arrangement of the
parts, fault detection and/or by their reliability. The categories are: B,
1, 2, 3 and 4.
CCF EN ISO 13849-1 Common cause failure (%)
256 The Safe torque off function

Abbr. Reference Description

DC EN ISO 13849-1 Diagnostic coverage
HFT IEC 61508 Hardware fault tolerance
MTTFD EN ISO 13849-1 Mean time to dangerous failure: (Total number of life units) / (Number
of dangerous, undetected failures) during a particular measurement
interval under stated conditions
PFDavg IEC 61508 Average probability of dangerous failure on demand, that is, mean
unavailability of a safety-related system to perform the specified safety
function when a demand occurs
PFH IEC 61508 Average frequency of dangerous failures per hour, that is, average
frequency of a dangerous failure of a safety related system to perform
the specified safety function over a given period of time
PL EN ISO 13849-1 Performance level. Levels a…e correspond to SIL
SC IEC 61508 Systematic capability
SFF IEC 61508 Safe failure fraction (%)
SIL IEC 61508 Safety integrity level (1…3)
SILCL IEC/EN 62061 Maximum SIL (level 1…3) that can be claimed for a safety function
or subsystem
STO IEC/EN 61800-5-2 Safe torque off
T1 IEC 61508-6 Proof test interval. T1 is a parameter used to define the probabilistic
failure rate (PFH or PFD) for the safety function or subsystem. Per-
forming a proof test at a maximum interval of T1 is required to keep
the SIL capability valid. The same interval must be followed to keep
the PL capability (EN ISO 13849) valid.
See also section Maintenance.
TM EN ISO 13849-1 Mission time: the period of time covering the intended use of the safety
function/device. After the mission time elapses, the safety device must
be replaced. Note that any TM values given cannot be regarded as a
guarantee or warranty.
 The Safe torque off function 257

￭ Declaration of conformity
258 The Safe torque off function

￭ TÜV certificate
The TÜV certificate is available on the Internet at www.abb.com/drives/documents.
 Optional I/O extension modules 259

15
Optional I/O extension modules

Contents of this chapter

This chapter describes how to install and start up the following optional modules:
• CBAI-01 bipolar analog IO extension module
• CHDI-01 115/230 V digital input extension module
• CMOD-01 multifunction extension module
• CMOD-02 multifunction extension module
• CPTC-02 ATEX-certified thermistor protection module
This chapter also contains diagnostics and technical data of these modules.

CBAI-01 bipolar analog IO extension module

￭ Hardware description
Product overview
The CBAI-01 bipolar analog IO extension module includes two bipolar analog inputs, two
unipolar analog outputs, and a switch which can be used to select scaling of the analog
output level.
 260 Optional I/O extension modules
109 [4.28]

Layout

59 [2.31]

71 [2.79]
1 Analog output 3 Terminal designations (page 261)
2 Analog input 3 Terminal designations (page 261)
3 Analog output scale switch Analog output scale switch: (page 265)
4 Grounding hole -
Prepared A.Piirainen 04-Oct-17 Title DIMENSION DRAWING Doc. des.
Check. 5 P.Viitala
Control unit interface (slot 2)04-Oct-17 CBAI-01
- DIMENSION DRAWING DIMENSION DRAWING
Appr. 6 J.Viman
Diagnostic LED 04-Oct-17 Diagnostics (page 263)
Resp.dept. Rev.in
Project name Doc. No.
Weight 7kg Analog
0.11output 4 Terminal designations (page 261) 3AXD5000
8 Analog input 4 Terminal designations (page 261)

￭ Mechanical installation
Necessary tools and instructions
• Screwdriver and a set of suitable bits.

Unpacking and checking the delivery

1. Open the option package. Make sure that the package contains:
• CBAI-01 bipolar analog IO extension module
• a mounting screw.
2. Make sure that there are no signs of damage.

Installing the module

Note:
Frame R1: Do not install this module before you have installed the power cables as it would
cover the power terminals.

See section Installing optional modules in chapter Electrical installation.

 Optional I/O extension modules 261

￭ Electrical installation
WARNING!
Obey the instructions in chapter Safety instructions. If you ignore them, injury or
death, or damage to the equipment can occur. If you are not a qualified electrician,
do not do electrical work.
Make sure that the drive is disconnected from the input power during
installation. If the drive is already connected to the input power, wait for
5 minutes after disconnecting the input power.

