ABB general purpose drives

Hardware manual
ACS580-01 drives
List of related manuals
Drive manuals and guides Code (English)
ACS580 firmware manual 3AXD50000016097
ACS580-01 hardware manual 3AXD50000018826
ACS580-01 quick installation and start-up guide for 3AUA0000076332
frames R0 to R3
ACS580-01 quick installation and start-up guide for 3AXD50000007518
frame R5
ACS580-01 quick installation and start-up guide for 3AXD50000009286
frames R6 to R9
ACS-AP-x assistant control panels user’s manual 3AUA0000085685
Flange mounting quick guide for frames R6 to R9 3AXD50000019099
Flange mounting supplement 3AXD50000019100

Option manuals and guides

CDPI-01 communication adapter module user's manual 3AXD50000009929
DPMP-01 mounting platform for ACS-AP control panel 3AUA0000100140
DPMP-02 mounting platform for ACS-AP control panel 3AUA0000136205
FCAN-01 CANopen adapter module user's manual 3AFE68615500
FCNA-01 ControlNet adapter module user's manual 3AUA0000141650
FDNA-01 DeviceNet™ adapter module user's manual 3AFE68573360
FECA-01 EtherCAT adapter module user's manual 3AUA0000068940
FENA-01/-11/-21 Ethernet adapter module user's 3AUA0000093568
manual
FEPL-02 Ethernet POWERLINK adapter module user's 3AUA0000123527
manual
FPBA-01 PROFIBUS DP adapter module user's manual 3AFE68573271
FSCA-01 RS-485 adapter module user's manual 3AUA0000109533

Tool and maintenance manuals and guides

Drive composer PC tool user's manual 3AUA0000094606
Converter module capacitor reforming instructions 3BFE64059629
NETA-21 remote monitoring tool user's manual 3AUA00000969391
NETA-21 remote monitoring tool installation and start-up 3AUA0000096881
guide

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.

The QR code below opens an online listing of the manuals applicable to this product.

ACS580-01 manuals
 Hardware manual
ACS580-01 drives

Table of contents

1. Safety instructions

4. Mechanical installation

6. Electrical installation

 2014 ABB Oy. All Rights Reserved. 3AXD50000018826 Rev C

EN
EFFECTIVE: 2014-10-21
 Table of contents 5

Table of contents
List of related manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1. Safety instructions
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Use of warnings and notes in this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Additional instructions for permanent magnet motor drives . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety 17
Safety in installation, start-up and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
General safety in operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

2. Introduction to the manual

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Applicability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Target audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Purpose of the manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Contents of this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Related documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Categorization by frame (size) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Quick installation and commissioning flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

3. Operation principle and hardware description

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Operation principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Overview of power and control connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
External control connection terminals, frames R0…R3 . . . . . . . . . . . . . . . . . . . . . . . . . . 30
External control connection terminals, frame R5…R9 . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Type designation label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Locations of the labels on the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Type designation key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

4. Mechanical installation
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Checking the installation site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Required tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Moving the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Unpacking and examining delivery, frames R0…R3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
6 Table of contents

Unpacking and examining delivery, frame R5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Frame R5 cable entry box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Unpacking and examining delivery, frames R6…R9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Frame R6 cable entry box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Frame R7 cable entry box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Frame R8 cable entry box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Frame R9 cable entry box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Installing the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Installing the drive vertically, frames R0…R3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Installing the drive vertically, frame R5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Installing the drive vertically, frames R6…R9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Installing the drive vertically side by side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Installing the drive horizontally . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Flange mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

5. Planning the electrical installation

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Selecting the supply disconnecting device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
European Union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Other regions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Checking the compatibility of the motor and drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Selecting the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
General rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Typical power cable sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Alternative power cable types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Motor cable shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Additional US requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Selecting the control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Shielding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Signals in separate cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Signals allowed to be run in the same cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Relay cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Control panel cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Drive composer PC tool cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
FPBA-01 PROFIBUS DP adapter module connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Routing the cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
General rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Separate control cable ducts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Continuous motor cable shield or enclosure for equipment on the motor cable . . . . . . . 61
Implementing thermal overload and short-circuit protection . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Protecting the drive and input power cable in short-circuits . . . . . . . . . . . . . . . . . . . . . . . 62
Protecting the motor and motor cable in short-circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Protecting the drive and the input power and motor cables against thermal overload . . . 62
Protecting the motor against thermal overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Protecting the drive against ground faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Residual current device compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Implementing the Emergency stop function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Implementing the Safe torque off function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Implementing the Power-loss ride-through function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Using a safety switch between the drive and the motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
 Table of contents 7

Using a contactor between the drive and the motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Implementing a bypass connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Example bypass connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Protecting the contacts of relay outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Limiting relay output maximum voltages at high installation altitudes . . . . . . . . . . . . . . . . . . . 68

6. Electrical installation
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Required tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Checking the insulation of the assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Input power cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Motor and motor cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Brake resistor assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Checking the compatibility with IT (ungrounded) and corner-grounded TN systems . . . . . . . 71
Frames R0…R3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Frames R5…R9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Connecting the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Connection procedure, frames R0…R3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Connection procedure, frame R5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Connection procedure, frames R6…R9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Motor cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
DC connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Connecting the control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Default I/O connection diagram (ABB standard macro) . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Control cable connection procedure R0…R9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Installing option modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Mechanical installation of option modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Wiring the modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Reinstalling covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Reinstalling cover, frames R0…R3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Reinstalling covers, frame R5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Reinstalling side plates and covers, frames R6…R9 . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Connecting a PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

7. Installation checklist
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

8. Maintenance and hardware diagnostics

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Preventive maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Heatsink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
8 Table of contents

Replacing the cooling fan, frames R0…R3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

Replacing the cooling fan, frame R5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Replacing the main cooling fan, frames R6…R8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Replacing the main cooling fans, frame R9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Replacing the auxiliary cooling fan, frames R6…R9 . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Reforming the capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Cleaning the control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Replacing the battery in the assistant control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Drive LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Assistant panel LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

9. Technical data
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
IEC ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
NEMA ratings ....................................................... 129
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Ambient temperature derating, IP21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Ambient temperature derating, IP55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
IP55 (UL Type 12) type -045A-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
IP55 (UL Type 12) drive type -293A-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
IP55 (UL Type 12) drive type -363A-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
IP55 (UL Type 12) type -430A-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Switching frequency derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Altitude derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Fuses (IEC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
gG fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
uR and aR fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Dimensions, weights and free space requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Losses, cooling data and noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Terminal and lead-through data for the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Terminal and lead-through data for the control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Electrical power network specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Voltage (U1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Motor connection data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Brake resistor connection data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Control connection data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Degree of protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Applicable standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
CE marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Compliance with the European Low Voltage Directive . . . . . . . . . . . . . . . . . . . . . . . . . 155
Compliance with the European EMC Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
 Table of contents 9

Compliance with the European ROHS Directive 2011/65/EU . . . . . . . . . . . . . . . . . . . . . 155

Compliance with the European WEEE Directive 2002/96/EC . . . . . . . . . . . . . . . . . . . . . 155
Compliance with the European Machinery Directive
2006/42/EC 2nd Edition – June 2010 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Compliance with the EN 61800-3:2004 + A1:2012 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
Category C1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
Category C2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Category C3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Category C4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
EAC marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158

10. Dimension drawings

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Frame R0, IP21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
Frame R0, IP55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Frame R1, IP21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Frame R1, IP55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Frame R2, IP21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Frame R2, IP55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Frame R3, IP21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Frame R3, IP55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Frame R5, IP21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
Frame R6, IP21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
Frame R6, IP55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
Frame R7, IP21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
Frame R7, IP55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
Frame R8, IP21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Frame R8, IP55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
Frame R9, IP21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Frame R9, IP55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178

11. Resistor braking

Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Operation principle and hardware description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Resistor braking, frames R0…R3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
Planning the braking system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
Mechanical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
Electrical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
Resistor braking, frames R5…R9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186

12. Safe torque off function

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
Compliance with the European Machinery Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
Connection principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
10 Table of contents

Connection with internal +24 V DC power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189

Connection with external +24 V DC power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
Wiring examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
Activation switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
Cable types and lengths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
Grounding of protective shields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
Operation principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
Start-up including acceptance test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
Authorized person . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
Acceptance test reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
Acceptance test procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
Fault tracing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
Safety data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
Declaration of conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
Certificate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198

13. Optional I/O extension modules

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
CMOD-01 multifunction extension module (external 24 V AC/DC and digital I/O) . . . . . . . . 199
Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
Hardware description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
Mechanical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
Electrical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
CMOD-02 multifunction extension module
(external 24 V AC/DC and isolated PTC interface) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
Hardware description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
Mechanical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
Electrical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214

Further information
Product and service inquiries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
Product training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
Providing feedback on ABB Drives manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
Document library on the Internet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
 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 in this manual

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 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 carefully.

• Use safety shoes with a metal toe cap to avoid foot injury.
• Frames R6…R9: Lift the drive with a lifting device. Use the lifting eyes of the
drive.
• Frames R6…R9: Do not tilt the drive. The drive is heavy and its center of
gravity is high. An overturning drive can cause physical injury.

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

remain hot for a while after disconnection of the electrical supply.
• Keep the drive in its package or protect it otherwise from dust and burr from
drilling and grinding until you install it.
• Protect also the installed drive against dust and burr. Electrically conductive
debris inside the drive may cause damage or malfunction.
• Vacuum clean the area below the drive before the start-up to prevent the drive
cooling fan from drawing the dust inside the drive.
• Do not cover the air inlet and outlet when the drive runs.
• Make sure that there is sufficient cooling. See sections Checking the installation
site on page 38 and Losses, cooling data and noise on page 140 for more
information.
• Before you connect voltage to the drive, make sure that the drive covers are on.
Keep the covers on during the operation.
• 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 automatic fault reset functions of the drive control program,
 Safety instructions 13

make sure that no dangerous situations can occur. These functions reset the
drive automatically and continue operation after a fault.
• 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.
• If you have connected safety circuits to the drive (for example, emergency stop
and Safe torque off), validate them at the start up. For the validation of the Safe
torque off, see ACS580 firmware manual (3AXD50000016097 [English]). For the
validation of other safety circuits, see the instructions provided with them.
Note:
• If you select an external source for start command and it is on, the drive will start
immediately after fault reset. See parameters 20.02 Ext1 start trigger type and
20.07 Ext2 start trigger type in ACS580 firmware manual (3AXD50000016097
[English]).
• When the control location is not set to Local, the stop key on the control panel will
not stop the drive.
• Frames R0…R5 are not field repairable. Do not attempt to repair a malfunctioning
drive; contact your local ABB representative for replacement.
Frames R6…R9 can be repaired by authorized persons.
14 Safety instructions

Electrical safety in installation, start-up and maintenance

 Precautions before electrical work
These warnings are for all personnel who do work on the drive, motor cable or motor.

WARNING! Obey these instructions. If you ignore them, injury or death, or

damage to the equipment can occur. If you are not a qualified electrician, do
not do electrical 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 at the power supply of the drive.
• Make sure that reconnection is not possible. Lock the disconnector to open
position and attach a warning notice to it.
• 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 input power terminals (L1, L2,
L3) and the grounding terminal (PE) is close to 0 V.
• Make sure that the voltage between the drive DC terminals (UDC+ and UDC-)
and the grounding terminal (PE) 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.

 Additional instructions and notes

WARNING! Obey these instructions. If you ignore them, injury or death, or

damage to the equipment can occur.

• If you install the drive on an IT system (an ungrounded power system or a high-
resistance-grounded [over 30 ohms] power system), disconnect the internal EMC
filter; otherwise the system will be connected to ground potential through the EMC
 Safety instructions 15

filter capacitors. This can cause danger or damage the drive. See page 72.
Note: Disconnecting the internal EMC filter increases the conducted emission
and reduces the drive EMC compatibility considerably. See section EMC
compatibility and motor cable length on page 145.
• If you install the drive on a corner-grounded TN system, disconnect the internal
EMC filter; otherwise the system will be connected to ground potential through the
EMC filter capacitors. This will damage the drive. See page 72.
Note: Disconnecting the internal EMC filter increases the conducted emission
and reduces the drive EMC compatibility considerably. See section EMC
compatibility and motor cable length on page 145.
• Use all ELV (extra low voltage) circuits connected to the drive only within a zone
of equipotential bonding, that is, within a zone where all simultaneously
accessible conductive parts are electrically connected to prevent hazardous
voltages appearing between them. You can accomplish this by a proper factory
grounding, that is, make sure that all simultaneously accessible conductive parts
are grounded to the protective earth (PE) bus of the building.
• 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 and brake resistor terminals (UDC+, UDC-, R+ and R-) are at a
dangerous voltage.
• External wiring can supply dangerous voltages to the terminals of relay outputs
(RO1, RO2 and RO3).
• 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.
16 Safety instructions

 Grounding
These instructions are for all personnel who are responsible for the electrical
installation, including 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 to the protective
earth (PE) bus of the power supply. This is necessary for the personnel safety.
Proper grounding also reduces electromagnetic emission and interference.
• In a multiple-drive installation, connect each drive separately to the protective
earth (PE) bus of the power supply.
• Make sure that the conductivity of the protective earth (PE) conductors is
sufficient. See section Selecting the power cables on page 54. Obey the local
regulations.
• Connect the power cable shields to the protective earth (PE) terminals of the
drive.
• Make a 360° grounding of the power and control cable shields at the cable entries
to suppress electromagnetic disturbances.
Note:
• You can use power cable shields as grounding conductors only when their
conductivity is sufficient.
• Standard IEC/EN 61800-5-1 (section 4.3.5.5.2.) requires that as the normal touch
current of the drive is higher than 3.5 mA AC or 10 mA DC, you must use a fixed
protective earth (PE) connection. In addition,
• install a second protective earth conductor of the same cross-sectional area
as the original protective earthing conductor,
or
• install a protective earth conductor with a cross-section of at least 10 mm2 Cu
or 16 mm2 Al,
or
• install a device which automatically disconnects the supply if the protective
earth conductor breaks.
 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
damage to the equipment can occur.

