ABB general purpose drives

Hardware manual
ACS580-04 drive modules (200 to 500 kW)
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You can find manuals and other product documents in PDF format on the Internet. See section
Document library on the Internet on the inside of the back cover. For manuals not available in the
Document library, contact your local ABB representative.
 Hardware manual
ACS580-04 drive modules
(200 to 500 kW)

Table of contents

1. Safety instructions

6. Installation instructions

9. Start-up

 2015 ABB Oy. All Rights Reserved. 3AXD50000015497 Rev B

EN
EFFECTIVE: 2015-04-02
 5

Table of contents

List of related manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1. Safety instructions
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Use of warnings and notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
General safety in installation, start-up and maintenance . . . . . . . . . . . . . . . . . . . . . . . . 12
Electrical safety in installation, start-up and maintenance . . . . . . . . . . . . . . . . . . . . . . . 14
Precautions before electrical work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Additional instructions and notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Additional instructions for permanent magnet motor drives . . . . . . . . . . . . . . . . . . . . . . 17
Safety in installation, start-up and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

2. Introduction to the manual

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Target audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Contents of the manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Categorization by frame size and option code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Quick installation, commissioning and operating flowchart . . . . . . . . . . . . . . . . . . . . . . . 21
Terms and abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

3. Operation principle and hardware description

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Product overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Standard drive module configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Drive module configuration with option +B051 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Overview of power and control connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
External control connection terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Type designation label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Type designation key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

4. Guidelines for planning the cabinet installation

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Limitation of liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Installation positions of the drive module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Basic requirements for the cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Planning the layout of the cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Layout example, door closed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Layout example, door open (standard drive module configuration) . . . . . . . . . . . . . . 37
Layout example, door open (option +B051) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Arranging the grounding inside the cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Selecting the busbar material and preparation of the joints . . . . . . . . . . . . . . . . . . . . . . 39
Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Planning the fastening of the cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
6

Planning the cabinet placement on a cable channel . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Planning the electromagnetic compatibility (EMC) of the cabinet . . . . . . . . . . . . . . . . . 40
Planning the cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Preventing the recirculation of hot air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Standard drive module configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Drive module with option +B051 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Required free space . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Free space at the top of the drive module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Free space around the drive module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Other installation positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Drive module on its back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Planning the placement of the control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Planning the use of cubicle heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Arc welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

5. Guidelines for planning the electrical installation

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Selecting the supply disconnecting device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
European Union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Other regions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Selecting the main contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Examining the compatibility of the motor and drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Protecting the motor insulation and bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Requirements table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Additional requirements for ABB motors of types other than M2_, M3_, M4_, HX_
and AM_ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Additional requirements for ABB high-output and IP23 motors . . . . . . . . . . . . . . 52
Additional requirements for non-ABB high-output and IP23 motors . . . . . . . . . . . 52
Additional data for calculating the rise time and the peak line-to-line voltage . . . 53
Additional note for common mode filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Selecting the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
General rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Typical power cable sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Alternative power cable types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Recommended power cable types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Power cable types for restricted use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Not allowed power cable types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Motor cable shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Selecting the control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Shielding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Signals in separate cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Signals allowed to be run in the same cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Relay cable type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Control panel cable length and type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Routing the cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Separate control cable ducts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Continuous motor cable shield or enclosure for equipment in the motor cable . . . . 58
Implementing thermal overload and short-circuit protection . . . . . . . . . . . . . . . . . . . . . 58
Protecting the drive and input power cable in short-circuits . . . . . . . . . . . . . . . . . . . 58
Protecting the motor and motor cable in short-circuits . . . . . . . . . . . . . . . . . . . . . . . 58
Protecting the drive and the input power and motor cables
against thermal overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Protecting the motor against thermal overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
 7

Protecting the drive against ground faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Residual current device compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Implementing the Emergency stop function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Implementing the Safe torque off function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Implementing the Power loss ride-through function . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Using power factor compensation capacitors with the drive . . . . . . . . . . . . . . . . . . . . . . 60
Implementing a safety switch between the drive and the motor . . . . . . . . . . . . . . . . . . . 60
Using a contactor between the drive and the motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Implementing a bypass connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Example bypass connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Switching the motor power supply from drive to direct-on-line . . . . . . . . . . . . . . . 62
Switching the motor power supply from direct-on-line to drive . . . . . . . . . . . . . . . 63
Protecting the contacts of relay outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Connecting a motor temperature sensor to the drive I/O . . . . . . . . . . . . . . . . . . . . . . . . 64
Example circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

6. Installation instructions
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Checking the installation site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Moving and unpacking the unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Checking the delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Installing the motor cable at the motor end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Checking the insulation of the assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Input cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Motor and motor cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Installation alternatives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Standard drive module configuration and option +B051 . . . . . . . . . . . . . . . . . . . . . . . 71
Optional input power cable connection terminals and
ground busbar assembly (+H370) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Drive module without output cable connection terminals (option +0H371) . . . . . . . . . 72
Drive module without pedestal (option +0H354) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Attaching the drive module to a mounting plate or wall . . . . . . . . . . . . . . . . . . . . . . . 73
Alternatives for grounding the drive module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Installing the bottom grille (for IP20 degree protection) . . . . . . . . . . . . . . . . . . . . . . . 74
Connecting the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Power cable connection procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
DC connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Connecting the control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Default I/O connection diagram (ABB standard macro) . . . . . . . . . . . . . . . . . . . . . . . 80
Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
PNP configuration for digital inputs (DIGITAL IN) . . . . . . . . . . . . . . . . . . . . . . . . . 82
NPN configuration for digital inputs (DIGITAL IN) . . . . . . . . . . . . . . . . . . . . . . . . . 83
Connection for obtaining 0…10 V from analog output 2 (ANALOG IN/OUT) . . . . 83
Connection examples of two-wire and three-wire sensors . . . . . . . . . . . . . . . . . . 84
DI6 as frequency input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
AI1 and AI2 as Pt100, Pt1000, Ni1000, KTY83 and KTY84 sensor inputs
(ANALOG IN/OUT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Safe torque off (STO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Installing optional modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Option slot 3 (embedded fieldbus adapter modules) . . . . . . . . . . . . . . . . . . . . . . . . . 86
8

Option slot 2 (I/O extension modules) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

Option slot 1 (fieldbus adapter modules) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Wiring the optional modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Connecting a PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

7. Installation example of drive module with IP20 shrouds (option +B051)

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Limitation of liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Required parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Required tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Overall flowchart of the installation process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Installing the drive module into a cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Connecting the power cables and installing the shrouds . . . . . . . . . . . . . . . . . . . . . . . . 91
Installing the roof and door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Input power cable lead-through from top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Attaching the drive module to a mounting plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

8. Installation checklist
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Installation checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

9. Start-up
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Start-up procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

10. Fault tracing

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Warning and fault messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

11. Maintenance
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Preventive maintenance interval table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Cleaning the interior of the cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Heatsink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Cleaning the interior of the heatsink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Replacing the circuit board compartment cooling fan . . . . . . . . . . . . . . . . . . . . . . . 107
Replacing the main cooling fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Replacing the drive module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Reforming the capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Cleaning the control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Replacing the battery in the assistant control panel . . . . . . . . . . . . . . . . . . . . . . . . 111
 9

12. Technical data

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
IEC ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
NEMA ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Ambient temperature derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Altitude derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Deratings for selections of parameter 97.02 Minimum switching frequency . . . . . . . . . 115
Fuses (IEC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Ultrarapid (aR) fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Dimensions, weights and free space requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Losses, cooling data and noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Terminal and lead-through data for the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Drive modules without output cable connection terminals (+0H371)
and with a common mode filter (+E208) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Terminal data for the control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Electrical power network specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Motor connection data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
DC connection data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Control unit (CCU-12) connection data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Control panel type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Degree of protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
CE marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Compliance with the European Low Voltage Directive . . . . . . . . . . . . . . . . . . . . . . . 121
Compliance with the European EMC Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Applicable standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Compliance with the European RoHS Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Compliance with the European Machinery Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Compliance with EN 61800-3:2004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Category C3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Category C4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

13. Dimension drawings

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
R10 standard configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
R10 with options +E208+0H354+H356+0H370+0H371 . . . . . . . . . . . . . . . . . . . . . . . . 127
R10 with option +B051 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
R11 standard configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
R11 with options +E208+0H354+H356+0H370+0H371 . . . . . . . . . . . . . . . . . . . . . . . . 130
R11 with option +B051 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Air baffles for the drive module with option +B051 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

14. Example circuit diagram

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Example circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
10

15. Safe torque off function

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Compliance with the European Machinery Directive . . . . . . . . . . . . . . . . . . . . . . . . 136
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Activation switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Cable types and lengths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Grounding of protective shields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Single drive (internal power supply) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Single drive (external +24 V DC power supply) . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Wiring examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Multiple drives (internal power supply) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Multiple drives (external power supply) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Operation principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Start-up including acceptance test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Competence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Acceptance test reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Acceptance test procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Competence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Fault tracing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Safety data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Declaration of conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

16. du/dt filters

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
du/dt filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
When is du/dt filter needed? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Selection table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Ordering codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Description, installation and technical data of the FOCH filters . . . . . . . . . . . . . . . 149

17. Step-by-step drawings for an installation example of drive module with options
+B051 and +E208 in Rittal TS 8 600 mm wide cabinet

Further information
Product and service inquiries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Product training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Providing feedback on ABB Drives manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Document library on the Internet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
 Safety instructions 11

1
Safety instructions

Contents of this chapter

This chapter contains the safety instructions which you must obey when you install and
operate the drive and do maintenance 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:

Electricity warning tells about hazards from electricity which can cause injury
or death, or damage to the equipment.

General warning tells about conditions, other than those caused by electricity,
which can cause injury or death, or damage to the equipment.

Electrostatic sensitive devices warning tells you about the risk of

electrostatic discharge which can cause damage to the equipment.
12 Safety instructions

General safety in installation, start-up and maintenance

These instructions are for all personnel that install the drive module and do maintenance
work on it.

WARNING! Obey these 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 prevent foot injury.
• Lift the drive module only by the lifting lugs.

• Make sure that the module does not topple over when you move it on the floor:
Open the support legs by pressing each leg a little down (1, 2) and turning it aside.
Whenever possible secure the module also with chains.
• Do not tilt the drive module (A). It is heavy and its center of gravity is high. The
module overturns from a sideways tilt of 5 degrees. Do not leave the module
unattended on a sloping floor.

1 3
A

3AUA0000086323

• Do not use the module installation ramp with plinth heights which exceed the
maximum height marked on the ramp. (The maximum plinth height is 50 mm
[1.97 in] when the telescopic ramp is fully retracted and 150 mm [5.91 in] when
the ramp is fully extended.)
• Attach the module installation ramp carefully.
 Safety instructions 13

• To prevent the drive module from falling, attach its top lifting lugs with chains to the
cabinet frame before you push the module into the cabinet and pull it from the
cabinet. Work carefully preferably with help from another person as shown below.
Keep a constant pressure with one foot on the base of the module to prevent the
module from falling on its back

3AUA0000088632

• Beware of hot surfaces. Some parts, such as heatsinks of power semiconductors,

remain hot for a while after disconnection of the electrical supply.
• Make sure that debris from borings and grindings 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.
• Before you connect voltage to the drive, make sure that the cabinet doors are closed.
Keep the doors closed during the operation. Obey the panel builder’s instructions.
• Before you adjust the drive operation limits, make sure that the motor and all driven
equipment can operate throughout the set operation limits.
• Before you activate the automatic fault reset or automatic restart functions of the drive
control program, make sure that no dangerous situations can occur. These functions
reset the drive automatically and continue operation after a fault or supply break.
• The maximum number of drive power-ups is five in ten minutes. Too frequent power-
ups can damage the charging circuit of the DC capacitors.
• Make sure that any safety circuits (for example, emergency stop and Safe torque off)
are validated in start-up. See chapter Start-up for reference of the validation
instructions.
Note:
• If you select an external source for 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.
• When the control location is not set to Local, the stop key on the control panel will not
stop the drive.
14 Safety instructions

Electrical safety in installation, start-up and maintenance

 Precautions before electrical work
These warnings are for all personnel that 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. Clearly identify the work location.
2. Disconnect all possible voltage sources.
• Open the main disconnector of the drive.
• Open the disconnector of the supply transformer as the main disconnector of the
drive does not remove the voltage from the input busbars of the drive.
• Make sure that reconnection is not possible. Lock the disconnectors to open
position and attach a warning notice to them.
• Disconnect any external power sources from the control circuits before you do
work on the control cables.
• After you disconnect the drive, always wait for 5 minutes to let the intermediate
circuit capacitors discharge before you continue.
3. Protect any other energized parts in the work location against contact.
4. Take special precautions when close to bare conductors.
5. Measure that the installation is de-energized.
• Use a multimeter with an impedance of at least 1 Mohm.
• Make sure that the voltage between the drive module input power terminals
(L1/U1, L2/V1, L3/W1) and the grounding (PE) busbar is close to 0 V.
• If the drive module is equipped with UDC+ and UDC- terminals (option +H356),
make sure that the voltage between the UDC+ and UDC- terminals and the
grounding (PE) busbar is close to 0 V.
6. Install temporary grounding as required by the local regulations.
7. Ask for a permit to work from the person in control of the electrical installation work.
 Safety instructions 15

 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.

• Do not install a drive with EMC filter option +E202 on an ungrounded power system or
a high resistance-grounded (over 30 ohms) power system.
• Do not connect the drive to a voltage higher than what is on the type designation label.
Overvoltage can cause the motor to rush to its maximum speed.
• We do not recommend that you secure the cabinet by arc welding. If you have to, obey
the instructions in section Arc welding on page 48.
• Do not do insulation or voltage withstand tests on the drive or drive modules.
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.
• The DC bus terminals (UDC+, UDC-) are at a dangerous voltage.
• External wiring can supply dangerous voltages to the terminals of relay outputs
(XRO1, XRO2 and XRO3).
• 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.

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

WARNING! Obey these instructions. If you ignore them, equipment malfunction

and damage to the fiber optic cables can occur.

• Handle the fiber optic cables with care.

• When you unplug the 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 in).
16 Safety instructions

 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 grounding conductors is sufficient. See section
Selecting the power cables on page 53. Obey the local regulations.
• Connect the power cable shields to protective earth (PE) 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 switch board or the transformer.
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 connection. See standard EN 61800-5-1, 4.3.5.5.2.
 Safety instructions 17

Additional instructions for permanent magnet motor

drives
 Safety in installation, start-up and 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 and
equipment malfunction can occur.