Necessary tools and instructions

• Screwdriver and a set of suitable bits
• Cabling tools

Terminal designations
For more detailed information on the connectors, see section Technical data (page 264).
Analog inputs

Marking Description
80 AI3+ Analog input positive signal
81 AI3- Analog input negative signal
82 SCR Cable shield connection (routed directly to output SCR)
83 AI4+ Analog input positive signal
84 AI4- Analog input negative signal
85 SCR Cable shield connection (routed directly to output SCR)

Analog outputs

Marking Description
86 AO3 Analog output signal
87 AGND Analog ground potential
88 SCR Cable shield connection (routed directly to output SCR)
89 AO3 Analog output signal
90 AGND Analog ground potential
91 SCR Cable shield connection (routed directly to output SCR)

General cabling instructions

Obey the instructions given in chapter Planning the electrical installation.

Wiring
Connect the external control cables to the applicable module terminals. Ground the outer
shield of the cables 360 degrees under a grounding clamp on the grounding shelf of the
control cables.
Note:
Do not connect both ends of the cable shields directly to ground.

Analog input connection example

262 Optional I/O extension modules

82 SCR
V+
81 AI3-
GND / V- 80 AI3+

CBAI-01

Analog output connection example

86 AO3
0...10 V
87 AGND
88 SCR
CBAI-01

An alternative way to make the connection is to connect the cable shield to the SCR terminal
of the control board.
Analog input connection example 2

82 SCR
V+
81 AI3-
GND / V- 80 AI3+

CBAI-01

Analog output connection example 2

86 AO3
0...10 V
87 AGND
1 88 SCR

CBAI-01

1 Cable shield connected to control board SCR terminal

 Optional I/O extension modules 263

Wiring example, extension module and control board

CBAI-01 CCU-23/24

AI3+ 80 86 1
AI3- 81 87 2
SCR 82 88 3

AI4+ 83 89
AI4- 84 90 5
SCR 85 91 6

￭ Start-up
Setting the parameters
1. Power up the drive.
2. Verify that the diagnostic LED is on.
Parameter setting example for AI1 (control board)
This example shows how to set the control board parameters for a bipolar speed reference
ranging from -50 Hz to 50 Hz, with detection of a wire break between the extension module
and the control board of the drive.

Parameter Setting Default

12.17 AI1 min 0.5 V 4.000 mA or 0.000 V
12.18 AI1 max 9.5 V 20.000 mA or 10.000 V
12.19 AI1 scaled at AI1 min -50 0.000
12.20 AI1 scaled at AI1 max 50 50
32.05 Supervision 1 function Low Disabled
32.06 Supervision 1 action Fault No action
32.07 Supervision 1 signal AI1 Frequency
32.09 Supervision 1 low 0.4 0.00

￭ Diagnostics
LEDs
The extension module has one diagnostic LED.

Color Description
Green The extension module is powered up.
 264 Optional I/O extension modules

￭ Technical data
3 4 5 6 7
Dimension
wing made with drawing
3D CAD. Set the correct scale factor when adding
dimensions after DWG/DXF conversion.

The dimensions are in millimeters and [inches].

31 [1.20]
109 [4.28]

59 [2.31]

71 [2.79]

Installation: Into an option slot on the drive control board

Degree of protection: IP20
Prepared A.Piirainen
Ambient conditions: 04-Oct-17
See the driveTitle DIMENSION
technical data.DRAWING Doc. des. Scale Form
Check. P.Viitala 04-Oct-17 CBAI-01 DIMENSION DRAWING DIMENSION DRAWING 1:1 A4
Appr. Package: Cardboard
J.Viman 04-Oct-17 Resp.dept. Rev.ind. -.2 (DR)
Project name Doc. No.
Weight kg 0.11
3AXD50000182008
364 Optional I/O extension modules Optional I/O extension modules 265

Isolation areas:
Isolation areas:

CBAI-01

AO3 1 AO4

AI4 AI4

Symbol Symbol
Description Description
1 1 to drive
Plugged Plugged
SLOT2to drive SLOT2
2 2
SWITCH SWITCH
Reinforced
Reinforced insulation insulation (IEC
(IEC 61800-5-1:2007) 61800-5-1:2007)
Functional insulation (IEC 61800-5-1:2007)
Functional insulation (IEC 61800-5-1:2007)
Analog inputs (80...82, 83...85):
• Wire size max. 1.5 mm2
Analog inputs
• Input (80...82,
voltage 83...85)
(AI+ and AI-): -10 V ... +10 V
• Input resistance: > 200 kohm
• Wire size max. 1.5 mm 2
• Optional cable shield connection
• Input voltage (AI+ and AI-): -10 V ... +10 V
Analog outputs (86...88, 89...91):
• •Input resistance: > 200 kohm
Wire size max. 1.5 mm2
• •Optional
Outputcable
voltageshield
(AO andconnection
AGND): 0 V ... 10 V
• Output resistance: < 20 ohm
Analog outputs (86...88, 89...91)
• Recommended load: > 10 kohm
• •Wire size max.typical
Inaccuracy: 1.5 mm 2 max. ± 1.5% of full scale
± 1%,
• •Output
Optional cable(AO
voltage shield
andconnection
AGND): 0 V ... 10 V
• Analog
Outputoutput scale <
resistance: switch:
20 ohm
• ON state: 0.5 V ... 9.5 V range in use
• Recommended load: > 10 kohm
• OFF state: 0 V ... 10 V range in use
• Inaccuracy: typical ± 1%, max. ± 1.5% of full scale
• Optional cable shield connection

Analog output scale switch

• ON state: 0.5 V ... 9.5 V range in use
• OFF state: 0 V ... 10 V range in use
266 Optional I/O extension modules

CHDI-01 115/230 V digital input extension module

￭ Hardware description
Product overview
The CHDI-01 115/230 V digital input extension module expands the inputs of the drive
control unit. It has six high voltage inputs and two relay outputs.

Layout

4 3

5
4 3

1 Grounding screw -
2 Hole for mounting screw -
3 3-pin terminal blocks for relay outputs Terminal designations (page 267)
4 3-pin terminal block for 115/230 V inputs Terminal designations (page 267)
5 Diagnostic LED LEDs (page 270)

￭ Mechanical installation
Necessary tools and instructions
• Screwdriver and a set of suitable bits.

Unpacking and checking the delivery

1. Open the option package.
2. Make sure that the package contains:
• CHDI-01 high voltage digital extension module
• a mounting screw
• support part
 Optional I/O extension modules 267

Note:
The support part is needed for the following frame R1 drive types -02A7, -03A4,
-04A1, -05A7, -08A5 and -12A7.

3. Make sure that there are no signs of damage.

Installing the module

See section Installing optional modules in chapter Electrical installation.

￭ Electrical installation
WARNING!
Obey the instructions in chapter Safety instructions. If you ignore them, injury or
death, or damage to the equipment can occur. If you are not a qualified electrician,
do not do electrical work.
Make sure that the drive is disconnected from the input power during
installation. If the drive is already connected to the input power, wait for
5 minutes after disconnecting the input power.

Necessary tools and instructions

• Screwdriver and a set of suitable bits
• Cabling tools

Terminal designations
For more detailed information on the connectors, see section Technical data (page 270).
Relay outputs

Marking Description
50 RO4C Common, C
51 RO4A Normally closed, NC
52 RO4B Normally open, NO
53 RO5C Common, C
54 RO5A Normally closed, NC
55 RO5B Normally open, NO

115/230 V inputs

Marking Description
70 HDI7 115/230 V input 1
71 HDI8 115/230 V input 2
72 NEUTRAL 1) Neutral point

73 HDI9 115/230 V input 3

74 HDI10 115/230 V input 4
75 NEUTRAL1) Neutral point
76 HDI11 115/230 V input 5
77 HDI12 115/230 V input 6
268 Optional I/O extension modules

Marking Description
78 NEUTRAL1) Neutral point

1) Neutral points 72, 75 and 78 are connected.

General cabling instructions

Obey the instructions given in chapter Guidelines for planning the electrical installation.