• Do not work on a drive when a rotating permanent magnet motor is connected to

it. 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/U, T2/V,
T3/W) and the grounding (PE) busbar is close to 0 V.
• Make sure that the voltage between the drive input power terminals (L1, L2,
L3) and the grounding (PE) busbar is close to 0 V.
• Make sure that the voltage between the drive DC terminals (UDC+, UDC-) and
the grounding (PE) terminal is close to 0 V.
• Install temporary grounding to the drive output terminals (T1/U, T2/V, T3/W).
Connect the output terminals together as well as to the PE.
Start-up and operation:
• Make sure that the operator cannot run the motor over the rated speed. Motor
overspeed causes overvoltage that can damage or explode the capacitors in the
intermediate circuit of the drive.
18 Safety instructions

General safety in operation

These instructions are for all personnel that operate the drive.

WARNING! Obey these instructions. If you ignore them, injury or death, or

damage to the equipment can occur.

• Do not control the motor with the disconnector at the drive power supply; instead,
use the control panel start and stop keys or commands through the I/O terminals
of the drive.
• Give a stop command to the drive before you reset a fault. If you have an external
source for the start command and the start is on, the drive will start immediately
after the fault reset, unless you configure the drive for pulse start. See the
firmware manual.
• Before you activate automatic fault reset functions of the drive control program,
make sure that no dangerous situations can occur. These functions reset the
drive automatically and continue operation after a fault.
Note: When the control location is not set to Local, the stop key on the control panel
will not stop the drive.
 Introduction to the manual 19

2
Introduction to the manual
Contents of this chapter
The chapter describes applicability, target audience and purpose of this manual. It
describes the contents of this manual and refers to a list of related manuals for more
information. The chapter also contains a flowchart of steps for checking the delivery,
installing and commissioning the drive. The flowchart refers to chapters/sections in
this manual.

Applicability
The manual applies to the ACS580-01 drives.

Target audience
The reader is 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.
Special US instructions for installations in the United States are given.

Purpose of the manual

This manual provides information needed for planning the installation, installing, and
servicing the drive.
20 Introduction to the manual

Contents of this manual

The manual consists of the following chapters:
• Safety instructions (page 11) gives safety instructions you must obey when
installing, commissioning, operating and servicing the drive.
• Introduction to the manual (this chapter, page 19) describes applicability, target
audience, purpose and contents of this manual. It also contains a quick
installation and commissioning flowchart. At the end, it lists terms and
abbreviations.
• Operation principle and hardware description (page 25) describes the operation
principle, layout, power connections and control interfaces, type designation label
and type designation information in short.
• Mechanical installation (page 37) describes how to check the installation site,
unpack, check the delivery and install the drive mechanically.
• Planning the electrical installation (page 53) describes how to plan the electrical
installation of the drive, for example, how to check the compatibility of the motor
and the drive and select cables, protections and cable routing.
• Electrical installation (page 69) describes how to check the insulation of the
assembly and the compatibility with IT (ungrounded) and corner-grounded TN
systems. It then shows how to connect the power and control cables, install
optional modules and connect a PC.
• Installation checklist (page 111) contains a checklist for checking the mechanical
and electrical installation of the drive before start-up.
• Maintenance and hardware diagnostics (page 113) contains preventive
maintenance instructions and LED indicator descriptions.
• Technical data (page 127) contains technical specifications of the drive, eg
ratings, sizes and technical requirements as well as provisions for fulfilling the
requirements for CE and other marks.
• Dimension drawings (page 161) shows dimension drawings of the drive.
• Resistor braking (page 179) tells how to select the brake resistor.
• Safe torque off function (page 187) describes STO features, installation and
technical data.
• Optional I/O extension modules (page 199) describes CMOD-01 and CMOD-02
multifunction extension modules, their installation, start-up, diagnostics and
technical data.
• Further information (inside of the back cover, page 217) tells how to make product
and service inquiries, get information on product training, provide feedback on
ABB Drives manuals and find documents on the Internet.

Related documents
See List of related manuals on page 2 (inside of the front cover).
 Introduction to the manual 21

Categorization by frame (size)

The ACS580-01 is manufactured in frames (frame sizes) R0…R3 and R5…R9. Some
instructions and other information which only concern certain frames are marked with
the symbol of the frame (R0…R3, R5…R9). The frame is marked on the type
designation label attached to the drive, see section Type designation label on page
33.
22 Introduction to the manual

Quick installation and commissioning flowchart

Task See
Identify the frame of your drive: R0…R3, Operation principle and hardware description:
R5…R9. Type designation key on page 35

Plan the installation: select the cables, etc. Planning the electrical installation on page 53
Check the ambient conditions, ratings and Technical data on page 127
required cooling air flow.

Unpack and check the drive. Mechanical installation: Unpacking and

examining delivery, frames R0…R3 on page
40, Unpacking and examining delivery, frame
R5 on page 41, Unpacking and examining
delivery, frames R6…R9 on page 43

If the drive will be connected to an IT Operation principle and hardware description:

(ungrounded) system or corner-grounded TN Type designation key on page 35
system, check that the internal EMC filter is Electrical installation: Checking the
not connected. compatibility with IT (ungrounded) and corner-
grounded TN systems on page 71

Install the drive on a wall. Mechanical installation on page 37

Route the cables. Planning the electrical installation: Routing the

cables on page 60

Check the insulation of the input cable and the Electrical installation: Checking the insulation
motor and the motor cable. of the assembly on page 70

Connect the power cables. Electrical installation: Connecting the power

cables on page 74

Connect the control cables. Electrical installation: Connecting the control

cables on page 91

Check the installation. Installation checklist on page 111

Commission the drive. ACS580 firmware manual

(3AXD50000016097 [English])
 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.
Brake chopper Conducts the surplus energy from the intermediate circuit of the drive to
the brake resistor when necessary. The chopper operates when the DC
link voltage exceeds a certain maximum limit. The voltage rise is
typically caused by deceleration (braking) of a high inertia motor.
Brake resistor Dissipates the drive surplus braking energy conducted by the brake
chopper to heat. Essential part of the brake circuit. See Brake chopper.
Control board Circuit board in which the control program runs.
Capacitor bank See DC link capacitors.
CDPI-01 Communication adapter module
CCA-01 Configuration adapter
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)
DC link DC circuit between rectifier and inverter
DC link capacitors Energy storage which stabilizes the intermediate circuit DC voltage
DPMP-01 Mounting platform for ACS-AP control panel (flange mounting)
DPMP-02 Mounting platform for ACS-AP control panel (surface mounting)
Drive Frequency converter for controlling AC motors
EMC Electromagnetic compatibility
EFB Embedded fieldbus
FBA Fieldbus adapter
FCAN-01 Optional CANopen adapter module
FCNA-01 ControlNet adapter module
FDNA-01 Optional DeviceNet adapter module
FECA-01 Optional EtherCAT adapter module
FENA-01/-11/-21 Optional Ethernet adapter module for EtherNet/IP, Modbus TCP and
PROFINET IO protocols
FEPL-02 Ethernet POWERLINK adapter module
FPBA-01 Optional PROFIBUS DP adapter module
Frame (size) Refers to drive physical size, for example R0 and R1. The type
designation label attached to the drive shows the frame of the drive, see
section Type designation key on page 35.
FSCA-01 Optional RSA-485 adapter module
I/O Input/Output
24 Introduction to the manual

Term/abbreviation Explanation
IGBT Insulated gate bipolar transistor
Intermediate circuit See DC link.
Inverter Converts direct current and voltage to alternating current and voltage.
LRFI Series of optional EMC filters
LSW Least significant word
Macro Pre-defined default values of parameters in drive control program. Each
macro is intended for a specific application. See ACS580 firmware
manual (3AXD50000016097 [English]).
NETA-21 Remote monitoring tool
Network control With fieldbus protocols based on the Common Industrial Protocol
(CIPTM), such as DeviceNet and Ethernet/IP, denotes the control of the
drive using the Net Ctrl and Net Ref objects of the ODVA AC/DC Drive
Profile. For more information, see www.odva.org, and the following
manuals:
• FDNA-01 DeviceNet adapter module user’s manual (3AFE68573360
[English]), and
• FENA-01/-11/-21 Ethernet adapter module user’s manual
(3AUA0000093568 [English]).
Parameter User-adjustable operation instruction to the drive, or signal measured or
calculated by the drive
PLC Programmable logic controller
PROFIBUS, Registered trademarks of PI - PROFIBUS & PROFINET International
PROFIBUS DP,
PROFINET IO
R0, R1, … Frame (size)
RCD Residual current device
Rectifier Converts alternating current and voltage to direct current and voltage.
RFI Radio-frequency interference
SIL Safety integrity level. See chapter Safe torque off function on page 187.
STO Safe torque off. See chapter Safe torque off function on page 187.
 Operation principle and hardware description 25

3
Operation principle and
hardware description
Contents of this chapter
This chapter briefly describes the operation principle, layout, type designation label
and type designation information. It also shows a general diagram of power
connections and control interfaces.
26 Operation principle and hardware description

Operation principle
The ACS580-01 is a drive for controlling asynchronous AC induction motors and
permanent magnet synchronous motors.
The figure below shows the simplified main circuit diagram of the drive.

ACS580-01
1 2 3
L1 T1/U
L2 T2/V
L3 T3/W

4 5

R- UDC+ UDC-
R+
1 Rectifier. Converts alternating current and voltage to direct current and voltage.
2 DC link. DC circuit between rectifier and inverter.
3 Inverter. Converts direct current and voltage to alternating current and voltage.
4 Brake chopper (R-, R+). Conducts the surplus energy from the intermediate DC circuit
of the drive to the brake resistor when necessary. The chopper operates when the DC
link voltage exceeds a certain maximum limit. The voltage rise is typically caused by
deceleration (braking) of a high inertia motor. The user obtains and installs the brake
resistor when needed.
Brake chopper is as standard in frames R0…R3.
5 DC connection (UDC+, UDC-), as standard for R5…R9.
 Operation principle and hardware description 27

Layout
Frames R0…R3
The layout of a frame R0 drive is presented below. The construction of frames
R1…R3 differs to some extent.
R0

1
4
5
6
17
7
8

8
10
2 17
9
11
PE 12 13
3
14 15
16
1 1

1 Mounting points (4 pieces) 10 EMC filter grounding switch (EMC).

2 Cover R0…R2: On the right side of the drive.
R3: On the front, near the I/O
3 Cover screw connections.
4 Assistant control panel See Checking the compatibility with IT
5 Control panel connection (ungrounded) and corner-grounded TN
systems on page 71.
6 Cold configuration connection for CCA-01
11 Input power connection (L1, L2, L3),
7 Power OK and Fault LEDs. See section motor connection (T1/U, T2/V, T3/W) and
LEDs on page 124. brake connection (R-, R+/UDC+).
8 I/O connections. See section External 12 PE connection (power line)
control connection terminals, frames
R0…R3 on page 30. 13 Grounding connection (motor)
9 Varistor grounding switch (VAR) 14 Additional grounding connection
15 Lead-through plate
16 Fan
17 Cable tie mounts for I/O cables

Frame R5
The layout of a frame R5 drive to be added.
28 Operation principle and hardware description

Frames R6…R9
The layout of a frame R6 drive is presented below. The constructions of frames
R7…R9 differ to some extent.
R6…R9
13 14
1 5

7
8
5 20 9
6
9
11
4
2
14 10
12
12
15

3 17
5
PE 16

1
19 18

1 Mounting points (2 at the top, 2 at the 13 Varistor grounding screw (VAR), under
bottom of the main part of the frame, 2 at the control panel platform
the top of the cable entry box) 14 Two EMC filter grounding screws (EMC),
2 Cover one under the control panel platform and
3 Cable entry box one at the left, above the shroud.
See Checking the compatibility with IT
4 Heatsink (ungrounded) and corner-grounded TN
5 Lifting holes (6 pieces) systems on page 71.
6 Assistant control panel 15 Shroud. Under the shroud: Input power
7 Control panel connection connection (L1, L2, L3), motor connection
(T1/U, T2/V, T3/W) and brake connection
8 Cold configuration connection for CCA-01 (R-, R+/UDC+) as well as DC connection
9 Power OK and Fault LEDs. See section (UDC+, UDC-).
LEDs on page 124. 16 PE connection (power line)
10 I/O connections. See section External 17 Grounding connection (motor)
control connection terminals, frame
R5…R9 on page 31. 18 Lead-through plate
11 Cable tie mounts for I/O cables 19 One main fan (R6…R8), two main fans
(R9) at the bottom
12 Clamps for I/O cable mechanical support
20 Auxiliary fan
 Operation principle and hardware description 29

Overview of power and control connections

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

Panel port
4

..........
.......... Slot 1
1
..........
..........

Slot 3
3

Slot 2 ..........
..........
..........
..........
2
PE PE
L1 L1 T1/U

L2 L2 T2/V M
3~
L3 L3 T3/W
UDC+
R- R+ UDC-

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.
30 Operation principle and hardware description

 External control connection terminals, frames R0…R3

The layout of the external control connection terminals of the R0 frame is shown
below. Layout of the external control connection terminals is identical in frames
R0…R3 but the location of the control unit with the terminals is different in frame R3.