• Do not do work on the drive when the permanent magnet motor is rotating. A rotating
permanent magnet motor energizes the drive including its input power terminals.
Before installation, start-up and maintenance work on the drive:
• Stop the motor.
• 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.
• Measure that the installation is de-energized.
• Use a multimeter with an impedance of at least 1 Mohm.
• Make sure that the voltage between the drive output terminals (T1/U2, T2/V2,
T3/W2) and the grounding (PE) busbar is close to 0 V.
• Make sure that the voltage between the drive input power terminals (L1/U1, L2/V1,
L3/W1) and the grounding (PE) busbar is close to 0 V.
• Make sure that the voltage between the drive module UDC+ and UDC- terminals
and the grounding (PE) busbar is close to 0 V.
• Install temporary grounding to the drive output terminals (T1/U2, T2/V2, T3/W2).
Connect the output terminals together as well as to the PE.
• Make sure that the operator cannot run the motor over the rated speed. Motor
overspeed causes overvoltage can damage or explode the capacitors in the
intermediate circuit of the drive.
18 Safety instructions
 Introduction to the manual 19

2
Introduction to the manual

Contents of this chapter

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

Target audience
This manual is intended for persons who
• plan the cabinet assembly of the drive module and install the module into a user-
defined cabinet
• plan the electrical installation of the drive cabinet
• make instructions for the end user of the drive concerning the mechanical installation
of the drive cabinet, connection of power and control cables to the cabinet-installed
drive 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.
20 Introduction to the manual

Contents of the manual

This manual contains the instructions and information for the basic drive module
configuration. The chapters of the manual are briefly described below.
Safety instructions gives safety instructions for the installation, commissioning, operation
and maintenance of the drive module.
Introduction to the manual introduces the manual.
Operation principle and hardware description describes the drive module.
Guidelines for planning the cabinet installation guides in planning drive cabinets and
installing the drive module into a user-defined cabinet. The chapter gives cabinet layout
examples and free space requirements around the module for cooling.
Guidelines for planning the electrical installation instructs in the motor and cable selection,
protections and cable routing.
Installation instructions gives the basic installation instructions that are common for the
different installation procedures.
Installation example of drive module with IP20 shrouds (option +B051) describes the
installation process of a standard drive module in a Rittal 600 mm wide cabinet.
Installation checklist contains lists for checking the mechanical and electrical installation of
the drive.
Start-up refers to the start-up instructions of the cabinet-installed drive.
Fault tracing describes the LED indications and refers to the fault tracing instructions of the
drive.
Maintenance contains maintenance instructions.
Technical data contains the technical specifications of the drive module, eg, the ratings,
sizes and technical requirements, provisions for fulfilling the requirements for CE and other
markings.
Dimension drawings contains dimension drawings of the drive module installed into a
Rittal TS 8 cabinet.
Example circuit diagram shows an example circuit diagram for a cabinet-installed drive
module.
Safe torque off function describes the Safe torque off function of the drive and gives
instructions on its implementing.
du/dt filters describes how to select du/dt filters for the drive.
Step-by-step drawings for an installation example of drive module with options +B051 and
+E208 in Rittal TS 8 600 mm wide cabinet shows how to install the drive module in a Rittal
TS 8 cabinet.
 Introduction to the manual 21

Categorization by frame size and option code

The instructions, technical data and dimension drawings which concern only certain drive
frame sizes are marked with the symbol of the frame size (R10 or R11). The frame size is
marked on the type designation label.
The instructions and technical data which concern only certain optional selections are
marked with option codes, eg, +J410. 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 on page 32.

Quick installation, commissioning and operating

flowchart
Task See

Plan the mechanical and electrical installation and acquire Guidelines for planning the cabinet installation
the accessories needed (cables, fuses, etc.). (page 35)
Check the ambient conditions, ratings, required cooling air Guidelines for planning the electrical installation
flow, input power connection, compatibility of the motor, (page 49)
motor connection, and other technical data. Technical data (page 113)
Option manual (if optional equipment is
included)

Unpack and check the units. Moving and unpacking the unit (page 66)
Check that all necessary optional modules and equipment Checking the delivery (page 70)
are present and correct. If the drive module has been non-operational
Only intact units can be started up. for more than one year, the converter DC link
capacitors need to be reformed. (Reforming the
capacitors, page 110)

Check the installation site. Attach the base of the cabinet to Checking the installation site (page 65)
the floor. Ambient conditions (page 120)
Guidelines for planning the cabinet installation
(page 35)

Route the cables. Routing the cables (page 57)

Check the insulation of the supply cable, the motor and the Checking the insulation of the assembly (page
motor cable. 71)
22 Introduction to the manual

Task See

Standard drive modules Installing the drive module into a cabinet (page
• Install the additional components into the cabinet: for 91)
example, main disconnector, main contactor, main AC Connecting the power cables (page 75)
fuses, etc. Manuals for any optional equipment
• Install the drive module into the cabinet.
• Connect the motor cables to the drive module terminals.
• Connect the DC connection cables (if any) to the drive
module terminals.
• If the main disconnector is installed into the cabinet,
connect it to the drive module terminals and the input
power cabling to the disconnector.

Drive modules with IP20 shrouds (option +B051) Step-by-step drawings for an installation
example of drive module with options +B051
and +E208 in Rittal TS 8 600 mm wide cabinet
(page 151)

Connect the external control cables to the drive control unit. Connecting the control cables (page 78)

Check the installation. Installation checklist (page 95)

Commission the drive. Start-up (page 99)

Operate the drive: start, stop, speed control etc. Firmware manual
 Introduction to the manual 23

Terms and abbreviations

Term/Abbreviation Explanation

ACS-AP-x Assistant control panel, advanced operator keypad for communication with the
drive. The ACS580 supports types ACS-AP-I and ACS-AP-S.

CEIA-01 Embedded EIA-485 fieldbus adapter module

CHDI-01 Optional 115/230 V digital input extension module

CMOD-01 Optional multifunction extension module (external 24 V AC/DC and digital I/O
extension)

CMOD-02 Optional multifunction extension module (external 24 V AC/DC and isolated PTC
interface)

CMF Common mode filtering

EMC Electromagnetic compatibility

EMI Electromagnetic interference

FCAN-01 Optional CANopen adapter module

FCNA-01 Optional ControlNet fieldbus adapter module

FDNA-01 Optional DeviceNet™ fieldbus adapter module

FECA-01 Optional EtherCAT adapter module

FENA-11 Optional high performance Ethernet/IP™, Modbus/TCP and PROFINET IO

adapter module

FEPL-02 Optional Ethernet POWERLINK fieldbus adapter module

FPBA-01 Optional PROFIBUS DP adapter module

Frame (size) Size of the drive module. The drive modules described in this manual are of frame
size R10 and R11.

FSCA-01 Optional Modbus RTU adapter module

IGBT Insulated gate bipolar transistor; a voltage-controlled semiconductor type widely

used in converters due to their easy controllability and high switching frequency.

I/O Input/Output

IT system Type of supply network that has no (low-impedance) connection to ground.

NETA-21 Remote monitoring tool

PLC Programmable logic controller

RFI Radio-frequency interference

STO Safe torque off

TN system Type of supply network that provides a direct connection to ground.

24 Introduction to the manual
 Operation principle and hardware description 25

3
Operation principle and
hardware description

Contents of this chapter

This chapter describes the operating principle and construction of the drive module.

Product overview
The ACC580-04 is a drive module for controlling asynchronous AC induction motors and
permanent magnet motors.
The main circuit of the drive module is shown below.

ACS580-04
UDC+
UDC-
PE
L1/U1 T1/U2
L2/V1 T2/V2
L3/W1 T3/W2
1 2 3 4

1 AC choke
2 Rectifier. Converts alternating current and voltage to direct current and voltage.
3 DC link. DC circuit between rectifier and inverter
4 Inverter. Converts direct current and voltage to alternating current and voltage.
26 Operation principle and hardware description

Layout
 Standard drive module configuration

2 1

10
7

3
12

13
5
7

6 11

17
8

16
9
14

15

1 Lifting lugs
2 Fastening bracket
3 Input cable connection busbars (L1/U1, L2/V1, L3/W1)
4 Circuit board compartment
5 PE busbar
6 Output cable connection terminals (T1/U2, T2/V2, T3/W2) attached
7 Control cable duct
8 Main cooling fans
9 Pedestal
10 Upper front cover
11 Lower front cover
12 Control panel
13 Handle for pulling the drive module out of the cabinet
14 Retractable support legs
15 Base fastening screws behind the Retractable support legs
16 Pedestal guide plate
17 Telescopic extraction and insertion ramp
 Operation principle and hardware description 27

 Drive module configuration with option +B051

The drive module configuration with clear plastic shrouds (option +B051) mounted is
shown below.

1 Upper front cover 4 Pedestal

2 Lower front cover 5 Control panel
3 Clear plastic shrouds attached (option +B051) - -
See the next page for the part descriptions.
28 Operation principle and hardware description

3
A
+B051
10

+H370 7

1a 4 6

1b

11

2 5

13

12

1 Clear plastic shroud to be attached onto the 8 Output power cable connection terminals
drive module input power cabling (a). Lead-
through shroud for side cabling (b). Option
+B051.
2 Clear plastic shrouds to be attached onto the 9 Grounding terminal for output power cable
drive module output power cabling with option shields
+B051
3 Clear plastic shroud to be attached on top of 10 Metallic shroud. With option +H370, the
the drive module (lead-through for top cabling) shroud includes a ground bar.
with option +B051
4 Upper back clear plastic shroud with option 11 Control unit
+B051
5 Lower back clear plastic shroud with option 12 Pedestal guide plate
+B051
6 Front clear plastic shroud with option +B051 13 Telescopic extraction and insertion ramp
7 Input power cable connection terminals A Drive module with clear plastic shrouds
(option +H370) mounted (front view)
 Operation principle and hardware description 29

 Control panel

1 2 3

1 ACS-AP-S assistant control panel

2 ACS-AP-I assistant control panel (option +J425)
3 DPMP-03 door mounting kit (option +J410)

In the standard drive module configuration, the control panel is located on the internal
control unit.
DPMP-03 door mounting platform is also available with option +J410.
For the use of the control panel, see the firmware manual or ACS-AP-X assistant control
panels user’s manual (3AUA0000085685 [English])
30 Operation principle and hardware description

Overview of power and control connections

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

6
X15
4
...

.......... SLOT 1 7
1
..........

..........
..........
SLOT 3
3

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

UDC+

UDC-

PE PE
L1 L1/U1 T1/U2

L2 T2/V2 M
L2/V1
3~
L3 L3/W1 T3/W2 8

1 Option slot 1 for optional fieldbus adapter modules

2 Option slot 2 for optional I/O extension modules
3 Option slot 3 for optional embedded fieldbus adapter modules
4 Panel port
6 I/O terminal blocks. See section External control connection terminals below and section Default I/O
connection diagram (ABB standard macro) on page 80.
7 Control panel (see page 87)
8 du/dt or sine filter (optional, see page 149)
 Operation principle and hardware description 31

 External control connection terminals

The layout of the external control connection terminals on the drive module control are
shown below.

SLOT 1 SLOT 1
Option slot 1 (fieldbus adapter modules)
X15
ANALOG IN/OUT
1…3 Analog input 1
AI1 Current/Voltage selection switch
for analog input 1
1…3, AI1
4…6 Analog input 2
4…6, AI2 AI2 Current/Voltage selection switch
for analog input 2
7…9 Analog outputs
7…9, AO1
AO1 Current/Voltage selection switch
for analog output 1
10…12
SLOT 3
10…12 Auxiliary voltage output
13…15
DIGITAL IN
16…18 13…18 Digital inputs
STO
34…38 Safe torque off connection
34…38
40, 41
FAN2 Internal fan 2 connection

19…21 FAN1 Internal fan 1 connection

X12 Safety functions module
connection
22…24
X15 Panel port (control panel
X12 connection)
25…27
SLOT 3
Embedded EIA/R5-485 fieldbus module
(CEIA-01) is installed on SLOT 3 as
standard.
FAN 2, FAN 1 SLOT 2 BIAS Bias resistor switch
S101
BIAS S101 TERM End termination switch
S100
TERM S100 29…31 Connection terminals of the
CEIA-01
SLOT 2
Option slot 2 (I/O extension modules)

40, 41 24 V AC/DC external power

input
RO1 … R03
19…21 Relay output 1 (RO1)
22…24 Relay output 2 (RO2)
25…27 Relay output 3 (RO3)
32 Operation principle and hardware description

Type designation label

The type designation label includes a rating, markings, a type designation and a serial
number, which allow individual recognition of each drive module. The type designation
label is located on the front cover. An example label is shown below.

1
4
3
2

1 Type designation, see section Type designation key on page 32.

2 Frame size
3 Ratings
4 Valid markings
5 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 module. The first digits from left express the basic configuration. The optional
selections are given thereafter, separated by plus signs, eg, +J410. The main selections
are described below. Not all selections are available for all types. For more information,
refer to ACS580-04 Ordering Information (3AXD10000307681), available on request.
Code Description
Basic code, eg, ACS580-04-880A-4
Product series
ACS580 ACS580 product series
Type
-04 When no options are selected: drive module to be installed in a cabinet, IP00 (UL open type),
bookshelf mounting with pedestal, internal control unit (inside the drive module), assistant control
panel ACS-AP-S and panel holder, build-in choke, installation ramp, full-size output cable
connection terminals, no EMC filter, no DC connection busbars, ACS580 standard control program,
RS-485 Modbus RTU adapter module (CEIA-01), Safe torque off function, coated boards, printed
multilingual quick installation and start-up guide.
Size
xxxA Refer to the rating tables, page 113.
Voltage range
-4 380…480 V
Option codes (plus codes)
Construction, pedestal and cabling
B051 IP20 shrouds for cabling area
0H354 No pedestal
H356 DC connection busbars
H370 Full-size input power cable connection terminals and PE busbar
0H371 No full-size output power cable connection terminals
0P919 No installation ramp
 Operation principle and hardware description 33

Code Description
Control panel and mounting platform
0J400 No control panel. Note: You need at least one loose control panel to be able to commission the
drive.
J410 DPMP-03 door mounting kit (flush mounting) for the control panel. Includes a control panel
mounting platform, an IP65 cover and a 3-meter panel connection cable.
J425 Assistant control panel compatible with ACS580 drives (ACS-AP-I)
0J427 No control panel holder and no control panel
Filters
E210 EMC filter for second environment TN (grounded) and IT (ungrounded)) systems, category C3
E208 Common mode filter
Fieldbus adapter modules
K451 FDNA-01 DeviceNet™ fieldbus adapter module
K454 FPBA-01 PROFIBUS DP fieldbus adapter module
K457 FCAN-01 CANopen fieldbus adapter module
K458 FSCA-01 Modbus/RTU adapter module
K462 FCNA-01 ControlNet fieldbus adapter module
K469 FECA-01 EtherCAT® fieldbus adapter module
K470 FEPL-02 Ethernet POWERLINK fieldbus adapter module
K473 FENA-11 Ethernet/IP™, Modbus/TCP and PROFINET IO fieldbus adapter module
I/O extension and feedback interface modules
L501 CMOD-01 external 24 V DC/AC and digital I/O extension module (two relay outputs and one digital
output)
L512 CHDI-01 115/230 V digital input module (six digital inputs and two relay outputs)
L523 CMOD-02 external 24 V and isolated PTC interface
Paper manuals. Note: The delivered manual set can include manuals in English if the translation is not
available.
R700 English
R712 Chinese
34 Operation principle and hardware description
 Guidelines for planning the cabinet installation 35

4
Guidelines for planning the
cabinet installation

Contents of this chapter

This chapter guides in planning drive cabinets and installing the drive module into a user-
defined cabinet. The chapter gives cabinet layout examples and free space requirements
around the module for cooling. These guidelines are essential for the safe and trouble-free
use of the drive system.

Limitation of liability
You must always plan and make the installation 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.

Installation positions of the drive module

You can put the drive module in the bookshelf position in a cabinet.

Basic requirements for the cabinet

Use a cabinet which
• has a frame sturdy enough to carry the weight of the drive components, control
circuitry and other equipment installed in it
• protects the user and drive module against contact and agrees with the requirements
for dust and humidity
• has sufficient air inlet and outlet gratings that allow free flow of cooling air through the
cabinet. This is critical for proper cooling of the drive module.
36 Guidelines for planning the cabinet installation

Planning the layout of the cabinet

Plan a spacious layout to ensure easy installation and maintenance. Sufficient cooling air
flow, obligatory clearances, cables and cable support structures all require space.
Place the control board(s) away from:
• main circuit components such as contactors, switches and power cables
• hot parts (heat sink, air outlet of the drive module).

 Layout example, door closed

This diagram shows a cabinet layout example with the input power cable lead-through
from top and the motor cable lead-through from bottom.