Wiring
Connect the external control cables to the applicable module terminals. Ground the outer
shield of the cables 360 degrees under a grounding clamp on the grounding shelf of the
control cables.
Relay output connection example

RO4C
50
24 V DC RO4A
51
RO4B
52

CHDI-01

Digital input connection example

230 V AC source 65 HDI7

66 HDI8
67 NEUTRAL
CHDI-01

￭ Start-up
Setting the parameters
1. Power up the drive.
2. If no warning is shown,
• make sure that the value of both parameters 15.02 and 15.01 is CHDI-01.
If warning A7AB Extension I/O configuration failure is shown,
• make sure that the value of parameter 15.02 is CHDI-01.
• set parameter 15.01 value to CHDI-01.
You can now see the parameters of the extension module in parameter group 15 I/O
extension module.
3. Set the parameters of the extension module to applicable values.
Parameter setting example for relay output
This example shows how make relay output RO4 of the extension module indicate the
reverse direction of rotation of the motor with a one-second delay.

Parameter Setting
15.07 RO4 source Reverse
15.08 RO4 ON delay 1s
 Optional I/O extension modules 269

Parameter Setting
15.09 RO4 OFF delay 1s
270 Optional I/O extension modules

￭ Diagnostics
Faults and warning messages
Warning A7AB Extension I/O configuration failure.

LEDs
The extension module has one diagnostic LED.

Color Description
Green The extension module is powered up.

￭ Technical data
Dimension drawing:
The dimensions are in millimeters and [inches].

Installation: Into an option slot on the drive control unit

Degree of protection: IP20
Ambient conditions: See the drive technical data.
 Optional I/O extension modules 271

Package: Cardboard
Isolation areas:

CHDI-01

HDI 1
RO4

HDI

RO5

HDI
1 Plugged to drive SLOT2
Reinforced insulation (IEC 61800-5-1:2007)
Functional insulation (IEC 61800-5-1:2007)

Relay outputs (50…52, 53…55):

• Wire size max. 1.5 mm2
• Minimum contact rating: 12 V / 10 mA
• Maximum contact rating: 250 V AC / 30 V DC / 2 A
• Maximum breaking capacity: 1500 VA
115/230 V inputs (70…78):
• Wire size max. 1.5 mm2
• Input voltage: 115 to 230 V AC ±10%
• Maximum current leakage in digital off state: 2 mA
272 Optional I/O extension modules

CMOD-01 multifunction extension module (external

24 V AC/DC and digital I/O)
￭ Hardware description
Product overview
The CMOD-01 multifunction extension module (external 24 V AC/DC and digital I/O) expands
the outputs of the drive control unit. It has two relay outputs and one transistor output, which
can function as a digital or frequency output.
In addition, the extension module has an external power supply interface, which can be
used to power up the drive control unit in case the drive power supply is not on. If you do
not need the back-up power supply, you do not have to connect it because the module is
powered from the drive control unit by default.
Note:
In frames R6…R9, you do not need a CMOD-01 module to use external 24 V AC/DC supply.
The external supply is connected directly to terminals 40 and 41 on the control unit.

WARNING!
Do not connect the +24 V AC cable to the control unit ground when the control
unit is powered using an external 24 V AC supply.

Layout

5
3

6
4 3

1 Grounding screw Mechanical installation (page 273)

2 Hole for mounting screw Mechanical installation (page 273)
3 3-pin terminal blocks for relay outputs Terminal designations (page 273)
 Optional I/O extension modules 273

4 3-pin terminal block for transistor output Terminal designations (page 273)
5 2-pin terminal block for external power supply Terminal designations (page 273)
6 Diagnostic LED LEDs (page 277)

￭ Mechanical installation
Necessary tools and instructions
• Screwdriver and a set of suitable bits.

Unpacking and checking the delivery

1. Open the option package.
2. Make sure that the package contains:
• CMOD-01 multifunction extension module
• a mounting screw
• support part
Note:
The support part is needed for the following frame R1 drive types -02A7, -03A4,
-04A1, -05A7, -08A5 and -12A7.

3. Make sure that there are no signs of damage.

Installing the module

See section Installing optional modules in chapter Electrical installation.

￭ Electrical installation
WARNING!
Obey the instructions in chapter Safety instructions. If you ignore them, injury or
death, or damage to the equipment can occur. If you are not a qualified electrician,
do not do electrical work.
Make sure that the drive is disconnected from the input power during
installation. If the drive is already connected to the input power, wait for
5 minutes after disconnecting the input power.