X10 Description
R0…R3
X1 Analog inputs and outputs
X2 Aux. voltage output
S1 X3 Programmable digital inputs
S2
X4 Safe torque off connection
X5 Connection to embedded EIA-485
1 fieldbus adapter module (installed in
X1
option slot 3)
X6 Relay output 1
S3 2
X7 Relay output 2
3 X8 Relay output 3
X2
X10 Internal fan connection (IP55)
X13 Option slot 1 (fieldbus adapter
X3 modules)
X14 Option slot 2 (I/O extension
modules)
X15 Option slot 3 (embedded EIA-485
X4 X13 fieldbus adapter module)
X8 S1, S2 Voltage/Current selection switches
for analog input 1 (S1) and analog
X5 input 2 (S2), see section Switches
X15 X7
on page 94.
S5 S4
X6 S3 Voltage/Current selection switch for
analog output 1, see section
Switches on page 94.
X14 S4, S5 Termination switch (S4), bias
resistor switch (S5), see section
Switches on page 94
1 Panel port (control panel
connection)
2 Cold configuration connection. This
connector is used with the CCA-01
configuration adapter.
3 Power OK and Fault LEDs. See
section LEDs on page 124.
 Operation principle and hardware description 31

 External control connection terminals, frame R5…R9

The layout of the external control connection terminals of frames R5…R9 is shown
below.

R5…R9 Description
X1 Analog inputs and outputs
X2 Aux. voltage output
X3 Digital inputs
X4 Safe torque off connection
1
X5 Connection to embedded EIA-
485 fieldbus adapter module
2 (installed in option slot 3)
3 X6 Relay output 1
X7 Relay output 2
X8 Relay output 3
X10 External +24 V AC/DC
connection
X1:1…3 S1
X13 X13 Option slot 1 (fieldbus adapter
X1:4…6 S2 modules)
X14 Option slot 2 (I/O extension
X1:7…9 S3 modules)
X15 Option slot 3 (embedded EIA-
X2 485 fieldbus adapter module)

X3:1…3 X16 Internal fan 1 connection

X17 Internal fan 2 connection
X3:4…6 S1, S2 Voltage/Current selection
switches for analog input 1 (S1)
X4 and analog input 2 (S2), see
X5 X10
X15 section Switches on page 94.
S3 Voltage/Current selection
S4, S5 X8
switch for analog output 1, see
X16X17 section Switches on page 94.
X7
X14 S4, S5 Termination switch (S4), bias
X6 resistor switch (S5), see section
Switches on page 94
1 Panel port (control panel
connection)
2 Cold configuration connection.
This connector is used with the
CCA-01 configuration adapter.
3 Power OK and Fault LEDs. See
section LEDs on page 124.
32 Operation principle and hardware description

Control panel
To remove the control panel, press the retaining clip at the top (1a) and pull it forward
from the top edge (1b).

1a

1b

To reinstall the control panel, put the bottom of the container in position (1a), press
the retaining clip at the top (1a) 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]).
 Operation principle and hardware description 33

Type designation label

The type designation label includes IEC and NEMA ratings, appropriate markings
and the type designation and serial number, which allow identification of each drive.
The type designation label is located on the left side of the drive, see section
Locations of the labels on the drive. An example label is shown below.

1
4 5
2
3 4
6

No. Description
1 Type designation, see section Type designation key on page 35.
2 Frame (size)
3 Degree of protection
4 Nominal ratings in the supply voltage range, see section Ratings on page 128.
5 Valid markings
6 S/N: Serial number of format MYYWWXXXX, where
M: Manufacturer
YY: 13, 14, 15, … for 2013, 2014, 2015, …
WW: 01, 02, 03, … for week 1, week 2, week 3, …
XXXXX: Integer starting every week from 0001
34 Operation principle and hardware description

 Locations of the labels on the drive

3
 Operation principle and hardware description 35

Type designation key

The type designation contains information on the specifications and configuration of
the drive. You find the type designation on the type designation label attached to the
drive. The first digits from the left express the basic configuration, for example,
ACS580-01-12A6-5. The optional selections are given after that, separated by plus
signs, for example, +L501. The main selections are described below. Not all
selections are available for all types.
For more information, see ACS580 Ordering information (3AXD10000081909),
available on the Internet, see section Document library on the Internet on the inside of
the back cover.

ACS580-01-12A6-4+L501+K457+...
1 2 3 4

CODE DESCRIPTION
Basic codes

1 ACS580 Product series

01 When no options are selected: Wall mounted, IP21 (UL type 1), assistant
control panel with USB port, choke, EMC C2 filter (internal EMC filter), Safe
torque off, braking chopper in frames R0, R1, R2, R3, coated boards, cable
lead through entry from bottom, cable entry box or conduit plate with cable
entries, Quick guides with default set of languages as well as web links to
basic PC tool and latest manual versions.

2 Size

xxxx Refer to the rating table, page 128

3 Voltage rating

4 380…480 V

4 Option codes (plus codes)

Control panel and panel options

J400 ACS-AP-S Assistant control panel (as standard)
J425 ACS-AP-I Assistant control panel
J424 CDUM-01 Blank control panel cover (no control panel)
K450 CDPI-01 panel bus adapter
I/O (one slot available for I/O options)
L501 CMOD-01 External 24 V AC/DC and digital I/O extension (2×RO and 1×DO)
L523 CMOD-02 External 24 V AC/DC and isolated PTC interface
L512 CHDI-01 115/230 V Digital input extension (6×DI and 2×RO)
36 Operation principle and hardware description

CODE DESCRIPTION
Fieldbus adapters
K454 FPBA-01 PROFIBUS DP
K457 FCAN-01 CANopen
K451 FDNA-01 DeviceNet™
K474 FENA-11 Ethernet (EtherNet/IP™, Modbus/TCP, PROFINET)
K469 FECA-01 EtherCAT
K458 FSCA-01 Modbus/RTU
K470 FEPL-02 Ethernet POWERLINK
K462 FCNA-01 ControlNet™
K475 FENA-21 2-port Ethernet (EtherNet/IP™, Modbus/TCP, PROFINET)
Embedded fieldbus
CEIA-01 Embedded Modbus RTU adapter, EIA-485 (as standard)
Construction
B056 IP55 (UL type 12). Factory option, retro-fit not possible.
H358 Cable conduit plate, blank. Up to frame R3.
Full set of printed manuals in selected language. Note: The delivered manual set
may include manuals in English if the translation is not available.
R700 English
R701 German
R702 Italian
R703 Dutch
R704 Danish
R705 Swedish
R706 Finnish
R707 French
R708 Spanish
R709 Portuguese (Portugal)
R711 Russian
R712 Chinese
R714 Turkish
 Mechanical installation 37

4
Mechanical installation
Contents of this chapter
The chapter tells how to check the installation site, unpack, check the delivery and
install the drive mechanically.

Safety

WARNING! Frames R6…R9: Lift the drive with a lifting device. Use the lifting
eyes of the drive. Do not tilt the drive. The drive is heavy and its center of
gravity is high. An overturning drive can cause physical injury.
38 Mechanical installation

Checking the installation site

The drive must be installed on the wall. There are three alternative ways to install it:
• vertically alone. Do not install the drive upside down.

a Frame Vertical installation -

size Free space
Above (a) Below (b)1)
mm in mm in
R0 200 7.9 200 7.9
R1 200 7.9 200 7.9
R2 200 7.9 200 7.9
R3 200 7.9 200 7.9
R5 200 7.9 300 11.8
b
R6 200 7.9 300 11.8
R7 200 7.9 300 11.8
R8 200 7.9 300 11.8
R9 200 7.9 300 11.8
3AXD00000586715.xls F
1)
Free space below is measured from the fan, not from
the cable entry box used in frames R5…R9.

• vertically side by side

c =0 Frame Vertical installation side by side -

size Free space
a a
Above (a) Below (b)1) Between (c)
mm in mm in mm in
R0 200 7.9 200 7.9 0 0
R1 200 7.9 200 7.9 0 0
R2 200 7.9 200 7.9 0 0
R3 200 7.9 200 7.9 0 0
R5 200 7.9 300 11.8 0 0
R6 200 7.9 300 11.8 0 0
b b R7 200 7.9 300 11.8 0 0
R8 200 7.9 300 11.8 0 0
R9 200 7.9 300 11.8 0 0
3AXD00000586715.xls F
1)
Free space below is measured from the fan, not from
the cable entry box used in frames R5…R9.
 Mechanical installation 39

• horizontally alone.

c Frame Horizontal installation - Free space

size Above (a) Below (b)1) Side (c)
b a
mm in mm in mm in
R0 TBA TBA TBA TBA TBA TBA
c R1 TBA TBA TBA TBA TBA TBA
R2 TBA TBA TBA TBA TBA TBA
c R3 TBA TBA TBA TBA TBA TBA
R5 TBA TBA TBA TBA TBA TBA
a b
R6 TBA TBA TBA TBA TBA TBA
R7 TBA TBA TBA TBA TBA TBA
c R8 TBA TBA TBA TBA TBA TBA
R9 TBA TBA TBA TBA TBA TBA
3AXD00000586715.xls F
1)
Free space below is measured from the fan, not
from the cable entry box used in frames R5…R9.

Check the installation site according to the requirements below:

• The installation site is sufficiently ventilated or cooled to transfer away the drive
losses. See section Losses, cooling data and noise on page 140.
• The operation conditions of the drive meet the specifications given in section
Ambient conditions on page 152.
• The wall is as close to vertical as possible, of non-flammable material and strong
enough to carry the weight of the drive, see section Dimensions, weights and free
space requirements on page 138.
• The floor/material below the installation is non-flammable.
• There is enough free space above and below the drive to enable cooling air flow,
service and maintenance, See the required free space tables for each of the
different mounting alignments on page 38 (or page 138).

Required tools
To install the drive mechanically, you need the following tools:
• drill with suitable bits
• screwdriver and/or wrench with a set of suitable bits (as appropriate for the
installation hardware used)
• tape measure, if you will not be using the provided mounting template.

Moving the drive

Frames R5…R9: Move the transport package by pallet truck to the installation site.
40 Mechanical installation

Unpacking and examining delivery, frames R0…R3

The figure below shows the drive package with its contents. Examine that all items
are present and there are no signs of damage. Read the data on the type designation
label of the drive to make sure that the drive is of the correct type. See section Type
designation label on page 33.

8 7
8
8
2

4 5
3

1 Drive (frame R1 shown) 6 User’s manual (if ordered with a plus

2 Mounting accessories in plastic bag(s), code)
under the drive cover 7 Control panel selected in the order (in a
3 Mounting template separate package)
4 Multilingual residual voltage warning 8 Possible options in separate packages, if
stickers they have been ordered with a plus code,
such as for example +K457 (FCAN-01
5 Multilingual quick installation and start-up CANopen adapter module)
guide
 Mechanical installation 41

Unpacking and examining delivery, frame R5

The figure below shows the layout of the transport package. Examine that all items
are present and there are no signs of damage. Read the data on the type designation
label of the drive to make sure that the drive is of the correct type. See section Type
designation label on page 33.

6
8
16
2
9
3
10
1

11
13
7 14 15
12

1 Drive with factory installed options. 10 Support tape

2 Multilingual quick installation and start- 11 PET straps
up guide, multilingual residual voltage 12 Cable entry box package
warning stickers 13 Option tray
3 User’s manual (if ordered with a plus 14 Control panel selected in the order (in a
code) separate package) in the option tray
4 Cardboard tray 15 Possible options in separate packages, if
5 Cardboard sleeve they have been ordered with a plus
code, such as for example +K457
6 Top cardboard cover (FCAN-01 CANopen adapter module) in
7, 8 Cushions the option tray
9 Cardboard support 16 Mounting template

To unpack:
• Cut the straps (11).
• Remove the top cardboard cover (6) and cushions (7, 8).
• Lift the cardboard sleeve (5).
• Lift the drive.
42 Mechanical installation

 Frame R5 cable entry box

This illustration shows the contents of the cable entry box package. The package also
includes an assembly drawing which shows how to install the cable entry box to the
drive module frame.

3aua0000118007
 Mechanical installation 43

Unpacking and examining delivery, frames R6…R9

The figure below shows the layout of the transport package. Examine that all items
are present and there are no signs of damage. Read the data on the type designation
label of the drive to make sure that the drive is of the correct type. See section Type
designation label on page 33.

8
9 10 11
4 12

7 1

1 Cable entry box. Power and control cable 9 In the option tray
grounding shelves in a plastic bag, • Multilingual quick installation and start-
assembly drawing. up guide
• User’s manual (if ordered with a plus
2 Drive with factory installed options.
code)
3 Cardboard box • Multilingual residual voltage warning
4 Straps stickers
5 VCI bag for protecting against corrosion 10 Control panel selected in the order (in a
6 Pallet separate package) in the option tray
7 Stopper 11 Possible options in separate packages, if
8 Option tray they have been ordered with a plus code,
such as for example +K457 (FCAN-01
CANopen adapter module) in the option
tray
12 Mounting template on top of the option
tray
44 Mechanical installation

To unpack:
• Cut the straps (4).
• Remove the cardboard box (3) and option tray (8).
• Remove the VCI bag (5).
• Attach lifting hooks to the lifting eyes of the drive (see the figure on page 37). Lift
the drive with a hoist.

 Frame R6 cable entry box

The figure below shows the contents of the cable entry box package. The package
also includes an assembly drawing which shows how to install the cable entry box to
the drive frame.

3aua0000112044
 Mechanical installation 45

 Frame R7 cable entry box

The figure below shows the contents of the cable entry box package. The package
also includes an assembly drawing which shows how to install the cable entry box to
the drive frame.

3aua0000111117
46 Mechanical installation

 Frame R8 cable entry box

The figure below shows the contents of the cable entry box package. The package
also includes an assembly drawing which shows how to install the cable entry box to
the drive frame.

3aua0000112174
 Mechanical installation 47

 Frame R9 cable entry box

The figure below shows the contents of the cable entry box package. The package
also includes an assembly drawing which shows how to install the cable entry box to
the drive frame.