6 2c

2b 2a 1a*) Air inlet for the drive module

1b Air inlet for the other equipment. An extra fan is not necessary if an
extra air baffle is used on the cabinet roof (see page 37).
4
1c*) Air inlet for circuit boards and DC and output busbars
5
2a*) Air outlet with an extra exhaust fan for the drive module
2b*) Air outlet for the other equipment
2c*) Air outlet for the drive module and other equipment on the cabinet
3 roof. An exhaust fan if needed. We recommend this alternative
1c
instead of 2a.
3 Drive control panel with DPMP-03 mounting platform (option
+J410). The control panel is connected to the drive module control
unit inside the cabinet.
4 Contactor control switch and emergency stop switch (connected to
the contactor control circuit inside the cabinet)
5 Operating handle of the disconnector
1b 6 Rubber grommets for degree of protection
7 Roof air flow viewed from top
1a
*) Note: The sizes of the air inlet and outlet gratings are critical for
proper cooling of the drive module. For losses and cooling data
requirements, see page 117.
 Guidelines for planning the cabinet installation 37

 Layout example, door open (standard drive module configuration)

2e

2a
13 13

4
2e

5 2a 1

6 13

3 2c
2b
L1/U1
L2/V1
2d L3/W1 15
9
7

12 PE
3 T3/W2
T2/V2
T1/U2

14

11

8 10 A–A
A

1 Supporting frame of the cabinet 8 Motor cable including the protective ground conductor
of the drive module
2 Vertical (2a, 2b) and horizontal (2c, 2d) air 9 Drive module control unit. Note: With the internal
baffles that separate the cool and hot areas control unit, the upper door air inlet is critical for proper
(leak-proof lead-throughs). See also page cooling of the control board.
43.
2e Optional air baffle that is needed when there 10 External control cables
is no fan on the lower part of the cabinet
door (see 1b on page on 36)
3 Cabinet grounding busbar (PE) 11 Grounding screws
4 Input power cable including the protective 12 Alternative to grounding screws (11)
ground conductor (PE) of the drive 13 Air flow to the roof
5 Disconnector and fuses 14 Air flow through the drive module
6 Contactor 15 Air flow through circuit boards and to DC output busbars
7 Drive module - -

Note 1: The power cable shields can also be grounded to the drive module grounding
terminals.
Note 2: See also section Required free space, page 47.
38 Guidelines for planning the cabinet installation

 Layout example, door open (option +B051)

This diagram shows a layout example for drive modules with IP20 shrouds (option +B051).

2e

2a
13 13

4
2c

5 2a 1

6 12

3 2b
L1/U1
L2/V1
L3/W1
14
9
7

PE
T3/W2
T2/V2
3 T1/U2
13
8

11

10 A–A
A

1 Supporting frame of the cabinet 7 Drive module

2a Vertical (2a) and horizontal (2b) air baffles 8 Motor cable including the protective ground conductor
2b that separate the cool and hot areas (leak- of the drive module
proof lead-throughs). See also page 43.
2c Optional air baffle that is needed when there 9 Drive module control unit. Note: With an internal control
is no fan on the lower part of the cabinet unit, the upper door air inlet is critical for proper cooling
door (see 1b on page on 36) of the control board.
3 Cabinet grounding busbar (PE) 10 External control cables
4 Input power cable including the protective 11 Grounding screws
ground conductor (PE) of the drive 12 Air flow to the roof
5 Disconnector and fuses 13 Air flow through the drive module
6 Contactor 14 Air flow through circuit boards and to DC output busbars
 Guidelines for planning the cabinet installation 39

Arranging the grounding inside the cabinet

Arrange the grounding of the drive module by leaving the contact surfaces of the fastening
points unpainted (bare metal-to-metal contact). The module frame will be grounded to the
PE busbar of the cabinet via the fastening surfaces, screws and the cabinet frame.
Alternatively, use a separate grounding conductor between the PE terminal of the drive
module and the PE busbar of the cabinet.
Ground also the other components in the cabinet according to the principle above.

Selecting the busbar material and preparation of the

joints
Note the following when you use busbars:
• Tin-plated copper is recommended but aluminum can also be used.
• The oxide layer from aluminum busbar joints must be removed and suitable anti-
oxidant joint compound applied.

Tightening torques
Apply the following torques to grade 8.8 screws (with or without joint compound) that
tighten electric contacts.
Screw size Torque
M5 3.5 N·m (2.6 lbf·ft)
M6 9 N·m (6.6 lbf·ft)
M8 20 N·m (14.8 lbf·ft)
M10 40 N·m (29.5 lbf·ft)
M12 70 N·m (52 lbf·ft)
M16 180 N·m (133 lbf·ft)

Planning the fastening of the cabinet

Note the following when you plan the fastening of the cabinet:
• Fasten the cabinet to the floor from the front and to the floor or wall from the back.
• Always fasten the drive module from its fastening points to the cabinet. For details, see
the module installation instructions.

WARNING! Do not fasten the cabinet by electric welding. ABB does not assume
any liability for damages caused by electric welding as the welding circuit can
damage electronic circuits in the cabinet. See section Arc welding on page 48.
40 Guidelines for planning the cabinet installation

Planning the cabinet placement on a cable channel

Note the following when you plan to place the cabinet on a cable channel:
• The cabinet structure must be sturdy enough. If the whole cabinet base is not
supported from below, the cabinet weight will lie on the sections that the floor carries.
• Equip the cabinet with a sealed bottom plate and cable lead-throughs to ensure the
degree of protection and to prevent the cooling air flow from the cable channel into the
cabinet.
Note for option +B051: When the bottom grille and clear plastic shrouds around the
motor cables are installed, the degree of protection of the drive module from bottom
side is IP20.

The carrying structure on a cable channel Cabinet side view with a bottom plate

Planning the electromagnetic compatibility (EMC) of the

cabinet
Note the following when you plan the electromagnetic compatibility of the cabinet:
• Generally, the fewer and smaller the holes in the cabinet, the better the interference
attenuation. The maximum recommended diameter of a hole in galvanic metal contact
in the covering cabinet structure is 100 mm (3.94 in). Pay special attention to the
cooling air inlet and outlet gratings.
• The best galvanic connection between the steel panels is achieved by welding them
together as no holes are necessary. If welding is not possible, we recommend to leave
the seams between the panels unpainted and equipped with special conductive EMC
strips to provide adequate galvanic connection. Usually, reliable strips are made of
flexible silicon mass covered with a metal mesh. The non-tightened touch-contact of
the metal surfaces is not sufficient, so a conductive gasket between the surfaces is
required. The maximum recommended distance between assembly screws is 100 mm
(3.94 in).
• Construct sufficient high-frequency grounding network in the cabinet to avoid voltage
differences and forming of high-impedance radiator structures. A good high-frequency
grounding is made with short flat copper braids for low inductance. One-point high-
frequency grounding cannot be used due to the long distances inside the cabinet.
• 360° high frequency grounding of the cable shields at the cable lead-throughs
improves the EMC shielding of the cabinet.
 Guidelines for planning the cabinet installation 41

• We recommend 360° high frequency grounding of the motor cable shields at their
entries. The grounding can be implemented by a knitted wire mesh screening as
shown below.

1
2 1 Cable
2 Cable tie
3 Strain relief
3 4 Bare cable shield
5 Knitted wire mesh
4
6 Cabinet lead-through plate
5
6

• We recommend 360° high frequency grounding of the control cable shields at their
entries. The shields can be grounded by means of conductive shielding cushions
pressed against the cable shield from both directions as shown below:

1 Tightening screw
2
2 EMI conductive cushion
2 1
1 3 Strain relief
4 Grommet
3 5 Lead-through plate

4
42 Guidelines for planning the cabinet installation

Planning the cooling

Note the following guidelines when you plan the cooling of the cabinet:
• Ventilate the installation site sufficiently so that the cooling air flow and ambient
temperature requirements of the drive module are met, see pages 117 and 120. The
internal cooling fan of the drive module rotates at a constant speed thus blowing
constant air flow through the module. Whether the same amount of air must be
replaced all the time in the facility depends on how much heat must be removed.
• Leave enough free space around the components to ensure sufficient cooling.
Observe the minimum clearances given for each component. For the required free
space around the drive module, see page 47.
• Also ventilate the heat dissipated by cables and other additional equipment.
• Make sure that the air inlets and outlets are large enough to allow sufficient air
flow in and out of the cabinet. This is critical for proper cooling of the drive module.
• Equip the air inlets and outlets with gratings that
- guide the air flow
- protect against contact
- prevent water splashes from entering the cabinet.
• The drawing below shows two typical cabinet cooling solutions. The air inlet is at the
bottom of the cabinet, while the outlet is at the top, either on the upper part of the door
or on the roof. We recommend that the air outlet is on the cabinet roof. Use an extra
exhaust fan if the air outlet is on the cabinet door.

Air inlets and outlets of the cabinet Air flow inside the drive module
1 Air inlet
2 Air outlet
 Guidelines for planning the cabinet installation 43

• The internal cooling fans of the drive modules and reactors/chokes are usually
sufficient to keep the component temperatures low enough in IP22 cabinets.
• In IP54 cabinets, thick filter mats are used to prevent water splashes from entering the
cabinet. This requires the installation of additional cooling equipment, such as a hot air
exhaust fan.

Preventing the recirculation of hot air

Prevent hot air circulation outside the cabinet by leading the out coming hot air away from
the area where the inlet air to the cabinet is taken. Possible solutions are listed below:
• gratings that guide air flow at the air inlet and outlet
• air inlet and outlet at different sides of the cabinet
• cool air inlet in the lower part of the front door, and an extra exhaust fan on the roof of
the cabinet.
Prevent hot air circulation inside the cabinet with, for example, leak-proof air baffles. No
gaskets are usually required.
44 Guidelines for planning the cabinet installation

 Standard drive module configuration

This diagram shows air baffle positions inside an example cabinet. For the descriptions,
see the next page.

D C

7 2e
2e

A A
2a 2a
4
2c 2c 2c
5 2b
B L1/U1 B
L2/V1
2b 2b 2b 2b
L3/W1
2d 2d 2d
6
1b
3

y
PE
T3/W2
3 T2/V2 3
T1/U2
1a

D C x

C–C

2b 2e
2c

3
2a

2a
2b

A-A
y

2d

3
2a

B-B x

D–D
 Guidelines for planning the cabinet installation 45

1a Air flow to the drive module, max. 40 °C 2e Optional air baffle that is needed when there is no
(104 °F) fan on the lower part of the cabinet door (see 1b
on page 36).
1b Air inlet to the drive module circuit boards and 3 Drive module
DC output busbars
2a Vertical air baffle that separates the cool and 4 Disconnector and fuses
hot areas in the cabinet
2b Vertical air baffle 5 Contactor
2c Upper horizontal air baffle. For vertical 6 Drive module control unit
location, see page 132.
2d Lower horizontal air baffle 7 Air flow out
46 Guidelines for planning the cabinet installation

 Drive module with option +B051

This diagram shows air baffle positions inside an example cabinet.

C B

7 2c
2c 2c

A A
2a 2a
4

5 2b 2b
L1/U1
L2/V1
L3/W1
2a
6
1b
3

3
PE
T3/W2
T2/V2
T1/U2
3 1

C B B–B C–C

2b 2b

2a 3

A–A
1a Air flow to the drive module, max. 40 °C 3 Drive module
(104 °F)
1b Air inlet to the drive module circuit boards and 4 Disconnector and fuses
DC output busbars
2a Vertical air baffle that separates the cool and 5 Contactor
hot areas in the cabinet
2b Horizontal air baffle, see page 132. 6 Drive module control unit
2c Optional air baffle that is needed when there is 7 Air flow out
no fan on the lower part of the cabinet door
(see 1b on page 36).
 Guidelines for planning the cabinet installation 47

Required free space

Free space around the drive module is needed for ensuring that sufficient cooling air flows
through the module and the module cools correctly.

 Free space at the top of the drive module

The required free space at the top of the drive module is shown below.

2
2 290 mm (11.42 in.)
270 mm (10.63 in.)

1 1

Air outlet on the cabinet roof Air outlet in the upper part of the cabinet door
1 Air inlet
2 Air outlet

 Free space around the drive module

20 mm (0.79 in.) free space around the drive module is required from the cabinet back
panel and front door. No free space for cooling is required on the left- and right-hand sides
of the module.
The module can be installed in a cabinet with the following dimensions:
• width 500 mm (19.68 in.)
• depth 600 mm (23.62 in.)
• height 2000 mm (78.74 in.).

Other installation positions

Contact your local ABB representative for more information.

 Drive module on its back

If you install the drive module on its back, make sure that the hot cooling air that flows
upwards from the module does not cause danger.
48 Guidelines for planning the cabinet installation

Planning the placement of the control panel

Note the following alternatives when you plan the placement of the control panel:
• As standard, the control panel is integrated on the control unit inside the drive module.
• The control panel can be mounted onto the cabinet door using a control panel
mounting platform (option +J410). For instructions, see DPMP-02/03 control panel
mounting platform kit installation guide (3AUA0000136205 [English]).

Planning the use of cubicle heaters

Use a cubicle heater if there is a risk of condensation in the cabinet. Although the primary
function of the heater is to keep the air dry, it may also be required for heating at low
temperatures.

Arc welding
Fastening the cabinet by arc welding is not recommended. However, if the arc welding is
the only mounting option, proceed as follows: Connect the return conductor of the welding
equipment to the cabinet frame at the bottom within 0.5 meters (1.5 ft) of the welding point.
Note: The thickness of the zinc coating of the cabinet frame is 100 to 200 micrometers.

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

WARNING! Do not inhale the welding fumes.

 Guidelines for planning the electrical installation 49

5
Guidelines for planning the
electrical installation

Contents of this chapter

This chapter contains the instructions that you must obey when you select the motor,
cables, protections, cable routing and way of operation for the drive system.

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 obeyed, the drive can experience problems that the warranty does
not cover.
50 Guidelines for planning the electrical installation

Selecting the supply disconnecting device

Install a hand-operated input disconnecting device between the AC power source and the
drive. The disconnecting device must be of a type that can be locked to the open position
for installation and maintenance work.

 European Union
To agree with the European Union Directives, according to standard EN 60204-1, Safety of
Machinery, the disconnecting device must be one of the following types:
• switch-disconnector of utilization category AC-23B (EN 60947-3)
• disconnector that has an auxiliary contact that in all cases causes switching devices to
break the load circuit before the opening of the main contacts of the disconnector
(EN 60947-3)
• circuit breaker suitable for isolation in accordance with EN 60947-2.

 Other regions
The disconnecting device must conform to the applicable safety regulations.

Selecting the main contactor

If a main contactor is used, its utilization category (number of operations under load) must
be AC-1 according to IEC 60947-4, Low-voltage switchgear and controlgear. Select the
contactor according to the nominal voltage and current of the drive.

Examining the compatibility of the motor and drive

Use an asynchronous AC induction motor or permanent magnet motor with the drive.
Several induction motors can be connected at a time.
Select the motor size and drive type from the rating tables in chapter Technical data on
basis of the AC line voltage and motor load.
Make sure that the motor withstands the maximum peak voltage in the motor terminals,
see the Requirements table on page 51. For basics of protecting the motor insulation and
bearings in drive systems, refer to section Protecting the motor insulation and bearings
below.
Note:
• Consult the motor manufacturer before you use a motor which 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.

 Protecting the motor insulation and bearings

The drive uses modern IGBT inverter technology. Regardless of frequency, the drive
output has pulses of approximately the drive DC bus voltage with a very short rise time. Up
to twice bus voltage can be at the motor terminals, depending on the attenuation and
reflection properties of the motor cable and the terminals. The increased voltage 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.
 Guidelines for planning the electrical installation 51

Optional du/dt filters protect motor insulation system and reduce bearing currents. Optional
common mode filters mainly reduce bearing currents. Insulated N-end (non-drive end)
bearings protect the motor bearings.