Necessary tools and instructions

• Screwdriver and a set of suitable bits
• Cabling tools

Terminal designations
For more detailed information on the connectors, see section Technical data (page 278).
Relay outputs

Marking Description
50 RO4C Common, C
51 RO4A Normally closed, NC
52 RO4B Normally open, NO
53 RO5C Common, C
274 Optional I/O extension modules

Marking Description
54 RO5A Normally closed, NC
55 RO5B Normally open, NO

Transistor output

Marking Description
42 DO1 SRC Source input
43 DO1 OUT Digital or frequency output
44 DO1 SGND Ground (earth) potential

External power supply

The external power supply is needed only if you want to connect an external back-up power
supply for the drive control unit.
Note:
CMOD +24V external power supply terminals are not in use with CCU-24 control unit.
External power supply to CCU-24 is connected to terminals 40 and 41 on the control unit.

Marking Description
40 24 V AC/DC + in External 24 V (AC/DC) input
41 24 V AC/DC - in External 24 V (AC/DC) input

General cabling instructions

Obey the instructions given in chapter Guidelines for planning the electrical installation.

Wiring
Connect the external control cables to the applicable module terminals. Ground the outer
shield of the cables 360 degrees under a grounding clamp on the grounding shelf of the
control cables.
Relay output connection example

RO4C
50
24 V DC RO4A
51
RO4B
52

CMOD-01

Digital output connection example

42 DO1 SRC
24 V DC
43 DO1 OUT
44 DO1 SGND
CMOD-01

Frequency output connection example

 Optional I/O extension modules 275

1) 42 DO1 SRC
43 DO1 OUT
44 DO1 SGND
CMOD-01

1) An externally supplied frequency indicator which provides, for example:

• a 40 mA / 12 V DC power supply for the sensor circuit (CMOD frequency output)
• suitable voltage pulse input (10 Hz … 16 kHz).

External power supply connection example

+
1) 40 24V AC/DC + in
- 41 24V AC/DC - in
CMOD-01

1) External power supply, 24 V AC/DC

WARNING!
Do not connect the +24 V AC cable to the control unit ground when the control
unit is powered using an external 24 V AC supply.

￭ Start-up
Setting the parameters
1. Power up the drive.
2. If no warning is shown,
• make sure that the value of both parameters 15.02 and 15.01 is CMOD-01.
If warning A7AB Extension I/O configuration failure is shown,
• make sure that the value of parameter 15.02 is CMOD-01.
• set the parameter 15.01 value to CMOD-01.
You can now see the parameters of the extension module in parameter group 15 I/O
extension module.
3. Set the parameters of the extension module to applicable values.
Examples are given below.
Parameter setting example for relay output
This example shows how make relay output RO4 of the extension module indicate the
reverse direction of rotation of the motor with a one-second delay.

Parameter Setting
15.07 RO4 source Reverse
15.08 RO4 ON delay 1s
15.09 RO4 OFF delay 1s

Parameter setting example for digital output

276 Optional I/O extension modules

This example shows how to make digital output DO1 of the extension module indicate the
reverse direction of rotation of the motor with a one-second delay.

Parameter Setting
15.22 DO1 configuration Digital output
15.23 DO1 source Reverse
15.24 DO1 ON delay 1s
15.25 DO1 OFF delay 1s
 Optional I/O extension modules 277

Parameter setting example for frequency output

This example shows how to make digital output DO1 of the extension module indicate the
motor speed 0... 1500 rpm with a frequency range of 0...10000 Hz.

Parameter Setting
15.22 DO1 configuration Frequency output
15.33 Freq out 1 source 01.01 Motor speed used
15.34 Freq out 1 src min 0
15.35 Freq out 1 src max 1500.00
15.36 Freq out 1 at src min 1000 Hz
15.37 Freq out 1 at src max 10000 Hz

￭ Diagnostics
Faults and warning messages
Warning A7AB Extension I/O configuration failure.

LEDs
The extension module has one diagnostic LED.

Color Description
Green The extension module is powered up.
278 Optional I/O extension modules

￭ Technical data
Dimension drawing:
The dimensions are in millimeters and [inches].