3aua0000112356
48 Mechanical installation

Installing the drive

 Installing the drive vertically, frames R0…R3
The figures show frame R0 as an example.
1. Mark the hole locations using the mounting template included in the package. Do
not leave the mounting template under the drive. The drive dimensions and hole
locations are also shown in the drawings in chapter Dimension drawings on page
161.
2. Drill the mounting holes.
3. Start the screws or bolts into the mounting holes.

1 a R0…R2: M5
2 3 ×4
R3: M6

×4
b

×4

R0 R1 R2 R3
mm in mm in mm in mm in
a 98 3.86 98 3.86 98 3.86 160 6.30
b 317 12.48 317 12.48 417 16.42 473 18.62
Weight kg lb kg lb kg lb kg lb
4.47 9.86 4.57 10.08 7.54 16.63 14.86 32.77

4. Position the drive onto the screws on the wall.

5. Tighten the screws in the wall securely.

4a 4b 5
×4
 Mechanical installation 49

 Installing the drive vertically, frame R5

1. Mark the hole locations using the mounting template included in the package. Do
not leave the mounting template under the drive. The drive dimensions and hole
locations are also shown in the drawings in chapter Dimension drawings on page
161.
2. Drill the mounting holes.
3. Start the screws or bolts into the mounting holes.

200 mm (7.9 in)

b
M6

R5
mm in
1 2 3 581/ 22.87/
a

a
611.5 24.07
b 160 6.30
kg lb

23.0 50.72

300 mm (11.8 in)

4. Remove the front cover: Remove the fastening screws, move the cover to the top
side and then up.

4
50 Mechanical installation

5. Attach the cable entry box to the drive frame. Push the box up to the drive frame
and tighten the box screws.

6. Position the drive (without the cover) onto the screws on the wall. Lift the drive
with another person or with a lifting device as it is heavy.
7. Tighten the screws in the wall securely.

200 mm
(7.9 in)

6 7

300 mm
(11.8 in)
 Mechanical installation 51

 Installing the drive vertically, frames R6…R9

1. Mark the hole locations for the six mounting holes using the mounting template
included in the package. Do not leave the mounting template under the drive.
The drive dimensions and hole locations are also shown in the drawings in
chapter Dimension drawings on page 161.
Note: You can use only two screws instead of four to attach the lower part of the
drive.

1 R6 R7 R8 R9
e

c mm in mm in mm in mm in
a 571 22.5 623 24.5 701 27.6 718 28.3
b 531 20.9 583 22.9 658 25.9 658 25.9
b
a

c 213 8.4 245 9.7 263 10.4 345 13.6

d 300 11.8 300 11.8 300 11.8 300 11.8
×4 e 200 7.9 200 7.9 200 7.9 200 7.9
d

kg lb kg lb kg lb kg lb

45 99 55 121 70 154 98 216

2. Drill the mounting holes.

3. Start the screws or bolts into the mounting holes.
4. Position the drive onto the screws on the wall. Lift the drive with another person
as it is heavy.
5. Tighten the screws in the wall securely.

2 3 M8 4
×2 ×2

5
52 Mechanical installation

6. Remove the front cover: Remove the fastening screws (a), move the cover to the
top side (b) and then up (c).
7. Attach the cable entry box to the drive frame.
8. Tighten the box screws: two at the top and four at the bottom.

7
8

6c

6a 8
6b
6a M6×6

 Installing the drive vertically side by side

Install the drive following the steps in the appropriate section Installing the drive
vertically, frames R0…R3 (page 48), Installing the drive vertically, frame R5 (page 49)
or Installing the drive vertically, frames R6…R9 (page 51).

 Installing the drive horizontally

Install the drive following the steps in the appropriate section Installing the drive
vertically, frames R0…R3 (page 48), Installing the drive vertically, frame R5 (page 49)
or Installing the drive vertically, frames R6…R9 (page 51). The drive can be installed
either the left or right side up.
Note: It is not allowed to install drives immediately on top of it each other.

Flange mounting
Instructions for flange mounting are delivered with the flange mounting kit: Flange
mounting quick guide for frames R6 to R9 (3AXD50000019099 [English]). For more
information on flange mounting, see Flange mounting supplement
(3AXD50000019100 [English]).
 Planning the electrical installation 53

5
Planning the electrical
installation
Contents of this chapter
This chapter contains instructions for planning the electrical installation of the drive,
for example, for checking the compatibility of the motor and drive, selecting cables,
protections and cable routing.
Note: The installation must always be designed and made according to applicable
local laws and regulations. ABB does not assume any liability whatsoever for any
installation which breaches the local laws and/or other regulations. Furthermore, if the
recommendations given by ABB are not followed, the drive may experience problems
that the warranty does not cover.

Selecting the supply disconnecting device

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 meet 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.
54 Planning the electrical installation

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

Checking the compatibility of the motor and drive

Use an asynchronous AC induction motor or a permanent magnet motor with the
drive. Several induction motors can be connected to the drive at a time but only one
permanent magnet motor can be connected to the drive at a time.
Check that the motor and the drive are compatible according to the rating table in
section Ratings on page 128. The table lists the typical motor power for each drive
type.

Selecting the power cables

 General rules
Select the input power and motor cables according to local regulations:
• The input power and the motor cables must be able to carry the corresponding
load currents. See section Ratings (page 128) for the rated currents.
• The cable must be rated for at least 70 °C maximum permissible temperature of
conductor in continuous use. For US, see Additional US requirements, page 57.
• The conductivity of the PE conductor must be sufficient, see the table on page 54.
• 600 V AC cable is accepted for up to 500 V AC.
To comply with the EMC requirements of the CE mark, use one of the approved cable
types in section Recommended power cable types on page 56.
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

Note: See the IEC/EN 61800-5-1 requirement on grounding in the Note on page 16.
 Planning the electrical installation 55

 Typical power cable sizes

The table below gives copper cable types with concentric copper shield for the drives
with nominal current. The value separated by the plus sign means the diameter of the
PE conductor.
Drive type Frame IEC1) US
size Cu cable type AI cable type2) Cu cable type AI cable type3)
mm2 mm2 AWG/kcmil AWG/kcmil
3-phase UN = 400 V (380…480 V)
ACS580-01-02A6-4 R0 3×1.5 + 1.5 - 16 -
ACS580-01-03A3-4 R0 3×1.5 + 1.5 - 16 -
ACS580-01-04A0-4 R0 3×1.5 + 1.5 - 16 -
ACS580-01-05A6-4 R0 3×1.5 + 1.5 - 16 -
ACS580-01-07A2-4 R1 3×1.5 + 1.5 - 16 -
ACS580-01-09A4-4 R1 3×2.5 + 2.5 - 14 -
ACS580-01-12A6-4 R1 3×2.5 + 2.5 - 14 -
ACS580-01-017A-4 R2 3×2.5 + 2.5 - 14 -
ACS580-01-025A-4 R2 3×6 + 6 - 10 -
ACS580-01-032A-4 R3 3×10 + 10 - 8 -
ACS580-01-038A-4 R3 3×10 + 10 - 8 -
ACS580-01-045A-4 R3 3×16 +16 - 6 -
ACS580-01-061A-4 R5 3×25 + 16 3×35 4 -
ACS580-01-072A-4 R5 3×35 + 16 3×50 2 -
ACS580-01-087A-4 R5 3×35 + 16 3×70 2 -
ACS580-01-105A-4 R6 3×50 + 25 3×70 1/0 -
ACS580-01-145A-4 R6 3×95 + 50 3×120 3/0 -
ACS580-01-169A-4 R7 3×120 + 70 3×150 250 MCM -
ACS580-01-206A-4 R7 3×150 + 70 3×240 300 MCM -
ACS580-01-246A-4 R8 2×(3×70+35) 2×(3×95) 2×2/0 -
ACS580-01-293A-4 R8 2×(3×95+50) 2×(3×120) 2×3/0 -
ACS580-01-363A-4 R9 2×(3×120+70) 2×(3×185) 2×250 MCM -
ACS580-01-430A-4 R9 2×(3×150+70) 2×(3×240) 2×300 MCM -
3AXD00000586715.xls F
1)
The cable sizing is based on max. 6 cables laid on a cable ladder side by side, ambient temperature 30 °C,
PVC insulation, surface temperature 70 °C (EN 60204-1 and IEC 60364-5-52/2001). For other conditions,
size the cables according to local safety regulations, appropriate input voltage and the load current of the
drive. See also page 141 for the accepted cable sizes of the drive.
2) Aluminum cables must not be used with frames R0…R3.
3)
In the USA, aluminum cables must not be used.

See also section Terminal and lead-through data for the power cables on page 141.
56 Planning the electrical installation

 Alternative power cable types

The recommended and the 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 the shield. The shield must meet the
requirements of IEC 61439-1, see page 54. Check with
local/state/country electrical codes for allowance.

Symmetrical shielded cable with three phase conductors and a

concentric PE conductor as the shield. A separate PE conductor is
required if the shield does not meet the requirements of IEC 61439-1,
see page 54.
PE

PE Symmetrical shielded cable with three phase conductors and

symmetrically constructed PE conductor, and a shield. The PE conductor
must meet the requirements of IEC 61439-1, see page 54.

Power cable types for limited use

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

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

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

a PVC conduit) is allowed for input cabling with phase conductor
PVC cross-section less than 10 mm2 (8 AWG) or motors < 30 kW (40 hp).
Not allowed in the USA.

Corrugated or EMT cable with three phase conductors and a protective

conductor is allowed for motor cabling with phase conductor cross
section less than 10 mm2 (8 AWG) or motors < 30 kW (40 hp).
EMT

Not allowed power cable types

PE Symmetrical shielded cable with individual shields for each phase

conductor is not allowed on any cable size for input or motor cabling.
 Planning the electrical installation 57

 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 section 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.

3 4 5

1 Sheath
2 Copper wire shield
3 Helix of copper tape or copper wire
4 Filling
5 Cable conductors

 Additional US requirements
Use type MC continuous corrugated aluminum armor cable with symmetrical grounds
or shielded power cable for the motor cables if metallic conduit is not used. For the
North American market, 600 V AC cable is accepted for up to 500 V AC. 1000 V AC
cable is required above 500 V AC (below 600 V AC). For drives rated over 100
amperes, the power cables must be rated for 75 °C (167 °F).

Conduit
Couple separate parts of a conduit together: bridge the joints with a ground conductor
bonded to the conduit on each side of the joint. Also bond the conduits to the drive
enclosure and motor frame. Use separate conduits for input power, motor, brake
resistor, and control wiring. When conduit is employed, type MC continuous
corrugated aluminum armor cable or shielded cable is not required. A dedicated
ground cable is always required.
Note: Do not run motor wiring from more than one drive in the same conduit.
58 Planning the electrical installation

Armored cable / shielded power cable

Six-conductor (three phases and three ground) type MC continuous corrugated
aluminum armor cable with symmetrical grounds is available from the following
suppliers (trade names in parentheses):
• Anixter Wire & Cable (Philsheath)
• BICC General Corp (Philsheath)
• Rockbestos Co. (Gardex)
• Oaknite (CLX).
Shielded power cables are available from the following suppliers:
• Belden
• LAPPKABEL (ÖLFLEX)
• Pirelli.

Selecting the control cables

 Shielding
All control cables must be shielded.
Use a double-shielded twisted pair cable (figure a below) for analog signals. Employ
one individually shielded pair for each signal. Do not use common return for different
analog signals.
A double-shielded cable is the best alternative for low-voltage digital signals but
single-shielded (b) twisted pair cable is also acceptable.

a b

 Signals in separate cables

Run analog and digital signals in separate, shielded cables.
Do not mix 24 V AC/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.
 Planning the electrical installation 59

 Relay cable
The cable type with braided metallic screen (for example ÖLFLEX by LAPPKABEL,
Germany) has been tested and approved by ABB.

 Control panel cable

In remote use, the cable connecting the control panel to the drive must not exceed
100 m (330 ft). If multiple panels or drives are connected, the total length of the panel
bus must not exceed 100 m (330 ft).
The cable type tested and approved by ABB is used in control panel option kits.
Suitable cables are CAT 5e unshielded or shielded twisted pair cables.

 Drive composer PC tool cable

Connect the Drive composer PC tool to the drive through the USB port of the control
panel. Use a USB type A (PC) - type B (control panel) cable. The maximum length of
the cable is 3 m (9.8 ft).

 FPBA-01 PROFIBUS DP adapter module connectors

Frames R0…R3: The following connector types have been tested to fit in the tight
space for option slot 1.
• Phoenix Contact SUBCON-PLUS-PROFIB/PG/SC2, part number 2708245. Lead
the cable through the control cable hole on the right in the lead-through plate (1).
• Siemens, part number 6GK1 500 0EA02. Lead the cable through the middle
control cable hole in the lead-through plate (2).

1
2
60 Planning the electrical installation

Routing the cables

 General rules
Route the motor cable away from other cable routes. Motor cables of several drives
can be run in parallel 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 run 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.

Drive

Motor cable

min. 300 mm (12 in)

Input power or
brake resistor cable

min. 500 mm (20 in)

Control cable 90° Motor cable

min. 200 mm (8 in)

Input power cable

Control cable
 Planning the electrical installation 61

 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
(120 V)

24 V

 Continuous motor cable shield or enclosure for equipment on the

motor cable
To minimize the emission level when safety switches, contactors, connection boxes
or similar equipment are installed on the motor cable between the drive and the
motor:
• 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.
62 Planning the electrical installation

Implementing thermal overload and short-circuit protection

 Protecting the drive and input power cable in short-circuits
Protect the drive and input cable with fuses as follows:

~ M
~ 3~

Size the fuses at the distribution board according to instructions given in chapter
Technical data on page 127. The fuses will protect 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.
Note: If you want to use circuit breakers, contact ABB for more information.