 Requirements table
The following table shows how to select the motor insulation system and when optional
ABB du/dt filters, insulated N-end (non-drive end) motor bearings and ABB common mode
filters are required. Failure of the motor to fulfil the following requirements or improper
installation may shorten motor life or damage the motor bearings and voids the warranty.
Motor Nominal AC supply Requirement for
type voltage Motor ABB du/dt and common mode filters, insulated N-end
insulation motor bearings
system 100 kW < PN < 350 kW PN > 350 kW
or or
IEC 315 < frame size < frame size > IEC 400
IEC 400
ABB motors
Random UN < 500 V Standard +N + N + CMF
-wound
M2_,
M3_ and
M4_
Form- 380 V < UN < 690 V Standard + N + CMF PN < 500 kW:
wound +N + CMF
HX_ and PN > 500 kW
AM_ +N + du/dt + CMF
Old* 380 V < UN < 690 V Check with + N + du/dt with voltages over 500 V + CMF
form- the motor
wound manufacturer.
HX_ and
modular
Random 0 V < UN < 500 V Enamelled + N + CMF
-wound wire with fiber
HX_ and glass taping
AM_ **
HDP Consult the motor manufacturer.
* manufactured before 1.1.1998
** For motors manufactured before 1.1.1998, check for additional instructions with the motor manufacturer.
Non-ABB motors
Random UN < 420 V Standard: + N or CMF + N + CMF
-wound ÛLL = 1300 V
and 420 V < UN < 500 V Standard: + du/dt + (N or CMF) + N + du/dt + CMF
form- ÛLL = 1300 V
wound
or
Reinforced: + N or CMF + N + CMF
ÛLL = 1600 V,
0.2
microsecond
rise time
52 Guidelines for planning the electrical installation

The abbreviations used in the table are defined below.

Abbreviation 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 (option +E208)
N N-end bearing (Insulated motor non-drive end bearing)

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 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. This table shows the requirements 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
100 kW < PN < 200 kW PN > 200 kW
UN < 500 V Standard +N + 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. The table below shows the requirements for random-wound
and form-wound non-ABB motors with nominal power smaller than 350 kW. For bigger
motors, consult the motor manufacturer.
Nominal AC Requirement for
supply voltage Motor insulation system ABB du/dt filter, insulated N-end bearing and ABB
common mode filter
100 kW < PN < 350 kW or
IEC 315 < frame size < IEC 400
UN < 420 V Standard: ÛLL = 1300 V + N + CMF
420 V < UN < 500 V Standard: ÛLL = 1300 V + N + du/dt + CMF
or
Reinforced: ÛLL = 1600 V, 0.2 + N + CMF
microsecond rise time
 Guidelines for planning the electrical installation 53

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 with and without a du/dt filter in use.
To calculate the actual peak voltage for a certain cable length read the relative ÛLL/UN
value from the appropriate diagram and multiply it by the nominal supply voltage (UN).
To calculate the actual voltage rise time for a certain cable length read the relative values
ÛLL/UN and (du/dt)/UN from the appropriate diagram. Multiply the values by the nominal
supply voltage (UN) and substitute into equation t = 0.8 · ÛLL/(du/dt).

3.0 5.5
ÛLL/UN 5.0
2.5 du/dt
------------- (1/μs)
4.5 UN

2.0 4.0
3.5
1.5
3.0
ÛLL/UN
1.0 2.5
du/dt
------------- (1/μs)
UN 2.0
0.5
1.5

0.0 1.0
100 200 300 100 200 300
l (m) l (m)

Drive with du/dt filter Drive without du/dt filter

I Motor cable length
ÛLL/UN Relative peak line-to-line voltage
du/dt /UN Relative du/dt value
Note: ÛLL and du/dt values are approximately 20% higher with resistor braking.

Additional note for common mode filters

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

Selecting the power cables

 General rules
Select the input power and motor cables according to local regulations:
• Select a cable capable of carrying the drive nominal current. See section Ratings
(page 113) for the rated currents.
• Select a cable rated for at least 70 °C (158 °F) maximum permissible temperature of
conductor in continuous use. For US, see Selecting the control cables, page 56.
• The inductance and impedance of the PE conductor/cable (grounding wire) must be
rated according to permissible touch voltage appearing under fault conditions (so that
the fault point voltage will not rise excessively when a ground fault occurs).
• 600 V AC cable is accepted for up to 500 V AC.
Use symmetrical shielded motor cables (see page 55). Ground motor cable shields 360° at
both ends. Keep the motor cable and its PE pigtail (twisted shield) as short as possible to
reduce high-frequency electromagnetic emissions.
54 Guidelines for planning the electrical installation

Note: When continuous metal conduit is employed, shielded cable is not required. The
conduit must have bonding at both ends.
A four-conductor system is allowed for input cabling, but shielded symmetrical cable is
recommended.
Compared to a four-conductor system, the use of symmetrical shielded cable reduces
electromagnetic emission of the whole drive system as well as the stress on motor
insulation, bearing currents and wear.
The protective conductor must always have an adequate conductivity. The table below
shows the minimum cross-sectional area related to the phase conductor size according to
IEC 61439-1 when the phase conductor and the protective conductor are made of the
same metal.
Cross-sectional area of the phase Minimum cross-sectional area of the
conductors corresponding protective conductor
S (mm2) Sp (mm2)
S < 16 S
16 < S < 35 16
35 < S S/2

 Typical power cable sizes

The table below gives copper and aluminium cable types with concentric copper shield for
the drives with nominal current. See also Terminal and lead-through data for the power
cables on page 117.
Drive type IEC 1)
ACS580- Cu cable type Al cable
04- type
mm2 mm2
UN = 380…415 V (380, 400, 415 V)
505A-4 3 × (3×95) 3 × (3×150)
585A-4 3 × (3×120) 3 × (3×185)
650A-4 3 × (3×150) 3 × (3×240)
725A-4 3 × (3×185) 4 × (3×185)
820A-4 3 × (3×240) 4 × (3×240)
880A-4 3 × (3×240) 4 × (3×240)
UN = 440…480 V (440, 460, 480 V)
505A-4 3 × (3×95) 3 × (3×150)
585A-4 3 × (3×95) 3 × (3×150)
650A-4 3 × (3×120) 3 × (3×185)
725A-4 3 × (3×150) 3 × (3×240)
820A-4 3 × (3×185) 4 × (3×185)
880A-4 3 × (3×240) 4 × (3×240)
3AXD00000588487

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 (86 °F) PVC insulation, surface temperature 70 °C
(158 °F) (EN 60204-1 and IEC 60364-5-52). For other conditions, dimension the cables according to local
safety regulations, appropriate input voltage and the load current of the drive.
 Guidelines for planning the electrical installation 55

 Alternative power cable types

The recommended and not allowed power cable types to be used with the drive are
presented below.

Recommended power cable types

PE Symmetrical shielded cable with three phase conductors and a concentric PE

conductor as shield. The shield must agree with the requirements of
IEC 61439-1, see section Motor cable shield on page 55. Check with local /
state / country electrical codes for allowance.

Symmetrical shielded cable with three phase conductors and a concentric PE

conductor as shield. A separate PE conductor is required if the shield does not
agree with the requirements of IEC 61439-1, see section Motor cable shield on
PE page 55.

PE Symmetrical shielded cable with three phase conductors and symmetrically

constructed PE conductor, and a shield. The PE conductor must agree with the
requirements of IEC 61439-1, see section Motor cable shield on page 55.

Power cable types for restricted use

PE A four-conductor system (three phase conductors and a protective conductor on

a cable tray) is not allowed for motor cabling (allowed for input cabling).

Not allowed power cable types

Symmetrical shielded cable with individual shields for each phase conductor is
PE not allowed on any cable size for input and motor cabling.

 Motor cable shield

If the motor cable shield is used as the sole protective earth conductor of the motor, make
sure that the conductivity of the shield is sufficient. See subsection General rules above, or
IEC 61439-1. 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.
56 Guidelines for planning the electrical installation

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
All control cables must be shielded.
Use a double-shielded twisted pair cable for analog signals. We recommend this type of
cable 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. Never mix 24 V DC and
115/230 V AC signals in the same cable.

 Signals allowed to be run in the same cable

Relay-controlled signals, providing their voltage does not exceed 48 V, 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 cable length and type

In remote use, the cable connecting the control panel to the drive must not exceed three
meters (10 ft). Cable type: shielded CAT 5e or better Ethernet patch cable with RJ-45
ends.
 Guidelines for planning the electrical installation 57

 Routing the cables

Route the motor cable away from other cable routes. Motor cables of several drives can be
run in parallel when installed next to each other. The motor cable, input power cable and
control cables should be installed 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 install extra cables through the drive.
The cable trays must have good electrical bonding to each other and to the grounding
electrodes. Aluminum tray systems can be used to improve local equalizing of potential
A diagram of the cable routing is shown below.

Control cables

min 200 mm (8 in.) 90 °

Input power cable

Motor cable

Drive
Power cable min 300 mm (12 in.)

Motor cable, brake cable

min 500 mm (20 in.)

Control cables

 Separate control cable ducts

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

230 V 230 V
24 V (120 V) 24 V (120 V)
58 Guidelines for planning the electrical installation

 Continuous motor cable shield or enclosure for equipment in 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:
• European Union: Install the equipment in a metal enclosure with 360 degree
grounding for the shields of both the incoming and outgoing cable, or connect the
shields of the cables otherwise together.
• US: Install the equipment in a metal enclosure in a way that the conduit or motor cable
shielding runs consistently without breaks from the drive to the motor.

Implementing thermal overload and short-circuit

protection
 Protecting the drive and input power cable in short-circuits
Protect the drive with fuses (a) and the input cable with fuses (b) as shown below:

ACS580-04
b a
~ M
3~
~

Size the fuses or the circuit breaker at the distribution board according to local regulations
for the input cable protection. Select the fuses for the drive according to the instructions
given in chapter Technical data. The fuses for the drive protection will restrict drive
damage and prevent damage to adjoining equipment in case of a short-circuit inside the
drive.
Note 1: If the fuses for the drive protection are placed at the distribution board and the
input cable is dimensioned according to the nominal input current of the drive given in the
rating table on page 113, the fuses will protect also the input cable in short-circuit
situations, restrict drive damage and prevent damage to adjoining equipment in case of a
short-circuit inside the drive. No separate fuses for the input cable protection are needed.
Note 2: Circuit breakers must not be used without fuses. For more information, contact
ABB.

 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 dimensioned according to the nominal current of the drive. No additional
protection devices are needed.
 Guidelines for planning the electrical installation 59

 Protecting the drive and the input power and motor cables
against thermal overload
The drive protects itself and the input and motor cables against thermal overload when the
cables are dimensioned according to the nominal current of the drive. No additional
thermal protection devices are needed.

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 user can tune the thermal model
further by feeding in additional motor and load data.
The most common temperature sensors are:
• motor sizes IEC 180…225: thermal switch, eg, Klixon
• motor sizes IEC 200…250 and larger: PTC or Pt100.
See the firmware manual for more information on the motor thermal protection, and the
connection and use of the temperature sensors.

Protecting the drive against ground faults

The drive is equipped with an internal ground fault protective function to protect the drive
against ground faults in the motor and motor cable in TN (grounded) networks. This is not
a personal safety or a fire protection feature. The ground fault protective function can be
disabled with a parameter, refer to the firmware manual.
Measures for protection in case of direct or indirect contact, such as separation from the
environment by double or reinforced insulation or isolation from the supply system by a
transformer, can be applied.

 Residual current device compatibility

The drive is suitable to be used with residual current devices of Type B.
Note: The EMC filter of the drive includes capacitors connected between the main circuit
and the frame. These capacitors and long motor cables increase the ground leakage
current and can cause fault current circuit breakers to function.
60 Guidelines for planning the electrical installation

Implementing the Emergency stop function

For safety reasons, install the emergency stop devices at each operator control station
and at other operating stations where emergency stop may be needed. You can implement
the emergency stop function using the Safe torque off function of the drive module (see
chapter Safe torque off function on page 135). Design the emergency stop according to
relevant standards.

Note: Pressing the stop key on the control panel of the drive does not generate an
emergency stop of the motor or separate the drive from dangerous potential.

Implementing the Safe torque off function

See chapter Safe torque off function on page 135.

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.

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, contact ABB for
instructions.

Implementing a safety switch between the drive and the

motor
We recommended 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.
 Guidelines for planning the electrical installation 61

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 on page 61.
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 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.

WARNING! Never connect the drive output to the electrical power network. The
connection may damage the drive.
62 Guidelines for planning the electrical installation

 Example bypass connection

An example bypass connection is shown below.

Q1 Drive main switch

Q4 Bypass circuit breaker
K1 Drive main contactor
K4 Bypass contactor
K5 Drive output contactor
S11 Drive main contactor on/off control
S40 Motor power supply selection (drive or direct-on-line)
S41 Start when motor is connected direct-on-line
S42 Stop when motor is connected direct-on-line

Switching the motor power supply from drive to direct-on-line

1. Stop the drive and the motor with the drive control panel (drive in the local control
mode) or the external stop signal (drive in the remote control mode).
2. Open the main contactor of the drive with S11.
3. Switch the motor power supply from the drive to direct-on-line with S40.
4. Wait for 10 seconds to allow the motor magnetization to die away.
5. Start the motor with S41.
 Guidelines for planning the electrical installation 63

Switching the motor power supply from direct-on-line to drive

1. Stop the motor with S42.
2. Switch the motor power supply from direct-on-line to the drive with S40.
3. Close the main contactor of the drive with switch S11 (-> turn to position ST for two
seconds and leave to position 1).
4. Start the drive and the motor with the drive control panel (drive in the local control
mode) or the external start signal (drive in the remote control mode).

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]) in order
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.

230 V AC

230 V AC

+ 24 V DC

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

64 Guidelines for planning the electrical installation

Connecting a motor temperature sensor to the drive I/O

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 fulfil this requirement, the connection of a thermistor (and other similar components) to
the inputs of the drive can be implemented in three alternate ways:
1. There is double or reinforced insulation between the thermistor and live parts of the
motor.
2. Circuits connected to all digital and analog inputs of the drive are protected against
contact and insulated with basic insulation (the same voltage level as the drive main
circuit) from other low voltage circuits.
3. An external thermistor relay is used. The insulation of the relay must be rated for the
same voltage level as the main circuit of the drive. For connection, see the firmware
manual.

See also section AI1 and AI2 as Pt100, Pt1000, Ni1000, KTY83 and KTY84 sensor inputs
(ANALOG IN/OUT) on page 85.

Example circuit diagram

See page 133.
 Installation instructions 65

6
Installation instructions

Contents of this chapter

This chapter contains the general installation instructions for the drive module. The
chapter refers to the installation example chapters which contain instructions that depend
on the selected drive configuration.

Safety

WARNING! If you are not a qualified electrician do not do the installation

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

Checking the installation site

The material below the drive must be non-flammable and strong enough to carry the
weight of the drive.
See section Ambient conditions on page 120 for the allowed ambient conditions and
section Losses, cooling data and noise on page 117 for the required cooling air.
66 Installation instructions

Moving and unpacking the unit

WARNING! Obey the safety instructions in chapter Safety instructions. If you

ignore them, injury or death, or damage to the equipment can occur.

Move the transport package by pallet truck to the installation site.

Unpack the package as follows (see the package drawing on page 67):
• Cut the bands (A).
• Unpack the additional boxes (B).
• Remove the outer sheathing by lifting it (C).
• Remove the sheathing by lifting it (D).
• Remove the pedestal guide plate (not included with options +0H354 and +0P919) as
shown below.
 Installation instructions 67

B 2

C
A

3AUA0000101742

Transport package contents

1 With option +B051: Clear plastic shrouds.
See below for the box contents.
2 With standard drive module configuration: Output cable connection terminals. With option +H370 also
Input cable connection terminals.
See below for the box contents.
3 Plywood support
4 Drive module with factory installed options and multilingual residual voltage warning sticker, top guide
plate, pedestal guide plate, telescopic ramp package, fastening screws in a plastic bag, control unit
options, delivery documents, printed multilingual installation and start-up quick guide. Other printed
manuals if ordered.
5 Pallet
68 Installation instructions

3
Box B1 contents (option +B051)
1 Paper fill
2 Clear plastic shroud for output
cabling
1 3 Cardboard box cover
4 Cardboard box bottom
12 13 5 Support
7 9 6 Bands
7 Back clear plastic shroud (lower)
8
11 8 Back clear plastic shroud (upper)

10 9 Front clear plastic shroud

2 10 Clear plastic shroud for input
6 cabling
15
11 Top clear plastic shroud
12 Clear plastic shroud for input
cable lead-through from side
13 Screws in a plastic bag
14 14 Metallic shroud
15 Bottom grille and mounting
5 bracket
4
3AXD50000009484

3 1
Box B2 contains this box with
standard drive module
7 configuration
4
1 Paper fill

2 2 Output cable connection terminal

5 T3/W2
3 Output cable connection terminal
T2/V2
4 Output cable connection terminal
T1/U2
5 Grounding terminal
6
6 Cardboard box
7 Screws and insulators a plastic
bag

33AXD5000009515
 Installation instructions 69

2
Box B2 contains additionally this
box with option +H370
7
1 Metallic shroud with ground bar
4 5 2 Paper fill
3 Input cable connection terminal
3 1
L3/W1
4 Input cable connection terminal
L2/V1
5 Input cable connection terminal
L1/U1
6 6 Cardboard box
7 Screws and insulators in a plastic
bag

33AXD5000009522

1
2 Ramp box contents
1 Screw package
2 Telescopic extraction and
insertion ramp
3 Cardboard box

3AXD50000010005
70 Installation instructions

2
1 Accessories box contents
1 Screw package
2 Feed through
3 3 Bracket for attaching the drive
module from top to Rittal cabinet
4 punched section. See page 73.
4 Support bracket for attaching the
drive module from top to a
mounting plate or wall. The
bracket brings a gap for cooling
air flow and prevents the drive
5 module screws from chafing the
plate. See page 73
5 Cardboard box

3AUA0000100915

Checking the delivery

Check that all items listed in section Moving and unpacking the unit are present.
Check that there are no signs of damage. Before attempting installation and operation,
check the information on the type designation label of the drive to verify that the unit is of
the correct type.