Installation: Into an option slot on the drive control unit

Degree of protection: IP20
Ambient conditions: See the drive technical data.
Package: Cardboard
 Optional I/O extension modules 279

Isolation areas:

CMOD-01

1
24 Vin RO4

DO1 RO5

Reinforced insulation (IEC 61800-5-1:2007)

Functional insulation (IEC 61800-5-1:2007)

Relay outputs (50…52, 53…55):

• Wire size max. 1.5 mm2
• Minimum contact rating: 12 V / 10 mA
• Maximum contact rating: 250 V AC / 30 V DC / 2 A
• Maximum breaking capacity: 1500 VA
Transistor output (42…44):
• Wire size max. 1.5 mm2
• Type: Transistor output PNP
• Maximum load: 4 kohm
• Maximum switching voltage: 30 V DC
• Maximum switching current: 100 mA / 30 V DC, short-circuit protected
• Frequency: 10 Hz … 16 kHz
• Resolution: 1 Hz
• Inaccuracy: 0.2%
External power supply (40…41):
• Wire size max. 1.5 mm2
• 24 V AC / V DC ±10% (GND, user potential)
• Maximum power consumption: 25 W, 1.04 A at 24 V DC
280 Optional I/O extension modules

CMOD-02 multifunction extension module (external

24 V AC/DC and isolated PTC interface)
￭ Hardware description
Product overview
The CMOD-02 multifunction extension module (external 24 V AC/DC and isolated PTC
interface) has a motor thermistor connection for supervising the motor temperature and one
relay output, which indicates the thermistor status. In case the thermistor overheats, the
drive trips on motor overtemperature. If Safe torque off tripping is required, the user must
wire the overtemperature indication relay to the certified Safe torque off input of the drive.
In addition, the extension module has an external power supply interface, which can be
used to power up the drive control unit in case the drive power supply is not on. If you do
not need the back-up power supply, you do not have to connect it because the module is
powered from the drive control unit by default.
There is reinforced insulation between the motor thermistor connection, the relay output
and the drive control unit interface. Thus, you can connect a motor thermistor to the drive
through the extension module.
Note:
In frames R6…R9, you do not need a CMOD-02 module to use external 24 V AC/DC supply.
The external supply is connected directly to terminals 40 and 41 on the control unit.

WARNING!
Do not connect the +24 V AC cable to the control unit ground when the control
unit is powered using an external 24 V AC supply.
 Optional I/O extension modules 281

Layout

5 4

6 3

1 Grounding screw Mechanical installation (page 281)

2 Hole for mounting screw Mechanical installation (page 281)
3 2-pin terminal block for motor thermistor connection Terminal designations (page 282)
4 2-pin terminal block for relay output Terminal designations (page 282)
5 2-pin terminal block for external power supply Terminal designations (page 282)
6 Diagnostic LED LEDs (page 284)

￭ Mechanical installation
Necessary tools and instructions
• Screwdriver and a set of suitable bits

Unpacking and checking the delivery

1. Open the option package.
2. Make sure that the package contains:
• CMOD-02 multifunction extension module
• a mounting screw
• support part
Note:
The support part is needed for the following frame R1 drive types -02A7, -03A4,
-04A1, -05A7, -08A5 and -12A7.

3. Make sure that there are no signs of damage.

282 Optional I/O extension modules

Installing the module

See section Installing optional modules in chapter Electrical installation.

￭ Electrical installation
WARNING!
Obey the instructions in chapter Safety instructions. If you ignore them, injury or
death, or damage to the equipment can occur. If you are not a qualified electrician,
do not do electrical work.
Make sure that the drive is disconnected from the input power during
installation. If the drive is already connected to the input power, wait for
5 minutes after disconnecting the input power.

Necessary tools and instructions

• Screwdriver and a set of suitable bits
• Cabling tools

Terminal designations
For more detailed information on the connectors, see section Technical data (page 284).
Motor thermistor connection

Marking Description
60 PTC IN PTC connection
61 PTC IN Ground (earth) potential

Relay output

Marking Description
62 RO PTC C Common, C
63 RO PTC B Normally open, NO

External power supply

The external power supply is needed only if you want to connect an external back-up power
supply for the drive control unit.
Note:
CMOD +24V external power supply terminals are not in use with CCU-24 control unit.
External power supply to CCU-24 is connected to terminals 40 and 41 on the control unit.