 Protecting the motor and motor cable in short-circuits

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

 Protecting the drive and the 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 sized 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.
 Planning the electrical installation 63

The most common temperature sensors are:

• motor sizes IEC180…225: thermal switch, eg, Klixon
• motor sizes IEC200…250 and larger: PTC or Pt100.
For more information, see ACS580 firmware manual (3AXD50000016097 [English]).

Protecting the drive against ground faults

The drive is equipped with an internal ground fault protective function to protect the
unit against ground faults in the motor and motor cable. This is not a personnel safety
or a fire protection feature. The ground fault protective function can be reduced with a
parameter 31.20 Earth fault.

 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 may cause fault current circuit breakers to function.

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.
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 187.
64 Planning the electrical installation

Implementing the Power-loss ride-through function

See ACS580 firmware manual (3AXD50000016097 [English]).

Using a safety switch between the drive and the motor

It is recommended to install a safety switch between the permanent magnet motor
and the drive output. This is needed to isolate the motor from the drive during
maintenance work on the drive.
 Planning the electrical installation 65

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 65.
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.
1. Wait until the drive decelerates the motor to zero speed.
2. 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 frequent 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.
66 Planning the electrical installation

 Example bypass connection

An example bypass connection is shown below.

Q1 Drive main switch S11 Drive main contactor on/off control

Q4 Bypass circuit breaker S40 Motor power supply selection (drive or
direct-on-line)
K1 Drive main contactor S41 Start when motor is connected direct-on-
line
K4 Bypass contactor S42 Stop when motor is connected direct-on-
line
K5 Drive output contactor
 Planning the electrical installation 67

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 local control
mode) or with the external stop signal (drive in 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.

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 at position 1).
4. Start the drive and the motor with the drive control panel (drive in local control
mode) or with the external start signal (drive in remote control mode).

Protecting the contacts of relay outputs

Inductive loads (relays, contactors, motors) cause voltage transients when switched
off.
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.
68 Planning the electrical installation

230 V AC

230 V AC

+ 24 V DC

1 Relay outputs
2 Varistor
3 RC filter
4 Diode

Limiting relay output maximum voltages at high installation

altitudes
See sections Isolation areas, R0…R3 (CCU-11): on page 148 and Isolation areas,
R5…R9 (CCU-12): on page 149.
 Electrical installation 69

6
Electrical installation
Contents of this chapter
The chapter describes how to check the insulation of the assembly and the
compatibility with IT (ungrounded) and corner-grounded TN systems. It then shows
how to connect the power and control cables, install optional modules and connect a
PC.

Warnings

WARNING! Obey the instructions in chapter Safety instructions on page 11. If

you ignore them, injury or death, or damage to the equipment can occur.
Make sure that the drive is disconnected from the input power during
installation. If the drive is already connected to the input power, wait for
5 minutes after disconnecting the input power.

Required tools
To perform the electrical installation, you need the following tools:
• wire stripper
• screwdriver and/or wrench with a set of suitable bits.
70 Electrical installation

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 power 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/U,
T2/V and T3/W.
2. Measure the insulation resistance between the phase conductors and between
each phase conductor and the Protective Earth conductor. Use a measuring
voltage of 1000 V DC. The insulation resistance of an ABB motor must exceed
100 Mohm (reference value at 25 °C or 77 °F). For the insulation resistance of
other motors, please consult the manufacturer’s instructions.
Note: Moisture inside the motor casing will reduce the insulation resistance. If
moisture is suspected, dry the motor and repeat the measurement.

U1
M
V1
3~
ohm W1
PE
 Electrical installation 71

 Brake resistor assembly

Check the insulation of the brake resistor assembly (if present) as follows:
1. Check that the resistor cable is connected to the resistor, and disconnected from
the drive output terminals R+ and R-.
2. At the drive end, connect the R+ and R- conductors of the resistor cable together.
Measure the insulation resistance between the combined conductors and the PE
conductor by using a measuring voltage of 1 kV DC. The insulation resistance
must be higher than 1 Mohm.

R+

R-
ohm
PE

Checking the compatibility with IT (ungrounded) and

corner-grounded TN systems
The internal EMC filter is not suitable for use on an IT (ungrounded) system or on a
corner-grounded TN system. Disconnect the EMC filter before connecting the drive to
the supply network. For instructions on how to do this, see page 72.

WARNING! Do not install the drive with the internal EMC filter connected on an
IT system (an ungrounded power system or a high-resistance-grounded [over
30 ohms] power system), otherwise the system will be connected to ground potential
through the EMC filter capacitors of the drive. This can cause danger, or damage the
drive.
Do not install the drive with the internal EMC filter connected on a corner-grounded
TN system, otherwise the drive will be damaged.

Note: When the internal EMC filter is disconnected, the drive EMC compatibility is
considerably reduced. See section EMC compatibility and motor cable length on
page 145.
72 Electrical installation

 Frames R0…R3
If you have an IT (ungrounded) or corner-grounded TN system, do as follows:
1. Switch off the power from the drive.
2. Open the front cover, if not already opened, see page 75.
3. Disconnect the internal EMC filter by sliding the EMC switch in the direction
shown by the arrow.
Pay attention to the switches! Do not confuse the EMC switch to the similar
varistor disconnecting switch. Do not disconnect the varistor. The varistor protects
the drive against power line voltage peaks.
R0…R2

3
EMC

R3

EMC

3
 Electrical installation 73

 Frames R5…R9
If you have an IT (ungrounded) or corner-grounded TN system, do as follows:
1. Switch off the power from the drive.
2. Open the cover, if not already opened. Frame R5: see page 49, frames R6…R9:
see page 52.
3. Disconnect the internal EMC filter by removing the two EMC screws.
R5

R6…R9

3
74 Electrical installation

Connecting the power cables

 Connection diagram

ACS580-01
UDC+
L1 L2 L3 R- R+ T1/U T2/V T3/W
PE
2b
2a
3 3 4

5
V1
1 W1
U1
3~M
(PE) PE (PE) L1 L2 L3

1 For alternatives, see section Selecting the supply disconnecting device on page 53.
2 Use a separate grounding PE cable (2a) or a cable with a separate PE conductor (2b)
if the conductivity of the shield does not meet the requirements for the PE conductor
(see page 54).
3 360-degree grounding is recommended if shielded cable is used. Ground the other end
of the input cable shield or PE conductor at the distribution board.
4 360-degree grounding is required.
5 External brake resistor
6 Use a separate grounding cable if the shield does not meet the requirements of
IEC 61439-1 (see page 54) and there is no symmetrically constructed grounding
conductor in the cable (see page 57).
Note:
If there is a symmetrically constructed grounding conductor on the motor cable in addition to
the conductive shield, connect the grounding conductor to the grounding terminal at the drive
and motor ends.
Do not use an asymmetrically constructed motor cable for motors above 30 kW (see page 54).
Connecting its fourth conductor at the motor end increases bearing currents and causes extra
wear.
 Electrical installation 75

 Connection procedure, frames R0…R3

1. Remove the front cover: Loosen the retaining screw with a screwdriver (1a) and
lift the cover from the bottom outwards (1b).

1b

1b 1a

WARNING! If the drive will be connected on an IT (ungrounded) system or on

a corner-grounded TN system, make sure you have disconnected the EMC
filter. See page 71.

2. Attach the residual voltage warning sticker in the local language.

R0…R1 R2 R3

2 2 2
76 Electrical installation

3. Remove the rubber grommets from the lead-through plate.

4. Frames R0…R2, optional: It is possible to temporarily remove the power cable
grounding shelf at this point to make it easier to connect the power cable
conductors and twisted shields in a tight space. The grounding shelf must be
reinstalled before grounding the stripped parts of the power cables 360 degrees.

3
4

Motor cable
5. Cut an adequate hole into the rubber grommet. Slide the grommet onto the cable.
6. Prepare the ends of the cable as illustrated in the figure. If you use aluminum
cables, put grease to the peeled aluminum cable before connecting it to the drive.
Two different motor cable types are shown in the figures (6a, 6b). Note: The bare
shield will be grounded 360 degrees.

5 6a
PE

6b

PE
 Electrical installation 77

7. Slide the cable through the hole of the lead-through plate and attach the grommet
to the hole.

8. Connect the motor cable:

If you temporarily removed the power cable grounding shelf in step 4, connect the
motor and input power cables except the 360 degree grounding, and then reinstall
the grounding shelf. Note: The screws are of different length; find out where each
of them is used in the figure at step 4. After reinstalling the grounding shelf, you
can make the 360 degree grounding for the cables.
• Ground the shield 360 degrees by tightening the clamp of the power cable
grounding shelf onto the stripped part of the cable. (8a)
• Connect the twisted shield of the cable to the grounding terminal. (8b)
• Connect the phase conductors of the cable to the T1/U, T2/V and T3/W
terminals. Tighten the screws to the torque given below the figure. (8c).
R0…R2 R3
8b
8c 8c
8b
8a
8a

Frame size R0…R1 R2 R3

N·m lbf·ft N·m lbf·ft N·m lbf·ft
L1, L2, L3, T1/U, T2/V, T3/W, R+, R- 0.5…0.6 0.4 1.2…1.5 0.9…1.1 2.5…4.5 1.8…3.3
78 Electrical installation

Input power cable

9. Cut an adequate hole into the rubber grommet. Slide the grommet onto the cable.
10. Prepare the ends of the cable as illustrated in the figure. If you use aluminum
cables, put grease to the peeled aluminum cable before connecting it to the drive.
Note: The bare shield will be grounded 360 degrees. Mark the pigtail made from
the shield as a PE conductor with yellow-and-green color.
11. Slide the cable through the hole of the lead-through plate and attach the grommet
to the hole.

10

PE

PE

9
11

12. Connect the input power cable:

• Ground the shield 360 degrees by tightening the clamp of the power cable
grounding shelf onto the stripped part of the cable. (12a)
• Connect the twisted shield of the cable to the grounding terminal. (12b)
• Connect the additional PE conductor (see the note on page 15 in chapter
Safety instructions) of the cable (12c).
• Connect the phase conductors of the cable to the L1, L2 and L3 terminals.
Tighten the screws to the torque given below the figure. (12d).
R0…R2 R3

12b 12c
12d 12b
12d
12c

12a
12a

Frame size R0…R1 R2 R3

N·m lbf·ft N·m lbf·ft N·m lbf·ft
L1, L2, L3, T1/U, T2/V, T3/W, R+, R- 0.5…0.6 0.4 1.2…1.5 0.9…1.1 2.5…4.5 1.8…3.3
 Electrical installation 79

Brake resistor cable (if used)

13. Frames R0…R2: Install the grounding shelf for the brake resistor cable (included
with the mounting screws in a plastic bag in the delivery) onto the grounding shelf
for the power cables.
R0…R2

13

14. Repeat steps 5…7 for the brake resistor cable. Cut off one phase conductor.

PE

14
80 Electrical installation

15. Connect the cable as the motor cable in step 8. Ground the shield 360 degrees
(15a). Connect the twisted shield to the grounding terminal (15b) and the
conductors to the R+ and R- terminals (15c) and tighten to the torque given below
the figure.
R0…R2 R3
15c 15b
15c

15b

15a
15a

Frame size R0…R1 R2 R3

N·m lbf·ft N·m lbf·ft N·m lbf·ft
L1, L2, L3, T1/U, T2/V, T3/W, R+, R- 0.5…0.6 0.4 1.2…1.5 0.9…1.1 2.5…4.5 1.8…3.3

Finalization
Note: Frames R0…R2: You have to install any optional I/O extension module, if used,
in options slot 2 at this point. See section Installing option modules on page 104.
16. Install the grounding shelf for the control cables (included with the mounting
screws in a plastic bag in the delivery) onto the grounding shelf for the power
cables.
R0…R2 R3

14 14
 Electrical installation 81

17. Put the (so far) unused rubber grommets to the holes in the lead-through plate,
unless you will continue with installing the control cables.
R0…R2 R3

15 15

18. Secure the cables outside the unit mechanically.

19. Ground the motor cable shield at the motor end. For minimum radio frequency
interference, ground the motor cable shield 360 degrees at the lead-through of
the motor terminal box.

17
82 Electrical installation

 Connection procedure, frame R5

Prepare the drive and the cables

WARNING! If the drive will be connected on an IT (ungrounded) system or on

a corner-grounded TN system, make sure you have disconnected the EMC
filter. See page 71.

1. Attach the residual voltage warning sticker in the local language next to the
control board.
2. Remove the shroud on the power cable terminals by releasing the clips and lifting
the shroud up from the sides with a screwdriver (2a). Knock out holes in the
shroud for the cables to be installed (2b).

2a

2b
 Electrical installation 83

3. Cut adequate holes into the rubber grommets. Slide the grommets onto the
cables. Prepare the ends of the cables as illustrated in the figure. If you use
aluminum cables, put grease to the peeled aluminum cable before connecting it to
the drive. Note: The bare shield will be grounded 360 degrees. Mark the pigtail
made from the shield as a PE conductor with yellow-and-green color. Slide the
cables through the holes of the lead-through plate and attach the grommets to the
holes (the motor cable to the right and the input power cable to the left).

3a

PE

3b

PE
84 Electrical installation

Connect the cables

4. Connect the motor cable:
• Ground the shield 360 degrees under the grounding clamps (4a).
• Connect the twisted shield of the cable to the grounding terminal (4b).
• Connect the phase conductors of the cable to the T1/U, T2/V and T3/W
terminals (4c). Tighten the screws to the torque given in table.
5. Connect the input power cable as in step 4. Ground the shield 360 degrees under
the grounding clamps (5a). Connect the twisted shield to the grounding terminal
(5b) and the phase conductors to the L1, L2 and L3 terminals (5c). Tighten the
screws to the torque given in table.
6. Install the EMC shroud separating the input and output cabling.
7. Reinstall the shroud on the power terminals.