Installing the motor cable at the motor end

Ground the motor cable shield 360 degrees at the lead-through of the motor terminal box.
 Installation instructions 71

Checking the insulation of the assembly

 Drive
Do not make any voltage tolerance 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.

 Input cable
Check the insulation of the input cable according to local regulations before connecting it
to the drive.

 Motor and motor cable

Check the insulation of the motor and motor cable as follows:
1. Check that the motor cable is disconnected from the drive output terminals T1/U2,
T2/V2 and T3/W2.
2. Measure the insulation resistance between each phase conductor and the Protective
Earth conductor using a measuring voltage of 1000 V DC. The insulation resistance of
an ABB motor must exceed 100 Mohm (reference value at 25 °C or 77 °F). For the
insulation resistance of other motors, consult the manufacturer’s instructions. Note:
Moisture inside the motor casing will reduce the insulation resistance. If you suspect
moisture, dry the motor and repeat the measurement.

U1
M
V1
3~
ohm W1
PE

Installation alternatives
You can install the drive module into a cabinet using different procedures depending on the
drive configuration. Obey the general power and control cable installation instructions that
we give in this chapter and see the installation example of your drive configuration in the
following chapters.

 Standard drive module configuration and option +B051

For an installation example on how to install the drive module into a Rittal TS 8 cabinet,
see chapter Installation example of drive module with IP20 shrouds (option +B051) on
page 89. See also ACS580-04 drive modules (200 to 560 kW, 300 to 700 hp) quick
installation guide (3AXD50000015469 [English]).

 Optional input power cable connection terminals and

ground busbar assembly (+H370)
Connect the input power cable connection terminals as shown in chapter Step-by-step
drawings for an installation example of drive module with options +B051 and +E208 in
Rittal TS 8 600 mm wide cabinet on page 149.
72 Installation instructions

Install the metallic shroud with ground bar as shown below.

Combi screw M4×8

Torx T20 2 N·m

3AXD50000017460

 Drive module without output cable connection terminals (option

+0H371)
The power cables can be connected directly to the drive module input and output terminals
with cable lugs or by busbars.

 Drive module without pedestal (option +0H354)

The drive module without pedestal can be mounted on a wall or a cabinet with four screws
through the fastening holes at the top and bottom of the module.
Make sure that the cabinet mounting plate and frame are strong enough to carry the
weight of the drive module. See section Dimensions, weights and free space requirements
on page 116.
 Installation instructions 73

 Attaching the drive module to a mounting plate or wall

Use the support bracket if you attach the drive module directly to a mounting plate or wall.
The support bracket prevents the drive module screws from chafing against the plate.

M4×12 Torx

 Alternatives for grounding the drive module

You can ground the drive module from its top back to the cabinet frame with these
alternatives:
1. from the grounding hole
2. to a Rittal punched section: with the fastening bracket.

Tapping screw M6×12 Torx T30 (Hex) 9 N·m

74 Installation instructions

 Installing the bottom grille (for IP20 degree protection)

For option +B051: If IP20 degree of protection is needed from the bottom side, install the
bottom grille as shown below.

Insert lifting hooks to the drive module lifting eyes and lift the module to the installation
place.
 Installation instructions 75

Connecting the power cables

 Connection diagram

(PE) PE (PE) L1 L2 L3

2a 2b

L1 L2 L3
PE
1

ACS580-04
L1/ L2/ L3/
UDC- UDC+
U1 V1 W1
INPUT
PE
OUTPUT
T1/ T2/ T3/
U2 V2 W2
9
6

V1
U1 W1
5
3 ~
M

1 For alternatives, see section Selecting the supply disconnecting device on page 50. In the installing
example of this chapter, the disconnecting device is not in the same cubicle with the drive module.
2 If a shielded cable is used (not required but recommended) and the conductivity of the shield is
< 50% of the conductivity of the phase conductor, use a separate PE cable (2a) or a cable with a
grounding conductor (2b).
3 We recommend 360-degree grounding at the cabinet entry if a shielded cable is used. Ground the
other end of the input cable shield or PE conductor at the distribution board.
4 We recommend 360-degree grounding at the cabinet entry, see page 40.
76 Installation instructions

5 Use a separate grounding cable if the conductivity of the cable shield is < 50% of the conductivity of
the phase conductor and there is no symmetrically constructed grounding conductor in the cable
(see page 55).
6 Common mode filter (optional, see page 50)
7 du/dt filter (optional, see page 147)
8 EMC filter (option +E210)
9 The drive module frame must be connected to the cabinet frame. See section Arranging the
grounding inside the cabinet on page 39 and Alternatives for grounding the drive module on page
73.
Note:
If there is a symmetrically constructed grounding conductor in 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
increases bearing currents and causes extra wear.

 Power cable connection procedure

WARNING! Obey the safety instructions in chapter Safety instructions. If you

ignore them, injury or death, or damage to the equipment can occur.

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

1. Run the motor cables from the motor to the cabinet. We recommend to ground the
cable shields 360° at the lead-through plate.

1
2 1 Cable
2 Cable tie
3 Strain relief
3 4 Bare cable shield
5 Knitted wire mesh
4
6 Cabinet lead-through plate
5
6
 Installation instructions 77

2. Twist the cable shields of the motor cables into bundles and connect them and any
separate ground conductors or cables to the grounding terminal of the drive module or
to the cabinet ground bar.

PE PE

3. Connect the phase conductors of the motor cables to terminals T1/U2, T2/V2 and
T3/W2 of the drive module. For the tightening torques, see page 117.
4. Make sure that all power is disconnected and reconnection is not possible. Use proper
safe disconnect procedures according to local codes.
5. Run the input cables from the supply source to the cabinet. If shielded cable is used:
we recommend to ground the cable shields 360° at the lead-through plate.
6. If shielded cable is used: twist the cable shields of the input cables into bundles and
connect them and any separate ground conductors or cables to the drive module
grounding terminal or to the cabinet PE busbar.
7. Connect the phase conductors of the input cables to terminals L1/U1, L2/V1 and
L3/W1 of the drive module. For the tightening torques, see page 117.

 DC connection
The UDC+ and UDC– terminals are intended for common DC configurations of a number
of drives, allowing regenerative energy from one drive to be utilized by the other drives in
the motoring mode. For more information, contact your local ABB representative.
78 Installation instructions

Connecting the control cables

1. Remove the middle front cover of the drive module.

1
2 × Combi screw
M4×8 Torx T20
2 N·m
3

2. Attach the option modules if not attached already. See section Installing optional
modules on page 86.
3. Lead the control cables inside the drive cabinet.
4. Ground the outer control cable shields 360 degrees at the cabinet lead-through plate
(recommendation).
5. Route the control cables along the control cable duct from bottom or top to the control
unit.
 Installation instructions 79

6. Ground the shields of the control cables at the clamp plate. The shields should be
continuous as close to the terminals of the control unit as possible. Only remove the
outer jacket of the cable at the cable clamp so that the clamp presses on the bare
shield. The shield (especially in case of multiple shields) can also be terminated with a
lug and fastened with a screw at the clamp plate. Leave the other end of the shield
unconnected or ground it indirectly via a few nanofarads high-frequency capacitor, 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.Tighten the
screws to secure the connection.

7. Connect the conductors to the appropriate detachable terminals of the control unit.
See section Default I/O connection diagram (ABB standard macro) on page 80 for the
default I/O connections of the ABB standard macro. For other macros, see the
firmware manual. Use shrink tubing or insulating tape to contain any stray strands.
Tighten the screws to secure the connection.
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.
80 Installation instructions

 Default I/O connection diagram (ABB standard macro)

The default I/O connections of the ABB Standard macro are shown below.
Analog input 1
1…10 kohm 1 SCR Signal cable shield (screen)
2 AI1 Output frequency/speed reference 1: 0…10 V 5)
3 AGND Analog input circuit common
AI1 AI1 Current/Voltage selection for analog input 1 1)
Analog input 2
4 +10V Reference voltage 10 V DC
5 AI2 Not configured
6 AGND Analog input circuit common
AI2 AI2 Current/Voltage selection for analog input 2 2)
Analog outputs
7 AO1 Output frequency: 0…20 mA
8 AO2 Output current: 0…20 mA
9 AGND Analog output circuit common
Max. 500 ohm AO1 AO1 Voltage/Current selection for analog output 1 3)
10)
Auxiliary voltage output
10 +24V Auxiliary voltage output +24 V DC, max. 250 mA 4)
11 DGND Auxiliary voltage output common
8) 12 DCOM Digital input common for all
Programmable digital inputs DI1…DI3
13 DI1 Stop (0) / Start (1)
14 DI2 Forward (0) / Reverse (1)
15 DI3 Constant frequency/speed selection 6)
Programmable digital inputs DI4…DI6
16 DI4 Constant frequency/speed selection 6)
17 DI5 Ramp set1 (0) / Ramp set 2 (1) 7)
9)
18 DI6 Not configured
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
EIA/5-485
29 B+
30 A- Embedded Modbus/RTU (EIA-485)
31 DGND
TERM TERM Serial data link termination switch
BIAS BIAS Serial data link bias resistors switch
Safe torque off
34 OUT1
Safe torque off. Factory connection: Both circuits must be
35 OUT2
closed for the drive to start. See chapter The Safe torque
8) 36 SGND
off function in ACS580-04 hardware manual
37 IN1
3AXD50000015497 [English])
38 IN2
External power input
40 24V AC/DC+ 24 V AC/DC, 1.5 A
41 24V AC/DC-

Wire sizes: 0.14…2.5 mm2 (all terminals)

Tightening torques: 0.5…0.6 N·m (0.4 lbf·ft)
 Installation instructions 81

Notes:
1)
Current [0(4)…20 mA, Rin = 100 ohm] or voltage [0(2)…10 V, Rin > 200 kohm] input selected with switch
AI1. Change of setting requires changing the corresponding parameter.
2)
Current [0(4)…20 mA, Rin = 100 ohm] or voltage [ 0(2)…10 V, Rin > 200 kohm] input selected with switch
AI2. Change of setting requires changing the corresponding parameter.
3) Current [0(4)…20 mA, Rin = 100 ohm] or voltage [ 0(2)…10 V, Rin > 200 kohm] output selected with switch
AO1. Change of setting requires changing the corresponding parameter.
4) 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.
5)AI1 is used as a speed reference if vector control is selected.
6)
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 setting - Start, stop, reference - Constant speeds or parameter
group 22 Speed reference selection.

DI3 DI4 Operation/Parameter

Scalar control (default) Vector control
0 0 Set frequency through AI1 Set speed through AI1
1 0 28.26 Constant frequency 1 22.26 Constant speed 1
0 1 28.27 Constant frequency 2 22.27 Constant speed 2
1 1 28.28 Constant frequency 3 22.28 Constant speed 3

7)In scalar control (default): See Menu - Primary settings - Ramps or parameter group 28 Frequency
reference chain.
In vector control: See Menu - Primary settings - Ramps or parameter group 23 Speed reference ramp.

DI5 Ramp Parameters

set Scalar control (default) Vector control
0 1 28.72 Freq acceleration time 1 23.12 Acceleration time 1
28.73 Freq deceleration time 1 23.13 Deceleration time 1
1 2 28.74 Freq acceleration time 2 23.14 Acceleration time 2
28.75 Freq deceleration time 2 23.15 Deceleration time 2

8)Connected with jumpers at the factory.

9)Note:
Use shielded twisted-pair cables for digital signals.
10)
Ground the outer shield of the cable 360 degrees under the grounding clamp on the grounding shelf for the
control cables.

Further information on the usage of the connectors and switches is given in the sections
below.
82 Installation instructions

Switches
Switch Description Position
AI1 Determines whether analog input AI1 is used as a voltage or I Voltage (U) (default)
current input. U
AI1
I Current (I)
U
AI1
AI2 Determines whether analog input AI2 is used as a voltage or I Voltage (U)
current input. U
AI2
I Current (I) (default)
U
AI2
AO1 Determines whether analog output AO1 is used as a current I Current (I) (default)
or voltage output. U
AO1
I Voltage (U)
U
AO1
TERM Drive-to-drive link termination. Must be set to the terminated ON Bus not terminated
(ON) position when the drive (or another device) is the first or (default)
last unit on the link. TERM
ON Bus terminated

TERM
BIAS Switches on the biasing voltages to the bus. One (and only ON Bias off (default)
one) device, preferably at the end of the bus must have the
bias on. BIAS
ON Bias on

BIAS

PNP configuration for digital inputs (DIGITAL IN)

Internal and external +24 V power supply connections for PNP configuration are shown in
the figure 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 +24 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
 Installation instructions 83

NPN configuration for digital inputs (DIGITAL IN)

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)

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

Connection for obtaining 0…10 V from analog output 2 (ANALOG IN/OUT)

To obtain 0…10 V from analog output AO2, connect a 500 ohm resistor (or two 1 kohm
resistors in parallel) between the analog output 2 AO2 and analog common ground AGND.
Examples are shown in the figure below.

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.

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.
84 Installation instructions

Connection examples of two-wire and three-wire sensors

Hand/Auto, Hand/PID, and PID macros use analog input 2 (AI2). The macro wiring
diagrams on these pages use an externally powered sensor (connections not shown). The
figures below give examples of connections using a two-wire or three-wire
sensor/transmitter supplied by the drive auxiliary voltage output.
Note: Maximum capability of the auxiliary 24 V DC (250 mA) output must not be
exceeded.

Two-wire sensor/transmitter

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

Note: 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.

Three-wire sensor/transmitter

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.
 Installation instructions 85

AI1 and AI2 as Pt100, Pt1000, Ni1000, KTY83 and KTY84 sensor inputs
(ANALOG IN/OUT)
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. Do not connect both ends of the cable shields
directly to ground. If a capacitor cannot be used at one end, leave that end of the shield
unconnected.

1…3 × (Pt100 or Pt100) or

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

T T T XAO
2)
AOn
AGND

3.3 nF
> 630 V AC

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 the 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 (STO)

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 Safe torque off function on page 129.
Note: Only 24 V DC can be used for STO. Only PNP input configuration can be used.
86 Installation instructions

Installing optional modules

Disconnect the drive from the power line. Lock the main disconnecting device and ensure
by measuring that there is no voltage.

 Option slot 3 (embedded fieldbus adapter modules)

The drive is delivered with the standard embedded fieldbus adapter module CEIA-01
installed. If you have ordered another optional module, remove the CEIA-01 module by
carefully bending the retaining clips to the sides while pulling the module outward, and put
the other module carefully into its position.

 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). Note: The screw grounds the module. It is
necessary for fulfilling the EMC requirements and for proper operation of the module.