Marking Description
40 24 V AC/DC + in External 24 V (AC/DC) input
41 24 V AC/DC - in External 24 V (AC/DC) input

General cabling instructions

Obey the instructions given in chapter Guidelines for planning the electrical installation.
 Optional I/O extension modules 283

Wiring
Connect the external control cables to the applicable module terminals. Ground the outer
shield of the cables 360 degrees under a grounding clamp on the grounding shelf of the
control cables.
Motor thermistor connection example

1)
60 PTC IN
61 PTC IN
CMOD-02

1) One or 3…6 PTC thermistors connected in series.

The PTC input is reinforced/double insulated. If the motor part of the PTC sensor and wiring
are reinforced/double insulated, voltages on the PTC wiring are within SELV limits.
If the motor PTC circuit is not reinforced/double insulated (ie, it is basic insulated), it is
mandatory to use reinforced/double insulated wiring between the motor PTC and CMOD-02
PTC terminal.
Relay output connection example

CMOD-02
RO PTC C
62
63
RO
PTC B

X4 CCU
34 OUT1
35 OUT2
36 SGND
37 IN1
38 IN2

Power supply connection example

+
1) 40 24V AC/DC + in
- 41 24V AC/DC - in
CMOD-02

1) External power supply, 24 V AC/DC

WARNING!
Do not connect the +24 V AC cable to the control unit ground when the control
unit is powered using an external 24 V AC supply.
284 Optional I/O extension modules

￭ Start-up
Setting the parameters
1. Power up the drive.
2. If no warning is shown,
• make sure that the values of both parameters 15.02 and 15.01 are CMOD-02.
If warning A7AB Extension I/O configuration failure is shown,
• make sure that the value of parameter 15.02 is CMOD-02.
• set the parameter 15.01 value to CMOD-02.
You can now see the parameters of the extension module in parameter group 15 I/O
extension module.

￭ Diagnostics
Faults and warning messages
Warning A7AB Extension I/O configuration failure.

LEDs
The extension module has one diagnostic LED.

Color Description
Green The extension module is powered up.

￭ Technical data
Dimension drawing:
The dimensions are in millimeters and [inches].
 Optional I/O extension modules 285

Installation: Into an option slot on the drive control unit

Degree of protection: IP20
Ambient conditions: See the drive technical data.
Package: Cardboard
286 Optional I/O extension modules

Isolation areas:

CMOD-02

1
24 Vin RO PTC

PTCin

Reinforced insulation (IEC 61800-5-1:2007)

Functional insulation (IEC 61800-5-1:2007)

1 Plugged to drive SLOT2.

Motor thermistor connection (60…61):

• Wire size max. 1.5 mm2
• Supported standards: DIN 44081 and DIN 44082
• Number of PTC thermistor relays: 1 or 3…6 in series
• Triggering threshold: 3.6 kohm ±10%
• Recovery threshold: 1.6 kohm ±10%
• PTC terminal voltage: < 5.0 V
• PTC terminal current: < 1 mA
• Short-circuit detection: < 50 ohm ±10%
Relay output (62…63):
• Wire size max. 1.5 mm2
• Maximum contact rating: 250 V AC / 30 V DC / 5 A
• Maximum breaking capacity: 1000 VA
External power supply (40…41):
• Wire size max. 1.5 mm2
• 24 V AC / V DC ±10% (GND, user potential)
• Maximum power consumption: 25 W, 1.04 A at 24 V DC

CPTC-02 ATEX-certified thermistor protection module

(external 24 V AC/DC and isolated PTC interface)
See CPTC-02 ATEX-certified thermistor protection module, EX II (2) GD (+L537+Q971)
user's manual (3AXD50000030058 [English]).
—
Further information
Product and service inquiries
Address any inquiries about the product to your local ABB representative, quoting the type
designation and serial number of the unit in question. A listing of ABB sales, support and service
contacts can be found by navigating to www.abb.com/searchchannels.

Product training
For information on ABB product training, navigate to new.abb.com/service/training.

Providing feedback on ABB manuals

Your comments on our manuals are welcome. Navigate to
new.abb.com/drives/manuals-feedback-form.

Document library on the Internet

You can find manuals and other product documents in PDF format on the Internet at
www.abb.com/drives/documents.

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PDF-Web
Created 2019-07-11, 07:52:48
www.abb.com/drives

3AXD50000045815D

3AXD50000045815 Rev D (EN) EFFECTIVE 2019-07-03

© 2019 ABB Oy. All Rights Reserved.

Specifications subject to change without notice.