4a

5c 4c

5b 4b

5a

L1, L2, L3, T1/U, T2/V, T3/W PE,

N·m lbf·ft N·m lbf·ft
R5 5.6 4.1 2.9 2.1

8. Put the unused rubber grommets to the holes in the lead-through plate.
9. Secure the cables outside the unit mechanically.
 Electrical installation 85

10. Ground the motor cable shield at the motor end. For minimum radio frequency
interference, ground the motor cable shield 360 degrees at the lead-through of
the motor terminal box.

14
86 Electrical installation

 Connection procedure, frames R6…R9

WARNING! If the drive will be connected on an IT (ungrounded) system or on

a corner-grounded TN system, make sure you have disconnected the EMC
filter. See page 71.

1. Attach the residual voltage warning sticker in the local language next to the
control board.
2. Remove the side plates of the cable entry box: Remove the retaining screws and
slide the walls out.

1 2

3. Remove the shroud on the power cable terminals by releasing the clips with a
screwdriver and pulling the shroud out.
4. Knock out holes in the shroud for the cables to be installed.
5. Frames R8…R9: If you install parallel cables, also knock out holes in the lower
shroud for the cables to be installed.
R8…R9
3 4 5
 Electrical installation 87

Motor cable
6. Cut an adequate hole into the rubber grommet. Slide the grommet onto the cable.
7. Prepare the ends of the input power cable and motor cable as illustrated in the
figure. If you use aluminum cables, put grease to the peeled aluminum cable
before connecting it to the drive. Two different motor cable types are shown in the
figures (7a, 7b). Note: The bare shield will be grounded 360 degrees. Mark the
pigtail made from the shield as a PE conductor with yellow-and-green color.

6 7a

PE

7b

PE

8. Slide the cables through the holes of the lead-through plate and attach the
grommets to the holes (the motor cable to the right and the input power cable to
the left).
9. Connect the motor cable:
• Ground the shield 360 degrees under the grounding clamps.
• Connect the twisted shield of the cable to the grounding terminal (9a).
• Connect the phase conductors of the cable to terminals T1/U, T2/V and T3/W.
Tighten the screws to the torque given in the figure (9b).
Note 1 for frames R8…R9: If you connect only one conductor to the connector,
we recommend that you put it under the upper pressure plate.
88 Electrical installation

Note 2 for frames R8…R9: The connectors are detachable but we do not
recommend that you detach them. If you do, detach and reinstall the connectors
as follows.
Terminals L1, L2 and L3
• Remove the combi screw that attaches the connector to its terminal post, and
pull the connector off.
• Put the conductor under the connector pressure plate and pre-tighten the
conductor.
• Put the connector back onto the terminal post. Start the combi screw, and turn
it at least two rotations by hand.

WARNING! Before using tools, make sure that the nut/screw is not cross-
threading. Cross-threading will damage the drive and cause danger.

• Tighten the combi screw to a torque of 30 N·m (22 lbf·ft).

• Tighten the conductor(s) to 40 N·m (30 lbf·ft) for frame R8 or to 70 N·m
(52 lbf·ft) for frame R9.
Terminals T1/U, T2/V and T3/W
• Remove the nut that attaches the connector to its busbar.
• Put the conductor under the connector pressure plate and pre-tighten the
conductor.
• Put the connector back to its busbar. Start the nut, and turn it at least two
rotations by hand.

WARNING! Before using tools, make sure that the nut/screw is not cross-
threading. Cross-threading will damage the drive and cause danger.

• Tighten the nut to a torque of 30 N·m (22 lbf·ft).

• Tighten the conductor(s) to 40 N·m (30 lbf·ft) for frame R8 or to 70 N·m
(52 lbf·ft) for frame R9.
 Electrical installation 89

10. Connect the input power cable as in step 9. Use terminals L1, L2 and L3.

9b 10b

9a 10a

M5×25/35

8 8

Frame size L1, L2, L3, T1/U, T2/V, T3/W PE,

N·m lbf·ft N·m lbf·ft
R6 30 22.1 9.8 7.2
R7 40 29.5 9.8 7.2
R8 40 29.5 9.8 7.2
R9 70 51.6 9.8 7.2

11. Frames R8…R9: If you install parallel cables, install the second grounding shelf
for the parallel power cables (11a). Repeat steps 6...10 (11b).
R8…R9 R8…R9

M5×25

11b 11b

11a 11a

M5×12

12. Install the grounding shelf of the control cables.

90 Electrical installation

13. Reinstall the shroud on the power terminals.

14. Secure the cables outside the unit mechanically.

12 13

15. Ground the motor cable shield at the motor end. For minimum radio frequency
interference, ground the motor cable shield 360 degrees at the lead-through of
the motor terminal box.

15

DC connection
The UDC+ and UDC- terminals (as standard in frames R5…R9) are for using external
brake chopper units.
 Electrical installation 91

Connecting the control cables

See section Default I/O connection diagram (ABB standard macro) on page 92 for the
default I/O connections of the ABB standard macro. For other macros, see ACS580
firmware manual (3AXD50000016097 [English]).
Connect the cables as described under Control cable connection procedure R0…R9
on page 99.
92 Electrical installation

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

S1 AI1 U/I Voltage/Current selection for AI1: U I 1)
S2 AI2 U/I Voltage/Current selection for AI2: U I 2)
XI Reference voltage and analog inputs and outputs
1 SCR Signal cable shield (screen)
1…10 kohm 2 AI1 Output frequency/speed reference: 0…10 V4)
3 AGND Analog input circuit common
4 +10V Reference voltage 10 V DC
5 AI2 Not configured
6 AGND Analog input circuit common
max. 7 AO1 Output frequency: 0…20 mA
500 ohm 8 AO2 Output current: 0…20 mA
9 AGND Analog output circuit common
9) S3 AO1 I/U Voltage/Current selection for AO1: I U
X2 & X3 Aux. voltage output and programmable digital inputs
10 +24V Aux. voltage output +24 V DC, max. 250 mA3)
11 DGND Aux. voltage output common
7)
12 DCOM Digital input common for all
13 DI1 Stop (0) / Start (1)
14 DI2 Forward (0) / Reverse (1)
15 DI3 Constant frequency/speed selection5)
16 DI4 Constant frequency/speed selection5)
17 DI5 Ramp set 1 (0) / Ramp set 2 (1)6)
8)
18 DI6 Not configured
X6, X7, X8 Relay outputs
19 RO1C Ready run
20 RO1A 250 V AC / 30 V DC
21 RO1B 2A
22 RO2C Running
23 RO2A 250 V AC / 30 V DC
24 RO2B 2A
25 RO3C Fault (-1)
26 RO3A 250 V AC / 30 V DC
27 RO3B 2A
X5 EIA-485 Modbus RTU
29 B+ Embedded Modbus RTU (EIA-485). See
30 A- ACS580 firmware manual (3AXD50000016097
31 DGND [English]).
S4 TERM Serial data link termination switch
S5 BIAS Serial data link bias resistors switch
X4 Safe torque off
34 OUT1
35 OUT2 Safe torque off. Factory connection. Both circuits
7) 36 SGND must be closed for the drive to start. See chapter
7)
37 IN1 Safe torque off function on page 187.
38 IN2
X10 24 V AC/DC
See the notes on 40 24 V AC/DC- in R5…R9 only: Ext. 24V AC/DC input to power up the
the next page. 41 24 V AC/DC+ in control unit when the main supply is disconnected.

Terminal sizes:
R0…R3: 0.2…2.5 mm2 (terminals +24V, DGND, DCOM, B+, A-, DGND, Ext. 24V)
0.14…1.5 mm2 (terminals DI, AI, AO, AGND, RO, STO)
R5…R9: 0.14…2.5 mm2 (all terminals)
Tightening torques: 0.5…0.6 N·m (0.4 lbf·ft)
 Electrical installation 93

Notes:
1)
Current [0(4)…20 mA, Rin = 100 ohm] or voltage [ 0(2)…10 V, Rin > 200 kohm] input selected
with jumper S1. 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 jumper S2. Change of setting requires changing the corresponding parameter.
3)
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.
4)
AI1 is used as a speed reference if vector control is selected.
5)
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
6)
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
7)
Connected with jumpers at the factory.
8)
Note: Use shielded twisted-pair cables for digital signals.
9)
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.
See also section Control connection data on page 146.
94 Electrical installation

Switches
Switch Description Position
S1 Determines whether analog input AI1 is U I Voltage (U) (default)
used as a voltage or current input. AI1
(AI1)
U I Current (I)
AI1
S2 Determines whether analog input AI2 is U I Voltage (U)
used as a voltage or current input. AI2
(AI2)
U I Current (I) (default)
AI2
S3 Determines whether analog output AO1 is I U Current (I) (default)
used as a current or voltage output. AO1
(AO1)
I U Voltage (U)
AO1
S4 Modbus link termination. Must be set to the ON Bus not terminated
(TERM) terminated (ON) position when the drive (or (default)
another device) is the first or last unit on
TERM
the link.
ON Bus terminated

TERM
S5 Switches on the biasing voltages to the ON Bias off (default)
(BIAS) bus. One (and only one) device, preferably
at the end of the bus must have the bias
BIAS
on.
ON Bias on

BIAS
 Electrical installation 95

PNP configuration for digital inputs

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)

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

NPN configuration for digital inputs

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

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

NPN connection (sink) NPN connection (sink)

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

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

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

X1

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

0…10 V

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

X1

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

0…10 V

1 kohm 1 kohm
Analog common ground. Internally connected
9 AGND
to chassis through a 2 Mohm resistor.
 Electrical installation 97

Connection examples of two-wire and three-wire sensors

Hand/Auto, Hand/PID, and PID macros (see ACS580 firmware manual
(3AXD50000016097 [English])) 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

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

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

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

DI6 as frequency input

If DI6 is used as a frequency input, see ACS580 firmware manual
(3AXD50000016097 [English]) for how to set parameters accordingly.

AI1 and AI2 as Pt100, Pt1000, Ni1000, KTY83 and KTY84 sensor inputs (X1)
One, two or three Pt100 sensors; one, two or three Pt1000 sensors; or one Ni1000,
KTY83 or KTY84 sensor for motor temperature measurement can be connected
between an analog input and output as shown below. 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)

AIn 1)
AGND

T T T 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 (X4)

For the drive to start, both connections (+24 V DC to IN1 and +24 V DC to IN2) must
be closed. By default, the terminal block has jumpers to close the circuit. Remove the
jumpers before connecting an external Safe torque off circuitry to the drive. See
chapter Safe torque off function on page 187.
Note: Only 24 V DC can be used for STO. Only PNP input configuration can be used.
 Electrical installation 99

 Control cable connection procedure R0…R9

WARNING! Obey the instructions in chapter Safety instructions on page 11. 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 front cover(s) if not already removed. See page 75 (R0…R3), page
49 (R5) or page 52 (R6…R9).
Analog signals
The figures for frames R0…R2 (page 101), R3 (page 101), R5 (page 102) and
R6…R7 (page 103) show an example of connecting a cable. Make the connections
according to the macro in use.
3. Cut an adequate hole into the rubber grommet and slide the grommet onto the
cable. Slide the cable through a hole in the lead-through plate and attach the
grommet to the hole.
4. Ground the outer shield of the cable 360 degrees under the grounding clamp.
Keep the cable unstripped as close to the terminals of the control board as
possible.
Frames R5…R9: Secure the cables mechanically at the clamps below the control
unit.
Ground also the pair-cable shields and grounding wire at the SCR terminal.
5. Route the cable as shown in the figures on pages 101 (R0…R2), 101 (R3), 102
(R5) or 103 (R6…R9).
6. Connect the conductors to the appropriate terminals of the control board and
tighten to 0.5…0.6 N·m (0.4 lbf·ft).
Digital signals
The figures for frames R0…R2 (page 101), R3 (page 101), R5 (page 102) and
R6…R7 (page 103) show an example of connecting a cable. Make the connections
according to the macro in use.
7. Cut an adequate hole into the rubber grommet and slide the grommet onto the
cable. Slide the cable through the hole in the lead-through plate and attach the
grommet to the hole.
8. Ground the outer shield of the cable 360 degrees under the grounding clamp.
Keep the cable unstripped as close to the terminals of the control board as
possible.
Frames R5…R9: Secure the cables mechanically at the clamps below the control
unit.
If you use double-shielded cables, ground also the pair-cable shields and
grounding wire at the SCR terminal.
100 Electrical installation

9. Route the cable as shown in the figures on pages 101 (R0…R2), 101 (R3), 102
(R5) or 103 (R6…R9).
10. Connect the conductors to the appropriate terminals of the control board and
tighten to 0.5…0.6 N·m (0.4 lbf·ft).
11. Tie all control cables to the provided cable tie mounts.
Note:
• Leave the other ends of the control cable shields unconnected or ground them
indirectly via a high-frequency capacitor with a few nanofarads, eg, 3.3 nF / 630 V.
The shield can also be grounded directly at both ends if they are in the same
ground line with no significant voltage drop between the end points.
• 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.
 Electrical installation 101

R0…R2 R3

6
11

11 10
5

10
9
11

5
9

11

4 8
3 7
4 8
R3: 0.5…0.6 N·m (0.4 lbf·ft)
3 7

R0…R2: 0.5…0.6 N·m (0.4 lbf·ft)

102 Electrical installation

R5

6
4
0.5…0.6 N·m
(0.4 lbf·ft)

11

11

0.5…0.6 N·m
(0.4 lbf·ft) 5 9

11
4 8

4 8
3 7
 Electrical installation 103

R6…R9
0.5...0.6 N·m
(0.4 lbf·ft)
4
6

0.5...0.6 N·m
(0.4 lbf·ft) 11

10 11

5 9

4 8

M4×20
4 8

3 7
104 Electrical installation

Installing option modules

Note: If you will install the FPBA-01 module, see section FPBA-01 PROFIBUS DP
adapter module connectors on page 59 for suitable connector types.