 Option slot 1 (fieldbus adapter modules)

1. Put the module carefully into its position on the control unit.
2. Tighten the mounting screw (CHASSIS). Note: The screw tightens the connections
and grounds the module. It is necessary for fulfilling the EMC requirements and for
proper operation of the module.

 Wiring the optional modules

See the appropriate optional module manual for specific installation and wiring
instructions.
 Installation instructions 87

Connecting a PC
You need a control panel to connect a PC to the drive module.
To connect a PC to the control panel with a USB data cable (USB Type A <-> USB Type
Mini-B):
1. Lift the USB connector cover on the control panel from bottom upwards.
2. Insert the USB cable Mini-B plug in the control panel USB connector.
3. Insert the USB cable A-plug in the USB connector of the PC (a). -> The panel displays:
USB connected (b).

USB connected
3b

Stop Loc/Rem Start

1 2a

1
?

Stop Loc/Rem Start

3a

Note: When a PC is connected to the control panel, the control panel keypad is disabled.
In this case, the control panel acts as a USB-RS485 adapter.
For information on using the Drive composer PC tool, see Drive composer PC tool user's
manual (3AUA0000094606 [English]).
88 Installation instructions
 Installation example of drive module with IP20 shrouds (option +B051) 89

7
Installation example of drive
module with IP20 shrouds
(option +B051)

Contents of this chapter

In this chapter, the drive module with IP20 shrouds (option +B051) is installed in a 600 mm
wide Rittal TS 8 cabinet in a bookshelf way of mounting. The module is placed in an
upright position on the cabinet bottom with its front facing the cabinet door.

Limitation of liability
Always obey the general rules given in this chapter and local laws and regulations. ABB
does not assume any liability whatsoever for any installation which breaches local laws
and/or other regulations.

Safety

WARNING! If you are not a qualified electrician do not do the installation

work described in this chapter. Obey the instructions in chapter Safety
instructions. If you ignore them, injury or death, or damage to the
equipment can occur.
90 Installation example of drive module with IP20 shrouds (option +B051)

Required parts
Drive module standard parts
• Drive module
• Fastening bracket
• Pedestal guide plate
• Telescopic extraction and insertion ramp
• Fastening screws and insulators in a plastic bag
• External control unit
Rittal parts
Rittal part code Qty Description
(pcs)
TS 8606.500 1 Enclosure without mounting plate, bottom plates and side panels.
TS 8612.160 5 Punched section with mounting flange, outer mounting level for 600 mm
horizontal
TS 4396.500 Support rails
SK 3243.200 4 Air filter 323 mm × 323 mm. Remove the filter mats.
Customer-made parts (not ABB or Rittal products)
Air baffles 2 See section Preventing the recirculation of hot air on page 43 and section Air
baffles for the drive module with option +B051 on page 132.

Required tools
• Set of screw drivers (Torx and Pozidriv)
• Set of metric magnetic-end hexagon sockets
• Torque wrench
• Step drill bit for drilling the holes in the clear plastic shroud for input power cables.

Overall flowchart of the installation process

Step Task For instructions, see

1 Install the Rittal parts, drive bottom guide plate Installing the drive module into a cabinet on
and loose drive options in the drive module page 91 and installation drawings on page
cubicle. 151.

2 Install the auxiliary components (such as The component manufacturer’s instructions

mounting plates, air baffles, switches, busbars Preventing the recirculation of hot air on page
etc.). 43.

Attach the drive module to the cabinet Step-by-step drawings for an installation
example of drive module with options +B051
3 Connect the power cables and clear plastic and +E208 in Rittal TS 8 600 mm wide cabinet
shrouds to the drive module. on page 151.
Connecting the power cables and installing the
shrouds on page 91

6 Connect the control cables. Connecting the control cables, page 78

7 Install the remaining parts, for example, cabinet The component manufacturer’s instructions.
doors, side plates, etc. Installing the roof and door on page 93
 Installation example of drive module with IP20 shrouds (option +B051) 91

Installing the drive module into a cabinet

See appendix Step-by-step drawings for an installation example of drive module with
options +B051 and +E208 in Rittal TS 8 600 mm wide cabinet on page 151 and ACS580-
04 quick installation guide (3AXD50000015469 [English]).
• Install the punched section to the back of the cabinet frame.
• Install the support rails and pedestal guide plate to the cabinet bottom frame.
• Install the telescopic insertion ramp to the pedestal guide plate.
• Remove the sheeting from the clear plastic shrouds from both sides.
• Install the top metallic shroud to the drive module.
• Install the back shrouds to the drive module.
• To prevent the drive module from falling, attach its lifting lugs with chains to the cabinet
frame.
• Push the drive module carefully into the cabinet along the telescopic insertion ramp.
• Remove the ramp.
• Fasten the drive module to the pedestal guide plate.
• Fasten the drive module from top to the punched section at the cabinet back. Note:
The fastening bracket grounds the drive module to the cabinet frame.
• Install the air baffles. See section Preventing the recirculation of hot air on page 43.

Connecting the power cables and installing the shrouds

Step Task (motor cables)
1 Install the grounding terminal to the drive module base.
2 Run the motor cables to the cabinet. Ground the cable shields 360 degrees at the cabinet lead-
through
3 Connect the twisted shields of the motor cables to the grounding terminal
4 Screw in and tighten the insulators to the drive module by hand. Install the T3/W2 connection
terminal to the insulators.
WARNING! Do not use longer screws or bigger tightening torque than given in the
installation drawing. They can damage the insulator and cause dangerous voltage to
be present at the module frame.

5 Connect the phase T3/W2 conductors to the T3/W2 terminal.

6 Install the T2/V2 connection terminal to the insulators See the warning in step 4.
7 Connect the phase T2/V2 conductors to the T2/V2 connection terminal.
8 Install the T1/U2 connection terminal to the insulators. See the warning in step 4.
9 Connect the phase T1/U2 conductors to the T1/U2 terminal.
10 Remove the plastic sheeting from the output clear plastic shroud from both sides.
11 Install the shroud to the drive module.
12 Install the lower front cover to the drive module.

Step Task (input cables)

1 Ground the input cable shields (if present) 360 degrees at the cabinet lead-through.
2 Connect the twisted shields of the input cables and separate ground cable (if present) to the cabinet
grounding busbar.
92 Installation example of drive module with IP20 shrouds (option +B051)

Step Task (input cables)

3 Step drill carefully sufficiently big holes to the lead-through clear plastic shroud for the cables to the
connected. Align the holes in the vertical direction according to the alignment holes in the shroud.
Smooth the hole edges.
Remove the plastic sheeting from both sides of the shroud.
Attach the cables firmly to the cabinet frame to prevent chafing against the hole edges.
4 Put the conductors of the input cables through the drilled holes in the clear plastic shroud.
5 For drive modules without option +H370: Connect the input cable conductors to the drive module
L1/U1, L2/V1 and L3/W1 connection busbars, Go to step 12.
For option +H370: Do steps 6 to 11.
6 Screw in and tighten the insulators to the drive module by hand. Install the L1/U1 connection
terminal to the insulators.
WARNING! Do not use longer screws or bigger tightening torque than given in the
installation drawing. They can damage the insulator and cause dangerous voltage to
be present at the module frame.

7 Connect the L1/U1 conductors to the L1/U1 connection terminal.

8 Install the L2/V1 connection terminal to the insulators. See the warning in step 5.
9 Connect the L2/V1 conductors to the L2/V1 connection terminal.
10 Install the L3/W1 connection terminal to the insulators. See the warning in step 5.
11 Connect the L3/W1 conductors to the L3/W1 connection terminal.
12 Install the lead-through clear plastic shroud. Install the front clear plastic shroud and upper front
cover. Remove the cardboard protective covering from the drive module air outlet.
13 Install the side and top clear plastic shrouds to the drive module.
 Installation example of drive module with IP20 shrouds (option +B051) 93

Installing the roof and door

Install the air inlet gratings to the cabinet door and the spacers on top of the cabinet as
shown below.

Rittal 7967.000

Rittal 3326.200
1978 [77.85]

592 [23.31]

3AUA0000145776

1 Door
2 Install these gratings as close to each other as possible. Remove the filter mats.
94 Installation example of drive module with IP20 shrouds (option +B051)

Miscellaneous
 Input power cable lead-through from top
If you run the input cables from top to the drive module, drill the lead-through holes to the
top clear plastic shroud.

 Attaching the drive module to a mounting plate

Use the assembly support if you attach the drive module directly to the cabinet back plate.
The support prevents the drive module screws from chafing the plate.

M4×12 Torx
 Installation checklist 95

8
Installation checklist

Contents of this chapter

This chapter contains a list for checking the mechanical and electrical installation of the
drive module.

Installation checklist
Go through the checklist below together with another person.

WARNING! Obey the safety instructions in chapter Safety instructions. If

you ignore them, injury or death, or damage to the equipment can occur.

Check that …

Cabinet construction

The drive module is fastened properly to the cabinet. (See chapters Guidelines for planning the
cabinet installation, Installation example of drive module with IP20 shrouds (option +B051).

Mechanical joints are tightened and not broken.

Parts are clean and painted surfaces not scratched.

The cabinet frame and parts which are in metal to metal contact with the frame (for example seams,
component fixing points on assembly plates, back of control unit mounting plate) are not finished
with non-conducting paint or material.

Degree of protection (IPxx)

96 Installation checklist

Check that …

Drive option modules and other components

Type and number of option modules and other equipment is correct. Option modules and other
equipment are not damaged.

Optional modules and terminals are labelled correctly.

The placement of optional modules and other equipment inside the cabinet and on the cabinet door
is correct.

The mounting of optional modules and other equipment is correct.

Internal cabling of the cabinet assembly

Main circuit:
• AC supply input cabling is ok.
• AC output cabling is ok.
• Supply for brake resistor (if used) is ok.

Cable types, cross-sections, colours and optional markings are correct.

Cabling is not susceptible to interference. Check the twisting of cables and cable routes.

Connection of cables to devices, terminal blocks and drive module circuit boards:
• Cables are connected to terminals tight enough by pulling the cable.
• Cable termination on terminals chaining is done correctly.
• Bare conductors are not too far outside the terminal causing an insufficient clearance or loss of
shielding against contact.
• The control unit is wired properly to the drive module.
• The control panel cable is connected properly.

Cables are not lying against sharp edges or bare live parts. Bending radius of fiber optic cables is at
least 3.5 cm (1.38 in.).

The type, markings, insulation plates and cross connections of terminal blocks are correct.

Grounding and protection

The grounding colors, cross-section and grounding points of modules and other equipment match
the circuit diagrams. No long routes for pigtails.

Connections of PE cables and busbars are tight enough. Pull the cable to test that it does not loosen.
No long routes for pigtails.

Doors equipped with electrical equipment are grounded. No long grounding routes. From EMC
standpoint best result is achieved with a flat copper braid.

Fans that can be touched are shrouded.

Live parts inside the doors are protected against direct contact to at least IP2x.

Labels

The type designation labels and warning and instruction stickers are made according to the local
regulations and placed correctly.

Switches and doors

Mechanical switches, main disconnecting switch and cabinet doors function properly.
 Installation checklist 97

Check that …

Installation of the cabinet

The drive cabinet has been attached to floor and also from top to the wall or roof.

The ambient operating conditions agree with the specifications given in chapter Technical data.

The cooling air will flow freely in and out of the drive cabinet, and air recirculation inside the cabinet
will not be possible (air baffle plates are on place).

If the drive module has been stored over one year: The electrolytic DC capacitors in the DC link of
the drive have been reformed. See page 110.

There is an adequately sized protective ground conductor between the drive and the switchboard.

There is an adequately sized protective ground conductor between the motor and the drive.

All protective ground conductors have been connected to the appropriate terminals and the terminals
have been tightened. (Pull the conductors to check.)

The enclosures of the equipment in the cabinet have proper galvanic connection to the cabinet
protective earth (ground) busbar; The connection surfaces at the fastening points are bare
(unpainted) and the connections are tight, or separate grounding conductors have been installed.

The supply voltage matches the nominal input voltage of the drive. Check the type designation label.

The input power cable has been connected to the appropriate terminals, the phase order is right, and
the terminals have been tightened. (Pull the conductors to check.)

Appropriate AC fuses and a main disconnector have been installed.

The motor cable has been connected to the appropriate terminals, the phase order is right, and the
terminals have been tightened. (Pull the conductors to check.)

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 (if any) have been connected to the appropriate terminals, and the terminals have
been tightened. (Pull the conductors to check.)

If a drive bypass connection is used: The direct-on-line contactor of the motor and the drive output
contactor are either mechanically or electrically interlocked, ie, cannot be closed simultaneously.

There are no tools, foreign objects or dust from drilling inside the drive module.

All shrouds and cover of the motor connection box are in place. Cabinet doors have been closed.

The motor and the driven equipment are ready for start.
98 Installation checklist
 Start-up 99

9
Start-up

Contents of this chapter

This chapter describes the start-up procedure of the drive.

Start-up procedure
1. Only qualified electricians are allowed to start-up the drive.
2. Make sure that the installation of the drive module has been checked according to the
checklist in chapter Installation checklist, and that the motor and driven equipment are
ready for start.
3. Perform the start-up tasks instructed by the cabinet-installer of the drive module.
4. Switch the power on, setup the drive control program, and perform the first start of the
drive and motor. See the ACS580-04 quick installation and start-up guide
(3AXD50000015469 [English]) or ACS580 firmware manual (3AXD50000016097
[English]). If you need more information on the use of the control panel, see ACS-AP-x
Assistant control panels user's manual (3AUA0000085685 [English]).
For drive modules in which the Safe torque off function is in use: Test and validate the
operation of the Safe torque off function. See section Start-up including acceptance test on
page 142.
100 Start-up
 Fault tracing 101

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 control program
warning and fault messages.
102 Fault tracing
 Maintenance 103

11
Maintenance

Contents of this chapter

This chapter contains maintenance instructions of the drive module.

Maintenance intervals
If installed in an appropriate environment, the drive requires very little maintenance. The
table below lists the routine maintenance intervals recommended by ABB.
The recommended maintenance intervals and component replacements are based on
specified operational and environmental conditions. ABB recommends annual drive
inspections to ensure the highest reliability and optimum performance. Consult your local
ABB Service representative for more details on the maintenance. On the Internet, go to
www.abb.com/searchchannels.
104 Maintenance

 Preventive maintenance interval table

The table below shows the intervals for the preventive maintenance tasks allowed for the
customer. For other maintenance tasks, consult your local ABB Service representative, or
see the complete maintenance table on the Internet.
Component Years from start-up
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 …
Cooling
Main cooling fan of the drive R R
module (frames R10 and R11)
Auxiliary cooling fan of the R R R
circuit board compartment
(frames R10 and R11)
Batteries
Control panel battery R R
Connections and environment
Quality of supply voltage O O O O O O O O O O O O O O O O O O O
Tightness of terminals I I I I I I I I I I I I I I I I I I I
Dustiness, corrosion and I I I I I I I I I I I I I I I I I I I
temperature
Spare parts
Spare parts I I I I I I I I I I I I I I I I I I I
DC circuit capacitors O O O O O O O O O O O O O O O O O O O
reforming, spare modules and
spare capacitors
Other useful tasks
Heatsink cleaning. O O O O O O O O O O O O O O O O O O O
4FPS10000326772

Symbols
I Inspection, maintenance action if needed
(I) Inspection in harsh conditions*, maintenance action if needed
R Replacement
(R) Replacement in harsh conditions*
O Other work (commissioning, tests, measurements, etc.)
* Ambient temperature constantly over 40 ˚C, especially dusty or humid ambient conditions, cyclic heavy load,
or continuous nominal (full) load.
To maintain the best possible performance and reliability of the drive, inspect it annually. Contact ABB Service
at least once in three years for replacement of aging components.
Note: Recommended maintenance intervals and component replacements are based on operation in specified
ambient conditions.
 Maintenance 105

Cabinet
 Cleaning the interior of the cabinet

WARNING! Obey the safety 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 Precautions before electrical work on page
14 before you start the work.
2. Make sure that the drive is disconnected from the power line and all other precautions
described under Grounding on page 16 have been taken into consideration.
3. When necessary, clean the interior of the cabinet with a soft brush and a vacuum
cleaner.
106 Maintenance

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

 Cleaning the interior of the heatsink

WARNING! Obey the safety 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 Precautions before electrical work on page
14 before you start the work.
2. Make sure that the drive is disconnected from the power line and all other precautions
described under Grounding on page 16 have been taken into consideration.
3. Undo the fastening 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.

5
6
3
 Maintenance 107

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

 Replacing the circuit board compartment cooling fan

WARNING! Obey the safety 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 Precautions before electrical work on page
14 before you start the work.
2. Remove the drive module out of the cabinet. See section Replacing the drive module
on page 109.
3. Undo the fastening screw of the fan enclosure.
4. Unplug the power supply cable of the fan.
5. Install the new fan in reverse order to the above.

3
108 Maintenance

 Replacing the main cooling fans

WARNING! Obey the safety 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 Precautions before electrical work on page
14 before you start the work.
2. Remove the drive module out of the cabinet. See section Replacing the drive module
on page 109.
3. Open the support legs of the pedestal.
4. Undo the two screws that fasten the fan assembly plate.
5. Tilt the fan assembly plate down.
6. Disconnect the power supply wires of the fans.
7. Remove the fan assembly from the drive module.
8. Undo the fastening screws of the fan(s) and remove the fan(s) from the assembly
plate.
9. Install the new fan(s) in reverse order to the above.

5 6

8
4 4

3 3
 Maintenance 109

Replacing the drive module

WARNING! Obey the safety 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 prevent foot injury.
• Lift the drive module only by the lifting lugs.
• Make sure that the module does not topple over when you move it on the floor:
Open the support legs by pressing each leg a little down (1, 2) and turning it aside.
Whenever possible secure the module also with chains.
• Do not tilt the drive module (A). It is heavy and its center of gravity is high. The
module overturns from a sideways tilt of 5 degrees. Do not leave the module
unattended on a sloping floor.

1
A
3

1. Stop the drive and do the steps in section Precautions before electrical work on page
14 before you start the work.
2. Make sure that all other precautions described under Grounding on page 16 have
been taken into consideration.
3. For option +B051, remove the clear plastic shrouds on the power cables and parts in
front of the drive module.
4. Disconnect the power cables.
5. Disconnect the external control cables from the drive module.
6. Remove the screws that attach the drive module to the cabinet at the top and behind
the front support legs.
7. Attach the extraction ramp to the cabinet base with two screws.
8. To prevent the drive module from falling, attach its top lifting lugs with chains with
chains to the cabinet frame.
9. Pull the drive module carefully out of the cabinet preferably with help from another
person.
10. Install the new module in reverse order to the above.
110 Maintenance

Capacitors
The drive intermediate circuit employs several electrolytic capacitors. Their lifespan
depends on the operating time of the drive, loading and ambient temperature. The lifespan
of the capacitor can be prolonged by lowering the ambient temperature.
It is not possible to predict a capacitor failure. The capacitor failure is usually followed by
damage to the unit and an input cable fuse failure, or a fault trip. Contact ABB if a capacitor
failure is suspected. Replacements are available from ABB. Do not use other than ABB
specified spare parts.

 Reforming the capacitors

If the drive module has been stored for a year or more, reform the capacitors. See page 32
for information on finding out the manufacturing date. For the reforming instructions, see
Converter modules with electrolytic DC capacitors in the DC link, capacitor reforming
instructions (3BFE64059629 [English]).
 Maintenance 111

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 in memory 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. Remove the control panel from the drive.
Press the retaining clip at the top (1a) and pull it forward from the top edge (1b).

1a

1b

2. To remove the battery, use a coin to rotate the battery cover on the back of the control
panel.
3. Replace the battery with type CR2032. Dispose the old battery according to local
disposal rules or applicable laws.

2
112 Maintenance

4. To reinstall the control panel, put the bottom of the container in position (1a), press the
retaining clip at the top (1b) and push the control panel in at the top edge (1c).

1b

1c

1a

For the use of the control panel, see ACS580 firmware manual (3AXD50000016097
[English]) and ACS-AP-X assistant control panels user’s manual (3AUA0000085685
[English]).
 Technical data 113

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 ratings of the drive modules with 50 Hz supply are given below.

 IEC ratings
IEC RATINGS
Drive type Frame Input Output ratings
ACS580-04- size current Nominal use Light-duty use Heavy-duty use
I1N Imax IN PN ILd PLd IHd PHd
A A A kW A kW A kW
UN = 380…415 V (380, 400, 415 V)
505A-4 R10 505 560 505 250 485 250 361 200
585A-4 R10 585 730 585 315 575 315 429 250
650A-4 R10 650 730 650 355 634 355 477 250
725A-4 R11 725 1020 725 400 715 400 566 315
820A-4 R11 820 1020 820 450 810 450 625 355
880A-4 R11 880 1100 880 500 865 500 725* 400
3AXD00000586715

See definitions and notes on page 114.

114 Technical data

 NEMA ratings
NEMA RATINGS
Drive type Frame Input Output ratings
ACS580-04- size current Nominal use Light-duty use Heavy-duty use
I1N Imax ILd PLd IHd PHd
A A A hp A hp
UN = 440…480 V (440, 460, 480 V)
505A-4 R10 483 560 483 400 361 300
585A-4 R10 573 730 573 450 414 350
650A-4 R10 623 730 623 500 477 400
725A-4 R11 705 850 705 600 566 450
820A-4 R11 807 1020 807 700 625 500
880A-4 R11 807 1020 807 700 625 500
3AXD00000586715

UN Nominal voltage of the drive

I1N Nominal input current (rms) at 40 °C (104 °F)
Imax Maximum output current. Available for 2 seconds at start, otherwise as long as allowed
by drive temperature.
IN Continuous rms output current. No overload capability at 40 °C (104 °F)
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 for light-overload use.
IHd Continuous rms output current allowing 50% overload for 1 minute every 10 minutes
* Continuous rms output current allowing 40% overload for 1 minute every 10 minutes
PHd Typical motor power for heavy-duty use.
Note: 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 power ratings apply to most IEC 34 motors at the nominal voltage of
the drive.
We recommend to select the drive, motor and gear combination for the required motion profile with the
DriveSize dimensioning tool available from ABB.

 Derating
Derate the continuous output current of the drive if
• ambient temperature exceeds +40 °C (+104 °F) or
• drive is installed higher than 1000 m (3280 ft) above sea level
• switching frequency is other than default.
Note: The final derating factor is a multiplication of all applicable derating factors.
 Technical data 115

Ambient temperature derating

In the temperature range +40…55 °C (+104…131 °F), the rated output current is derated
by 1% for every added 1 °C (1.8 °F) as follows. Calculate the output current by multiplying
the current given in the rating table by the derating factor.

Derating factor

1.00

0.85

+40 °C +55 °C Ambient temperature

+104 °F +131 °F

Altitude derating
At altitudes from 1000 to 4000 m (3300 to 13123 ft) above sea level, the derating is 1% for
every 100 m (328 ft). For a more accurate derating, use the DriveSize PC tool.

Deratings for selections of parameter 97.02 Minimum

switching frequency
Switching frequencies other than 1.5 kHz can require output current derating. For more
information, contact local ABB.
The output current is calculated by multiplying the current given in the rating table by the
derating factor given in the table below.
Note: If you change the minimum switching frequency with parameter 97.02 Minimum
switching frequency, derate according to the table below. Changing parameter 97.01
Switching frequency reference does not require derating.
Frame size Derating factor (k) for the minimum switching frequencies
1 kHz 2 kHz 4kHz 8 kHz
R10 1 0.92 0.78 0.58
R11 1 0.92 0.78 0.58
116 Technical data

Fuses (IEC)
aR fuses for protection against short-circuit in the input power cable or drive are listed
below.
Ultrarapid (aR) fuses
Drive type Input Fuse
ACS580-04- current A A2s V Manufacturer Type DIN 43620 Size
(A)

UN = 380…415 V (380, 400, 415 V)

505A-4 505 800 490000 690 Bussmann 170M6812D DIN3
585A-4 585 1000 985000 690 Bussmann 170M6814D DIN3
650A-4 650 1000 985000 690 Bussmann 170M6814D DIN3
725A-4 725 1250 2150000 690 Bussmann 170M8554D DIN3
820A-4 820 1600 4150000 690 Bussmann 170M8557D DIN3
880A-4 880 1600 4150000 690 Bussmann 170M8557D DIN3
UN = 440…480 V (440, 460, 480 V)
505A-4 505 800 490000 690 Bussmann 170M6812D DIN3
585A-4 585 1000 985000 690 Bussmann 170M6814D DIN3
650A-4 650 1000 985000 690 Bussmann 170M6814D DIN3
725A-4 725 1250 2150000 690 Bussmann 170M8554D DIN3
820A-4 820 1600 4150000 690 Bussmann 170M8557D DIN3
880A-4 880 1600 4150000 690 Bussmann 170M8557D DIN3
3AXD00000586715

Note 1: See also Implementing thermal overload and short-circuit protection on page 58.
Note 2: In multicable installations, install only one fuse per phase (not one fuse per conductor).
Note 3: Fuses with higher current rating than the recommended ones must not be used. Fuses with lower
current rating can be used.
Note 4: Fuses from other manufacturers can be used if they agree with the ratings and the melting curve of the
fuse does not exceed the melting curve of the fuse mentioned in the table.

Dimensions, weights and free space requirements

Standard drive module configuration (IP00) and option +B051 (IP20 shrounds)
Frame Height Width Depth Weight*
size mm in mm in mm in kg lb
R10 1462 57.55 345 13.58 529 20.81 161 355
R11 1662 65.43 345 13.58 529 20.81 199 439

Weight of optional selections

Frame +0H354 +E208 +H356 +0H371 +H370
size kg lb kg lb kg lb kg lb kg lb
R10 -7 -15 3 7 2 4 -2.9 -6 2.9 6
R11 -7 -15 3 7 2 4 -2.9 -6 2.9 6

Height of drive module without pedestal (option +H354)

Frame mm in
size
R10/R11 -100 -3.94

For requirements of free space around the drive module, see page 47.
 Technical data 117

Losses, cooling data and noise

Drive type Frame size Air flow Heat dissipation Noise
m3/h ft3/min W dB(A)
ACS580-505A-4 R10 1200 707 5602 72
ACS580-585A-4 R10 1200 707 6409 72
ACS580-650A-4 R10 1200 707 8122 72
ACS580-725A-4 R11 1200 707 8764 72
ACS580-820A-4 R11 1200 707 9862 72
ACS580-880A-4 R11 1420 848 10578 71
3AXD00000586715

Terminal and lead-through data for the power cables

The maximum accepted cable size is 4 × (3 × 240) mm2 or 4 × (3 × 500 AWG). Screw size
for connecting busbars to the drive module input and output busbars: M12, tightening
torque 50...75 N·m.

 Drive modules without output cable connection terminals (+0H371)

and with a common mode filter (+E208)
It is possible to use the maximum cable size (4 × [3 × 240] mm2 or 4 ×[(3 × 500 AWG]) only
with special cable lugs and additional insulation. For more information, contact your local
ABB representative.

Terminal data for the control cables

See page 80.

Electrical power network specification

Voltage (U1) ACS580-04-xxxx-4 drive modules: 380…480 V AC phase ± 10%
Network type TN (grounded) and IT (ungrounded) systems
Short-circuit withstand Maximum allowable prospective short-circuit current is 65 kA when protected
strength (IEC 61439-1) by the fuses given in the fuse table.
Frequency 48 to 63 Hz, maximum rate of change 17%/s
Imbalance Max. ± 3% of nominal phase to phase input voltage
Fundamental power factor 0.98 (at nominal load)
(cos phi1)

Motor connection data

Motor types Asynchronous AC induction motors and permanent magnet motors
Voltage (U2) 0 to U1, 3-phase symmetrical, Umax at the field weakening point
Frequency 0.…500 Hz
Frequency resolution 0.01 Hz
Current See section Ratings.
Frequency 0…500 Hz. For drives with du/dt filter: 200 Hz
Switching frequency = nominal switching frequency. Minimum switching frequency 1.5 kHz, 2 kHz,
4 kHz, 8 kHz (depends on the parameter settings)
Maximum recommended Vector control Scalar control
motor cable length 300 m (984 ft) 300 m (984 ft)
Note: Motor cable longer than 100 m (328 ft) is allowed but then the EMC
Directive requirements of Category C3 may not be fulfilled.
118 Technical data

DC connection data
Drive type IDC (A) Capacitance (mF)
UN = 400 V
ACS580-04-505A-4 640 14
ACS580-04-585A-4 714 14
ACS580-04-650A-4 870 14
ACS580-04-725A-4 909 21
ACS580-04-820A-4 1033 21
ACS580-04-880A-4 1120 21

Control unit (CCU-12) connection 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 the 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: 2,68 kohm
Hardware filtering: 0.04 ms, digital filtering: 2 ms sampling
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: 6.2 kohm
Max. frequency 16 kHz
Symmetrical signal (duty cycle D = 0.50)
Relay outputs RO1…RO3 250 V AC / 30 V DC, 2 A
(Term. 19…27) Terminal size: 0.14…2.5 mm2
Analog inputs AI1 and AI2 Current/voltage input mode selected with a dip switch, see page 82.
(Term. 2 and 5) 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 Current/voltage output mode for AO1 selected with a dip switch, see page 82.
AO2 Current output: 0…20 mA, Rload: < 500 ohm
(Term. 7 and 8) 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
analog inputs +10V DC Inaccuracy: ±1%
(Term. 4)
Safe torque off (STO) inputs 24 V DC logic levels: “0” < 5 V, “1” > 13 V
IN1 and IN2 Rin: 2.47 kohm
(Term. 37 and 38) Terminal size: 0.14…2.5 mm2
Control panel - drive EIA-485, male RJ-45 connector, max. cable length 100 m
connection
Control panel - PC USB Type Mini-B, max. cable length 2 m
connection
 Technical data 119

Isolation areas

Panel port 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 SLOT 3
Embedded fieldbus module
34…38
STO
40, 41
Ext. 24 V
19…21
SLOT 2 RO1
I/O 22…24
extension RO2
module
25…27
RO3

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

The terminals on the control board fulfil 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 reinforced insulation also between the individual relay outputs.
Note: There is reinforced insulation on the power unit.

Control panel type

ACS-AP-S assistant control panel. With option +J425: ACS-AP-I assistant
control panel

Efficiency
Approximately 98% at nominal power level

Degree of protection
IP00. With option +B051: IP20
120 Technical data

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 in the protective in the protective
use package package
Installation site altitude For TN and TT neutral- - -
grounded network
systems and IT non-
corner grounded
network systems:
0 to 4000 m (13123 ft)
above sea level
For TN, TT and IT
corner-grounded
network systems:
0 to 2000 m (6561 ft)
above sea level
Above 1000 m [3281 ft]),
see page 114.
Air temperature -15 to +55 °C -40 to +70 °C -40 to +70 °C
(5 to 131 °F). No frost (-40 to +158 °F) (-40 to +158 °F)
allowed. See page 114.
Relative humidity 5 to 95% Max. 95% Max. 95%
No condensation allowed. Maximum allowed relative humidity is 60% in the
presence of corrosive gases.
Contamination levels No conductive dust allowed.
(IEC 60721-3-3, Chemical gases: Chemical gases: Chemical gases:
IEC 60721-3-2, Class 3C2 Class 1C2 Class 2C2
IEC 60721-3-1) Solid particles: Solid particles: Solid particles:
Class 3S2 Class 1S3 Class 2S2
Atmospheric pressure 70 to 106 kPa 70 to 106 kPa 60 to 106 kPa
0.7 to 1.05 atmospheres 0.7 to 1.05 atmospheres 0.6 to 1.05 atmospheres
Vibration (IEC 60068-2-6. Max. 0.1 mm (0.004 in.) Max. 1 mm (0.04 in.) Max. 3.5 mm (0.14 in.)
Test Fc) (10 to 57 Hz), (5 to 13.2 Hz), (2 to 9 Hz),
max. 10 m/s2 (33 ft/s2) max. 7 m/s2 (23 ft/s2) max. 15 m/s2 (49 ft/s2)
(57 to 150 Hz) sinusoidal (13.2 to 100 Hz) (9 to 200 Hz) sinusoidal
sinusoidal
Shock (IEC 60068-2-27) Not allowed Max. 100 m/s2 Max. 100 m/s2
2), 11 ms
(330 ft./s (330 ft./s2), 11 ms
Free fall Not allowed 100 mm (4 in.) for weight 100 mm (4 in.) for weight
over 100 kg (220 lb) over 100 kg (220 lb)

Materials
Drive enclosure • PC/ABS 2.5 mm, color NCS 1502-Y (RAL 9002 / PMS 420 C)
• hot-dip zinc coated steel sheet 1.5 to 2.5 mm, thickness of coating
100 micrometers, color NCS 1502-Y
 Technical data 121

Package Plywood and cardboard, bands PP.