 Mechanical installation of option modules

See section Overview of power and control connections page 29 for the available
slots for each module. Install the optional modules as follows:

WARNING! Obey the instructions in chapter Safety instructions on page 11. If

you ignore them, injury or death, or damage to the equipment can occur.
Note: Slot 2 in frames R0…R3 is at UDC potential. You must disconnect power
supplies before installing or removing an I/O extension module.

Stop the drive and do the steps in section Precautions before electrical work on page
14 before you start the work.
1. Remove the front cover(s) if not already removed. See page 75 (R0…R3), page
49 (R5) or page 52 (R6…R9).
The figures for frames R0…R3 (page 105) and R6…R9 (page 106) show an example
of installing optional modules.

Option slot 3 (embedded fieldbus adapter modules)

2. 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.
Note: Frames R0…R3: The module in option slot 3 is under the module in option slot
1. If you have to change the module in option slot 3, remove first the any module in
option slot 1, if present.

Option slot 2 (I/O extension modules)

3. Put the module carefully into its position on the control unit.
4. Tighten the mounting screw.
5. 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.
Note: Frames R0…R3: The module in option slot 2 covers the power terminals. Do
not install a module in option slot 2 before you have installed the power cables.
 Electrical installation 105

Option slot 1 (fieldbus adapter modules)

6. Put the module carefully into its position on the control board.
7. 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.
R0…R2 R3

2 2

2 6

7
3 4
6
2
5

4
3

5
106 Electrical installation

R6…R9

2
7

 Wiring the modules

See the appropriate optional module manual for specific installation and wiring
instructions.
 Electrical installation 107

Reinstalling covers
 Reinstalling cover, frames R0…R3
1. Reinstall the cover: Put the tabs on the cover top in their counterparts on the
housing (1a) and the press the cover (1b).
2. Tighten the retaining screw at the bottom with a screwdriver.

1a

1b
108 Electrical installation

 Reinstalling covers, frame R5

1. Install the cover of the cable entry box.
2. Tighten the two retaining screws with a screwdriver.
3. Reinstall the module cover. Put the tabs on the cover top in their counterparts on
the housing and then press the cover.
4. Tighten the two retaining screws with a screwdriver.

1
 Electrical installation 109

 Reinstalling side plates and covers, frames R6…R9

1. Reinstall the side plates of the cable entry box. Tighten the retaining screws with a
screwdriver.
2. Slide the cover of the cable entry box on the module from below until the cover
snaps into place.
3. Reinstall the module cover. Tighten the two retaining screws with a screwdriver.

1 2

3
110 Electrical installation

Connecting a PC
To be able to connect a PC to the drive, you need an assistant control panel.
Connect a PC to the drive with a USB data cable (USB Type A <-> USB Type Mini-B)
as follows:
1. Lift the USB connector cover from bottom upwards.
2. Put the USB cable Mini-B plug in the control panel USB connector.
3. Put the USB cable A-plug in the USB connector of the PC (3a). The panel
displays text “USB connected” (3b).
Note: Panel keys cannot be used when a USB data cable is connected to the panel.

2
3a

1 2

For information on using the Drive composer PC tool, see Drive composer PC tool
user's manual (3AUA0000094606 [English]).
 Installation checklist 111

7
Installation checklist
Contents of this chapter
This chapter contains an installation checklist which you must complete before you
start up the drive.

Warnings

WARNING! Obey the instructions in chapter Safety instructions on page 11. If

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

Checklist
Do the steps in section Precautions before electrical work on page 14 before you start
the work. Go through the checklist together with another person.

Check that …

The ambient operating conditions meet the specification in section Ambient conditions
on page 152.

If the drive will be connected to an IT (ungrounded) or corner-grounded TN supply

network: Internal EMC filter has been disconnected. See section Checking the
compatibility with IT (ungrounded) and corner-grounded TN systems on page 71.

If the drive has been stored over one year: The electrolytic DC capacitors in the DC
link of the drive have been reformed. See section Capacitors on page 122.

There is an adequately sized protective earth (ground) conductor between the drive
and the switchboard.
112 Installation checklist

Check that …

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

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

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

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

Appropriate supply fuses and disconnector have been installed.

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

The brake resistor cable (if present) has been connected to appropriate terminals, and
the terminals have been tightened. (Pull conductors to check.)

The motor cable (and brake resistor cable, if present) has been routed away from other
cables.

The control cables (if any) have been connected to the control board.

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

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

Drive and motor connection box covers are in place.

The motor and the driven equipment are ready for start-up.
 Maintenance and hardware diagnostics 113

8
Maintenance and hardware
diagnostics
Contents of this chapter
The chapter contains preventive maintenance instructions and LED indicator
descriptions.

Maintenance intervals
If installed in an appropriate environment, the drive requires very little maintenance.
Section Preventive maintenance intervals on page 114 lists the routine maintenance
intervals recommended by ABB for customer maintenance tasks.
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 http://www.abb.com/drives. See the maintenance instructions in this
chapter.
114 Maintenance and hardware diagnostics

 Preventive maintenance intervals

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 schedule on the Internet.
Years from start-up
Maintenance task/object
0 1 2 3 4 5 6 7 8 9 10 11 12 …
Cooling fans
Main cooling fan (R0… R9). See R R
(R) (R)
page 116. (R) (R)
Auxiliary cooling fan for circuit R R R R
boards (R6…R9). See page 121. (R) (R) (R) (R)
Batteries
Control panel battery. See page R
123. (R)
Connections and environment
Quality of supply voltage O O O O O O O O O O O O O
Improvements
I I I I
Based on product notes
(I) (I) (I) (I)
Spare parts
I I I I I I I I I I I I I
Spare part stock
(I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I)
Reforming of DC circuit capacitors
(spare modules and spare O O O O O O O O O O O O O
capacitors). See page 122.
Other useful tasks
Checking tightness of cable and
I I I I I I I I I I I I I
busbar terminals. Tightening if
(I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I)
needed.
Checking ambient conditions I I I I I I I I I I I I I
(dustiness, moisture, temperature) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I)
Cleaning the heatsink. See page O O O O O O O O O O O O O
115. (O) (O) (O) (O) (O) (O) (O) (O) (O) (O) (O) (O) (O)
4FPS10000309652.xlsx B
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.)
 Maintenance and hardware diagnostics 115

* 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 the drive
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.

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

WARNING! Obey the instructions in chapter Safety instructions on page 11.

Ignoring the instructions can cause physical injury or death, or damage to the
equipment.

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 disconnect it from the power line. Wait for 5 minutes and then
make sure by measuring that there is no voltage. See section Precautions before
electrical work on page 14 before you start the work.
2. Remove the cooling fan(s). See section Fans on page 116.
3. Blow clean, dry and oil free compressed air from bottom to top and
simultaneously use a vacuum cleaner at the air outlet to trap the dust.
Note: If there is a risk of dust entering adjoining equipment, perform the cleaning
in another room.
4. Reinstall the cooling fan(s).
116 Maintenance and hardware diagnostics

Fans
See section Maintenance intervals on page 113 for the fan replacement interval in
average operation conditions. Parameter 05.04 Fan on-time counter indicates the
running time of the cooling fan. Reset the counter after a fan replacement.
In a speed-controlled fan, the speed of the fan matches the cooling needs. This
increases the life span of the fan.
Replacement fans are available from ABB. Do not use other than ABB specified
spare parts.

 Replacing the cooling fan, frames R0…R3

WARNING! Obey the instructions in chapter Safety instructions on page 11.

Ignoring the instructions can cause physical injury or death, or damage to the
equipment.

1. Stop the drive and disconnect it from the power line. Wait for 5 minutes and then
make sure by measuring that there is no voltage. See section Precautions before
electrical work on page 14 before you start the work.
 Maintenance and hardware diagnostics 117

2. Lever the fan assembly off the drive frame with for example a screwdriver (2a)
and pull out the fan assembly (2b).
R0 R1…R2 R3

2a 2a
2a

R0 R1…R2 R3

2b
2b 2b

3. Install the fan assembly in reverse order.

118 Maintenance and hardware diagnostics

 Replacing the cooling fan, frame R5

WARNING! Obey the instructions in chapter Safety instructions on page 11.

Ignoring the instructions can cause physical injury or death, or damage to the
equipment.

1. Stop the drive and disconnect it from the power line. Wait for 5 minutes and then
make sure by measuring that there is no voltage. See section Precautions before
electrical work on page 14 before you start the work.
2. Lift the fan assembly upwards from the front edge (2a) and remove the assembly
(2b).
3. Install the new fan assembly in reverse order.

2b
2a
 Maintenance and hardware diagnostics 119

 Replacing the main cooling fan, frames R6…R8

WARNING! Obey the instructions in chapter Safety instructions on page 11.

Ignoring the instructions can cause physical injury or death, or damage to the
equipment.

1. Stop the drive and disconnect it from the power line. Wait for 5 minutes and then
make sure by measuring that there is no voltage. See section Precautions before
electrical work on page 14 before you start the work.
2. Undo the two mounting screws of the fan mounting plate at the bottom of the
drive.
3. Pull the fan mounting plate down from the side edge.
4. Unplug the fan power supply wires from the drive.
5. Lift the fan mounting plate off.
6. Remove the fan from the mounting plate.
7. Install the new fan in reverse order.

6
3

2
120 Maintenance and hardware diagnostics

 Replacing the main cooling fans, frame R9

WARNING! Obey the instructions in chapter Safety instructions on page 11.

Ignoring the instructions can cause physical injury or death, or damage to the
equipment.

1. Stop the drive and disconnect it from the power line. Wait for 5 minutes and then
make sure by measuring that there is no voltage. See section Precautions before
electrical work on page 14 before you start the work.
2. Undo the two mounting screws of the fan mounting plate.
3. Turn the mounting plate downwards.
4. Unplug the fan power supply wires from the drive.
5. Remove the fan mounting plate.
6. Remove the fans by undoing the two mounting screws.
7. Install the new fans in reverse order.

4
3

2
6
2 6
 Maintenance and hardware diagnostics 121

 Replacing the auxiliary cooling fan, frames R6…R9

WARNING! Obey the instructions in chapter Safety instructions on page 11.

Ignoring the instructions can cause physical injury or death, or damage to the
equipment.

1. Stop the drive and disconnect it from the power line. Wait for 5 minutes and then
make sure by measuring that there is no voltage. See section Precautions before
electrical work on page 14 before you start the work.
2. Remove the front cover (see page 52).
3. Unplug fan power supply wires from the drive.
4. Release the retaining clips.
5. Lift the fan off.
6. Install the new fan in reverse order. Make sure that the arrow on the fan points up.

4
122 Maintenance and hardware diagnostics

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

 Reforming the capacitors

The capacitors must be reformed if the drive has been stored for a year or more. See
section Type designation label on page 33 for how to find out the manufacturing date
from the serial number.
For information on reforming the capacitors, see Converter module capacitor
reforming instructions (3BFE64059629 [English]), available on the Internet (go to
http://www.abb.com and enter the code in the Search field).
 Maintenance and hardware diagnostics 123

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. See section Control panel on page 32.
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.

CR2032

2
124 Maintenance and hardware diagnostics

LEDs
 Drive LEDs
There is a green POWER and a red FAULT LED on the front of the drive. They are
visible through the panel cover but invisible if a control panel is attached to the drive.
The table below describes the drive LED indications.

Drive LEDs POWER and FAULT, on the front of the drive, under the control panel / panel
cover
If a control panel is attached to the drive, switch to remote control (otherwise a fault will be
generated), and then remove the panel to be able to see the LEDs
LEDs off LED lit and steady LED blinking
No power Green Power supply on the board Green Blinking:
(POWER) OK (POWER) Drive in an alarm state
Blinking for one second:
Drive selected on the
control panel when multiple
drives are connected to the
same panel bus.
Red Active fault in the drive. To Red Active fault in the drive. To
(FAULT) reset the fault, press (FAULT) reset the fault, switch off the
RESET from the control drive power.
panel or switch off the drive
power.
 Maintenance and hardware diagnostics 125

 Assistant panel LEDs

The assistant control panel has one LED. The table below describes the control panel
LED indications. For more information see ACS-AP-x assistant control panels user’s
manual (3AUA0000085685 [English]).

Assistant control panel LED, at the left edge of the control panel
LED off LED lit and steady LED blinking/flickering
Panel has Green Drive functioning normally. Green Blinking:
no power. Connection between the Active warning in the drive
drive and control panel may Flickering:
be faulty or lost, or the Data transferred between
panel and drive may be the PC tool and drive
incompatible. Check the through the USB
control panel display. connection of the control
panel
Red Check the display to see Red Active fault in the drive.
where the fault is. To reset the fault, cycle the
• Active fault in the drive. drive power.
Reset the fault.
• Active fault in another
drive in the panel bus.
Switch to the drive in
question and check and
reset the fault.
126 Maintenance and hardware diagnostics
 Technical data 127

9
Technical data
Contents of this chapter
The chapter contains the technical specifications of the drive, for example ratings,
sizes and technical requirements as well as provisions for fulfilling the requirements
for CE, UL and other approval marks.
128 Technical data

Ratings
 IEC ratings
Type Input Max. Output ratings Frame
ACS580 rating current
Nominal use Light- duty use Heavy-duty use size
-01-
I1N Imax IN PN I Ld PLd IHd PHd
A A A kW A kW A kW
3-phase UN = 400 V (380…415 V)
02A6-4 2.6 3.2 2.6 0.75 2.5 0.75 1.8 0.55 R0
03A3-4 3.3 4.7 3.3 1.1 3.1 1.1 2.6 0.75 R0
04A0-4 4.0 5.9 4.0 1.5 3.8 1.5 3.3 1.1 R0
05A6-4 5.6 7.2 5.6 2.2 5.3 2.2 4.0 1.5 R0
07A2-4 7.2 10.1 7.2 3.0 6.8 3.0 5.6 2.2 R1
09A4-4 9.4 13.0 9.4 4.0 8.9 4.0 7.2 3.0 R1
12A6-4 12.6 14.1 12.6 5.5 12.0 5.5 9.4 4.0 R1
017A-4 17.0 22.7 17.0 7.5 16.2 7.5 12.6 5.5 R2
025A-4 25.0 30.6 25.0 11.0 23.8 11.0 17.0 7.5 R2
032A-4 32.0 44.3 32.0 15.0 30.4 15.0 24.6 11.0 R3
038A-4 38.0 56.9 38.0 18.5 36.1 18.5 31.6 15.0 R3
045A-4 45.0 67.9 45.0 22.0 42.8 22.0 37.7 18.5 R3
061A-4 61 76 61 30 58 30 45 22 R5
072A-4 72 104 72 37 68 37 61 30 R5
087A-4 87 122 87 45 83 45 72 37 R5
105A-4 105 148 105 55 100 55 87 45 R6
145A-4 145 178 145 75 138 75 105 55 R6
169A-4 169 247 169 90 161 90 145 75 R7
206A-4 206 287 206 110 196 110 169 90 R7
246A-4 246 350 246 132 234 132 206 110 R8
293A-4 293 418 293 160 278 160 2461) 132 R8
363A-4 363 498 363 200 345 200 293 160 R9
430A-4 430 617 430 250 400 200 3632) 200 R9
3AXD00000586715.xls F

See definitions and notes on page 129.