3AXD10000382225

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 DC capacitors (C1-1 to C1-x) 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.

Applicable standards
The drive complies with the following standards.
EN 61800-5-1:2007 Adjustable speed electrical power drive systems. Part 5-1: Safety
requirements – electrical, thermal and energy
EN 60204-1:2006 + A1:2010 Safety of machinery. Electrical equipment of machines. Part 1: General
requirements. Provisions for compliance: The final assembler of the machine
is responsible for installing
- emergency-stop device
- supply disconnecting device
- IP00 drive module into a cabinet.
IEC/EN 60529:1991 + Degrees of protection provided by enclosures (IP code)
A2:2013
EN 61800-3:2004 +A1:2012 Adjustable speed electrical power drive systems. Part 3: EMC requirements
and specific test methods

CE marking
A CE mark is attached to the drive to verify that the unit follows the provisions of the
European Low Voltage, EMC and RoHS 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
standards EN 60204-1 and 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 EN 61800-
3:2004 below.
122 Technical data

 Compliance with the European RoHS Directive

The RoHS Directive defines the restriction of the use of certain hazardous substances in
electrical and electronic equipment.

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.

Compliance with 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 C2: drive of rated voltage less than 1000 V and intended to be installed
and started up only by a professional when used in the first environment.
Note: A professional is a person or organization having necessary skills in installing and/or
starting up power drive systems, including their EMC aspects.
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 C3
The drive complies with the standard with the following provisions:
1. The drive is equipped with EMC filter +E210.
2. The motor and control cables are selected as specified in the hardware manual.
3. The drive is installed according to the instructions given in the hardware manual.
4. Maximum motor cable length is 100 meters.
5. The value of parameter 97.01 Switching frequency reference must be set to 2 kHz.

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.
 Technical data 123

 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 inherent suppression in transformers and cables is
sufficient. If in doubt, the supply transformer with static screening between the primary
and secondary windings can be used.

Medium voltage network

Supply transformer

Neighboring network
Static screen

Point of measurement

Low voltage Low voltage

Equipment
Drive
(victim)

Equipment Equipment

2. An EMC plan for preventing disturbances is drawn up for the installation. A template is
available from the local ABB representative.
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.

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.
124 Technical data
 Dimension drawings 125

13
Dimension drawings

Contents of this chapter

This chapter contains dimension drawings of the drive modules.
126 Dimension drawings

R10 standard configuration

3AXD50000017294
 Dimension drawings 127

R10 with options +E208+0H354+H356+0H370+0H371

3AXD50000017294
128 Dimension drawings

R10 with option +B051

3AXD50000017294
 Dimension drawings 129

R11 standard configuration

3AXD50000017041
130 Dimension drawings

R11 with options +E208+0H354+H356+0H370+0H371

3AXD50000017041
 Dimension drawings 131

R11 with option +B051

3AXD50000017041
132 Dimension drawings

Air baffles for the drive module with option +B051

This drawing shows the dimensions of the hole in the air baffle around the drive module
with option +B051. The drawing also shows the correct vertical location area of the air
baffle as measured from the top grill

[0.6]
15
 Example circuit diagram 133

14
Example circuit diagram

Contents of this chapter

This chapter shows an example circuit diagram for a cabinet-installed drive module.
134 Example circuit diagram

Example circuit diagram

This diagram is an example for the main wiring of a drive cabinet. Note that the diagram
includes components which are not included in a basic delivery (* plus code options,
** other options, *** to be acquired by the customer).

Drive module
mode filter
*Common

**du/dt filter

Motor
3~
***Main contactor

***Switch fuse
disconnector
Cabinet

Supply

360 degree grounding

**Motor temperature

recommended
supervision
CCU control unit

Alarm
*ACS-CP-S control panel

signals, see
Input and

page 80.
output
 Safe torque off function 135

15
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 construct safety or supervision
circuits that stop the drive in case of danger (such as an emergency stop circuit). Another
possible application is a prevention of unexpected start-up switch 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 diagram 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.
136 Safe torque off function

The Safe torque off function of the drive complies with these standards:

Standard Name

EN 60204-1:2006 + AC:2010 Safety of machinery – Electrical equipment of machines – Part 1: General

requirements

IEC 61326-3-1:2008 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/programmable electronic safety-related systems

IEC 61511:2003 Functional safety – Safety instrumented systems for the process industry
sector

IEC/EN 61800-5-2:2007 Adjustable speed electrical power drive systems –

Part 5-2: Safety requirements – Functional

IEC/EN 62061:2005 + Safety of machinery – Functional safety of safety-related electrical,

AC:2010 electronic and programmable electronic control systems

EN ISO 13849-1:2008 + Safety of machinery – Safety-related parts of control systems – Part 1:

AC:2009 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 1037:1995 + A1:2008 and Uncontrolled stop (stop category 0) as specified in
EN 60204-1:2006 + AC:2010.

 Compliance with the European Machinery Directive

See section Compliance with the European Machinery Directive on page 122.
 Safe torque off function 137

Wiring
The following diagrams present examples of Safe torque off wiring for
• a single drive (page 138)
• multiple drives (page 140)
• multiple drives when an external 24 V DC power supply is used (page 141).
For information on the specifications of the STO input, see section Default I/O connection
diagram (ABB standard macro) on page 80.

 Activation switch
In the wiring diagrams below, 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.
• An FSO-xx safety functions module can also be used. For more information, see the
FSO-xx module documentation.

 Cable types and lengths

We recommend double-shielded twisted-pair cable (see page 56).
Maximum cable lengths:
• 300 m (984 ft) between activation switch [K] and drive control unit
• 60 m (200 ft) between multiple drives
• 60 m (200 ft) between external power supply and first drive.
Note that the voltage at the INx terminals of each control unit must be at least 17 V DC to
be interpreted as “1”.

 Grounding of protective shields

• Ground the shield in the cabling between the activation switch and the control unit at
the control unit.
• Ground the shield in the cabling between two control units at one control unit only.
138 Safe torque off function

 Single drive (internal power supply)

Drive
Control unit

K STO
OUT1 34 + 24 V DC
OUT2 35 + 24 V DC
SGND 36
IN1 37
IN2 38 UDC+

T1/U,
Control logic
T2/V,
A
T3/W

UDC-

 Single drive (external +24 V DC power supply)

24 V DC Drive
- + Control unit

STO
K OUT1 34 + 24 V DC
OUT2 35 + 24 V DC
SGND 36
IN1 37
IN2 38 UDC+

T1/U,
Control logic T2/V,
A
T3/W

UDC-
 Safe torque off function 139

 Wiring examples
An example of a Safe torque off wiring with internal +24 V DC power supply is shown
below.

Drive Safe PLC

34 OUT1 OUT
35 OUT2

13 23 31 Y1 Y2
36 SGND K
Safety relay

14 24 32 A1 A2
37 IN1
38 IN2
GND

An example of a Safe torque off wiring with external +24 V DC power supply is shown
below.

Drive +24 V DC external power Safe PLC

supply
- +
34 OUT1 OUT
35 OUT2

13 23 31 Y1 Y2
36 SGND K
Safety relay

14 24 32 A1 A2
37 IN1
38 IN2
GND
140 Safe torque off function

 Multiple drives (internal power supply)

ACS580-04
Control unit STO

+24 V OUT1

SGND K

IN1
IN2

ACS580-04
Control unit STO
OUT1
SGND

IN1
IN2

ACS580-04
Control unit STO
OUT1
SGND

IN1
IN2
 Safe torque off function 141

 Multiple drives (external power supply)

ACS580-04 24 V DC
– +
Control unit STO
+24 V OUT1
SGND

IN1
IN2

ACS580-04
Control unit STO
OUT1
SGND

IN1
IN2

ACS580-04
Control unit STO
OUT1
SGND

IN1
IN2
142 Safe torque off function

Operation principle
1. The Safe torque off activates (the activation switch is opened, or safety relay contacts
open).
2. STO inputs on the drive control unit de-energize.
3. The control unit cuts off the control voltage from the drive IGBTs.
4. The control program generates an indication as defined by parameter 31.22 – see
ACS580 firmware manual (3AXD50000016097[English]).
5. Motor coasts to stop (if running). The drive cannot restart while the activation switch or
safety relay contacts are open. After the contacts close, a new start command is
required to start the drive.

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.
 Safe torque off function 143

 Acceptance test procedure

After wiring the Safe torque off function, validate its operation as follows.
Note: If an FSO-xx safety functions module is installed, refer to its documentation.
Action

WARNING! Obey the safety instructions in chapter 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 by a
disconnector.

Check the Safe torque off circuit connections against the circuit diagram.

Close the disconnector and switch the power on.

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 ‘stopped’ state in
parameter 31.22 (see the firmware manual).
• Give a start command to verify that the STO function blocks the drive operations. 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
‘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.

Document and sign the acceptance test report which verifies that the safety function is safe and
accepted for operation.

Use
1. Open the activation switch, or activate the safety functionality that is wired to the STO
connection.
2. STO inputs on the drive control unit de-energize, and the drive control unit cuts off the
control voltage from the drive IGBTs.
3. The control program generates an indication as defined by parameter 31.22 – see
ACS580 firmware manual (3AXD50000016097[English]).
4. Motor coasts to 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 resetting the safety
functionality that is wired to the STO connection.
6. Reset any faults before restarting.
144 Safe torque off function

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 main supply.

WARNING! (With permanent magnet motors only) In case of a multiple IGBT

power semiconductor failure, the drive system can produce an alignment torque
which maximally rotates the motor shaft by 180/p degrees regardless of the
activation of the Safe torque off function. p denotes the number of pole pairs.

Notes:
• If the Safe torque off function is activated when the drive is running, the control voltage
of the power semiconductors is cut off and the motor coasts 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.

Maintenance
After the operation of the circuit is validated at start-up, it does not need any maintenance.
However, 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 on page 143.
Use only ABB approved spare parts.

 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.
 Safe torque off function 145

Fault tracing
The indications given during the normal operation of the Safe torque off function are
selected by drive parameter 31.22 – see ACS580 firmware manual
(3AXD50000016097[English]).
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, triggers the
same reaction.
See the drive firmware manual 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.

Safety data
Preliminary 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.
IEC 61508
Frame size PFHD SFF Lifetime PFD
SIL SC HFT
(1/h) (%) (Years) (T1 = 2 a)
R10, R11 3 3 1.05E-09 1 99.88 20 1.61E-06

EN/ISO 13849-1 IEC 62061 IEC 61511

Frame size PL CCF MTTFd DC*
Cat. SILCL SIL
(%) (Years) (%)
R10, R11 e 80 12779 >90 3 3 3

According to Table E1 EN/ISO 13849-1

The following temperature profile is used in safety value calculations:

• 670 on/off cycles per year with T = 71.66 °C
• 1340 on/off cycles per year with T = 61.66 °C
• 30 on/off cycles per year with T = 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
• The STO is a type A safety component as defined in IEC 61508-2.
• Relevant failure modes:
• The STO trips spuriously (safe failure)
• The STO does not activate when requested
146 Safe torque off function

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 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
• 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 (%)
DC EN/ISO 13849-1 Diagnostic coverage
FIT IEC 61508 Failure in time: 1E-9 hours
HFT IEC 61508 Hardware fault tolerance
MTTFd EN/ISO 13849-1 Mean time to dangerous failure: (The total number of life units) / (the
number of dangerous, undetected failures) during a particular
measurement interval under stated conditions
PFD IEC 61508 Probability of failure on demand
PFHd IEC 61508 Probability of dangerous failures per hour
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 EN 62061 Maximum SIL (level 1…3) that can be claimed for a safety function or
subsystem
SS1 EN 61800-5-2 Safe stop 1
STO EN 61800-5-2 Safe torque off
T1 IEC 61508 Proof test interval
 Safe torque off function 147

 Declaration of conformity
148 Safe torque off function
 du/dt filters 149

16
du/dt filters

Contents of this chapter

This chapter describes how to select du/dt filters for the drive.

du/dt filters
 When is du/dt filter needed?
See section Examining the compatibility of the motor and drive, page 50.

 Selection table
Contact ABB.
du/dt filter types for the drive module types are given below.
Frame du/dt filter type
R10 FOCH0610-70
R11 FOCH0875-70
3AXD00000586715

 Ordering codes
Filter type ABB ordering code
FOCH-0610-70 68550483
FOCH-0875-70 3AUA0000125245

 Description, installation and technical data of the FOCH filters

See FOCH du/dt filters hardware manual (3AFE68577519 [English]).
150 du/dt filters
 Step-by-step drawings for an installation example of drive module with options +B051 and +E208 in Rittal TS 8 600 mm wide cabinet 149
Step-by-step drawings for an installation example of drive module with options +B051 and +E208 in Rittal TS 8 600 mm wide cabinet

Tapping screw M6×12 Torx Combi screw M8×30 (Hex) Tapping screw M6×12 Torx
Rittal 8612.160
T30 (Hex) 9 N·m 20 N·m T30 (Hex) 9 N·m
Combi screw M4×8 Torx
Rittal 8606.500 T20 2 N·m

M6x20 Torx T25 8 N·m

Rittal 4396.500 Combi screw M4×8 Torx Combi screw M8×30 Hex 20 N·m
T20 2 N·m

M8 Kalei nut or similar (2 pcs)

3AUA0000128301 Rev D
150 Step-by-step drawings for an installation example of drive module with options +B051 and +E208 in Rittal TS 8 600 mm wide cabinet

Combi screw M12×25 Hex

70 N·m

Combi screw M8×16 Hex Hex nut M12 70 N·m

20 N·m Combi screw M12×25 Hex Combi screw M6×12 Torx T25 Washer M12 or equal
20 N·m 8 N·m
Hex screw M12×35 full thread
70 N·m
Washer M12 or equal
 Step-by-step drawings for an installation example of drive module with options +B051 and +E208 in Rittal TS 8 600 mm wide cabinet 151

Hex nut M12 70 N·m

Washer M12 or equal
Hex screw M12×35 full thread
70 N·m
Washer M12 or equal

+B051

+B051

+B051

Combi screw M4×10

Torx T20 2 N·m

Combi screw M6×20 Combi screw M6×20

Torx T25 2 N·m Torx T25 2 N·m

+B051

Combi screw M4×10

Torx T20 2 N·m

+B051

Combi screw M6×20

Torx T25 2 N·m

Combi screw M4×8 Torx T20

2 N·m
152 Step-by-step drawings for an installation example of drive module with options +B051 and +E208 in Rittal TS 8 600 mm wide cabinet

Note: These air baffles are compatible with option +B051 only,
for the standard drive module configuration, see section
Standard drive module configuration on page 44.
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 www.abb.com/drives and select
ABB University.

Providing feedback on ABB Drives manuals

Your comments on our manuals are welcome. Go to www.abb.com/drives and select
Document Library – Manuals feedback form (LV AC drives).

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.
Contact us

www.abb.com/drives
www.abb.com/drivespartners

3AXD50000015497 Rev B (EN) 2015-04-02