 Technical data 129

 NEMA ratings
Type Input Output ratings Frame
ACS580 rating Nominal use Heavy-duty use size
-01-
I1N I Ld PLd I Hd PHd
A A hp A hp
3-phase UN = 460 V (440…480 V)
02A6-4 2.1 2.1 1.0 1.6 0.75 R0
03A3-4 3.0 3.0 1.5 2.1 1.0 R0
04A0-4 3.4 3.4 2.0 3.0 1.5 R0
05A6-4 4.8 4.8 3.0 3.4 2.0 R0
07A2-4 6.0 6.0 3.0 4.0 3.0 R1
09A4-4 7.6 7.6 5.0 4.8 3.0 R1
12A6-4 11.0 11.0 7.5 7.6 5.0 R1
017A-4 14.0 14.0 10.0 11.0 7.5 R2
025A-4 21.0 21.0 15.0 14.0 10.0 R2
032A-4 27.0 27.0 20.0 21.0 15.0 R3
038A-4 34.0 34.0 25.0 27.0 20.0 R3
045A-4 40.0 40.0 30.0 34.0 25.0 R3
061A-4 52 52 40 40 30 R5
072A-4 65 65 50 52 40 R5
087A-4 77 77 60 65 50 R5
105A-4 96 96 75 77 60 R6
145A-4 124 124 100 96 75 R6
169A-4 156 156 125 124 100 R7
206A-4 180 180 150 156 125 R7
246A-4 240 240 200 180 150 R8
293A-4 260 260 200 2401) 150 R8
363A-4 361 361 300 302 250 R9
430A-4 414 414 350 3612) 300 R9
3AXD00000586715.xls F

 Definitions
UN Nominal supply voltage
I1N Nominal input current. Continuous rms input current (for dimensioning cables
and fuses).
Imax Maximum output current. Available for two seconds at start.
IN Nominal output current. Maximum continuous rms output current allowed (no
overload).
PN Nominal power of the drive. Typical motor power (no overloading). The kilowatt
ratings apply to most IEC 4-pole motors. The horsepower ratings apply to most
NEMA 4-pole motors.
ILd Maximum current with 110% overload, allowed for one minute every ten minutes
PLd Typical motor power in light-duty use (110% overload)
130 Technical data

IHd Maximum current with 150% overload, allowed for one minute every ten minutes
1)
Maximum current with 130% overload, allowed for one minute every ten
minutes
2)
Maximum current with 125% overload, allowed for one minute every ten
minutes
PHd Typical motor power in heavy-duty use (150% overload)

 Sizing
Drive sizing is based on the rated motor current and power. 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. Also the rated power of the drive must be higher
than or equal to compared to the rated motor power. The power ratings are the same
regardless of the supply voltage within one voltage range.
Note: For frames R0…R3 the ratings apply at ambient temperature of 50 °C (122 °F)
for IN. For frames R5…R9, the ratings apply at ambient temperature of 40 °C (104 °F)
for IN. Above theses temperatures derating is required.
The DriveSize dimensioning tool available from ABB is recommended for selecting
the drive, motor and gear combination.

Derating
The load capacity (IN, ILd, IHd; note that Imax is not derated) decreases for certain
situations, as defined below. In such situations, where full motor power is required,
oversize the drive so that the derated value provides sufficient capacity.
Note: If several situations are present at a time, the effect of derating for each
situation is cumulative.
Example:
If your application requires continuous 12.0 A of motor current (IN) at 8 kHz switching frequency,
the supply voltage is 400 V and the drive is situated at 1500 m, calculate the appropriate drive
size requirement as follows:
Switching frequency derating (page 134):
The minimum size required is IN = 12.0 A / 0.66 = 18.18 A,
where 0.66 is the derating for 8 kHz switching frequency (frames R0…R3).
Altitude derating (page 134):
The derating factor for 1500 m is 1 - 1/10 000 m · (1500 - 1000) m = 0.95.
The minimum size required becomes then IN = 18.18 A / 0.95 = 19.14 A.
Referring to IN in the ratings tables (starting from page 128), drive type ACS580-01-025A-4
exceeds the IN requirement of 19.24 A.
 Technical data 131

 Ambient temperature derating, IP21

Frame size Temperature
range
R0…R3 up to +50 °C No derating
up to +122 °F
R5…R9 up to +40 °C No derating
up to +104 °F
+40…+50 °C Derate 1% for every 1 °C (1.8 °F)
+104…+122 °F

The output current is calculated by multiplying the current given in the rating table by
the derating factor (k, in the diagram below).
k

1.00 R0…R3

0.95

0.90 R5…R9

0.85

0.80
-15 °C … +40 °C +50 °C T
-59 °F +104 °F +122 °F
132 Technical data

 Ambient temperature derating, IP55

IP55 (UL Type 12) drive types, other than the exceptions listed in the following
subheadings
In the temperature range +40…50 °C (+104…122 °F), the rated output current is
derated by 1% for every added 1 °C (1.8 °F). The output current can be calculated by
multiplying the current given in the rating table by the derating factor (k):
k

1.00

0.95

0.90

0.85

0.80
-15 °C … +40 °C +50 °C
T
-59 °F +104 °F +122 °F

 IP55 (UL Type 12) type -045A-4

In the temperature range +40…45 °C (+104…113 °F), the rated output current is
derated by 1% for every added 1 °C (1.8 °F). In the temperature range +45…50 °C
(+113…122 °F), the rated output current is derated by 1.5% for every added 1 °C (1.8
°F).
k

1.00

0.95

0.90

0.85

0.80
-15 °C … +40 °C +45 °C +50 °C
T
-59 °F +104 °F +113 °F +122 °F

 IP55 (UL Type 12) drive type -293A-4

In the temperature range +40…45 °C (+104…113 °F), the rated output current is
derated by 1% for every added 1 °C (1.8 °F). In the temperature range +45…50 °C
(+113…122 °F), the rated output current is derated by 2.5% for every added 1 °C (1.8
 Technical data 133

°F). The output current can be calculated by multiplying the current given in the rating
table by the derating factor (k):
k

1.00

0.95

0.90

0.85

0.80

0.75
-15 °C … +40 °C +45 °C +50 °C
T
-59 °F +104 °F +113 °F +122 °F

 IP55 (UL Type 12) drive type -363A-4

In the temperature range +40…45 °C (+104…113 °F), the rated output current is
derated by 1% for every added 1 °C (1.8 °F). In the temperature range +45…50 °C
(+113…122 °F), the rated output current is derated by 2.5% for every added 1 °C (1.8
°F). The output current can be calculated by multiplying the current given in the rating
table by the derating factor (k):
k

1.00

0.95

0.90

0.85

0.80

0.75
-15 °C … +40 °C +45 °C +50 °C
T
-59 °F +104 °F +113 °F +122 °F

 IP55 (UL Type 12) type -430A-4

The maximum ambient temperature is 35 °C (95 °F).
134 Technical data

 Switching frequency derating

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 12 kHz
R0 1 1 1 0.67 0.5
R1 1 1 1 0.67 0.5
R2 1 1 1 0.65 0.48
R3 1 1 1 0.65 0.48
R5 1 1 0.92 0.7 0.56
R6 1 0.97 0.83 0.66 0.5
R7 1 0.98 0.88 0.7 0.5
R8 1 0.96 0.81 0.6 N/A
R9 1 0.95 0.78 0.56 N/A

 Altitude derating
In altitudes 1000…4000 m (3300…13120 ft) above sea level, the derating is 1% for
every 100 m (330 ft).
The output current is calculated by multiplying the current given in the rating table by
the derating factor k, which for x meters (1000 m <= x <= 4000 m) is:
1 . (x - 1000) m
k=1-
10 000 m

Check the network compatibility restrictions above 2000 m (6562 ft), see Installation
site altitude on page 152. Check also PELV limitation on relay output terminals above
2000 m (6562 ft), see sections Isolation areas, R0…R3 (CCU-11): on page 148 and
Isolation areas, R5…R9 (CCU-12): on page 149.
 Technical data 135

Fuses (IEC)
gG as well as uR or aR fuses for protection against short-circuit in the input power
cable or drive are listed below. Either fuse type can be used for frames R0…R3 and
R5…R6 if it operates rapidly enough. The operating time depends on the supply
network impedance and the cross-sectional area and length of the supply cable. For
frames R7…R9 ultrarapid (aR) fuses must be used.
Note 1: See also Implementing thermal overload and short-circuit protection on page
62.
Note 2: Fuses with higher current rating than the recommended ones must not be
used.
Note 3: Fuses from other manufacturers can be used if they meet the ratings and the
melting curve of the fuse does not exceed the melting curve of the fuse mentioned in
the table.
136 Technical data

 gG fuses
Check on the fuse time-current curve to ensure the operating time of the fuse is
below 0.5 seconds. Obey the local regulations.
Type Min. short- Input gG (IEC 60269)
ACS580 circuit current
current1) Nominal VoltageI2 t ABB type IEC 60269
-01- current rating size
A A A A 2s V
3-phase UN = 400 or 460 V (380…415 V, 440…480 V)
02A6-4 32 2.6 4 55 500 OFAF000H4 000
03A3-4 48 3.3 6 110 500 OFAF000H6 000
04A0-4 48 4.0 6 110 500 OFAF000H6 000
05A6-4 80 5.6 10 360 500 OFAF000H10 000
07A2-4 80 7.2 10 360 500 OFAF000H10 000
09A4-4 128 9.4 16 740 500 OFAF000H16 000
12A6-4 128 12.6 16 740 500 OFAF000H16 000
017A-4 200 17.0 25 2500 500 OFAF000H25 000
025A-4 256 25.0 32 4000 500 OFAF000H32 000
032A-4 320 32.0 40 7700 500 OFAF000H40 000
038A-4 400 38.0 50 16000 500 OFAF000H50 000
045A-4 500 45.0 63 20100 500 OFAF000H63 000
061A-4 800 61 80 37500 500 OFAF000H80 000
072A-4 1000 72 100 65000 500 OFAF000H100 000
087A-4 1000 87 100 65000 500 OFAF000H100 000
105A-4 1300 105 125 103000 500 OFAF00H125 1
145A-4 1700 145 160 185000 500 OFAF00H160 1
169A-4 3300 169 250 600000 500 OFAF0H250 1
206A-4 5500 206 315 710000 500 OFAF1H315 1
246A-4 6400 246 355 920000 500 OFAF1H355 2
293A-4 7800 293 425 1300000 500 OFAF2H425 2
363A-4 9400 363 500 2000000 500 OFAF2H500 2
430A-4 10200 430 630 2800000 500 OFAF3H630 2
3AXD00000586715.xls F
1) Minimum short-circuit current of the installation
 Technical data 137

 uR and aR fuses
Type Min. short- Input uR or aR
ACS580 circuit current
current1) Nominal I2 t Voltage Bussmann IEC 60269
-01- current rating type size
A A A A 2s V
3-phase UN = 400 or 460 V (380…415 V, 440…480 V)
02A6-4 TBA 2.6 25 130 690 170M1561 000
03A3-4 TBA 3.3 25 130 690 170M1561 000
04A0-4 TBA 4.0 25 130 690 170M1561 000
05A6-4 TBA 5.6 25 130 690 170M1561 000
07A2-4 TBA 7.2 25 130 690 170M1561 000
09A4-4 TBA 9.4 25 130 690 170M1561 000
12A6-4 TBA 12.6 25 130 690 170M1561 000
017A-4 TBA 17.0 40 460 690 170M1563 000
025A-4 TBA 25.0 40 460 690 170M1563 000
032A-4 TBA 32.0 63 1450 690 170M1565 000
038A-4 TBA 38.0 63 1450 690 170M1565 000
045A-4 TBA 45.0 80 2550 690 170M1566 000
061A-4 380 61 100 4650 690 170M1567 1
072A-4 480 72 125 8500 690 170M1568 1
087A-4 480 87 160 16000 690 170M1569 1
105A-4 700 105 200 15000 690 170M3815 1
145A-4 700 145 250 28500 690 170M3816 1
169A-4 1280 169 315 46500 690 170M3817 1
206A-4 1520 206 350 68500 690 170M3818 1
246A-4 2050 246 450 105000 690 170M5809 2
293A-4 2200 293 500 145000 690 170M5810 2
363A-4 3100 363 630 275000 690 170M5812 2
430A-4 3600 430 700 405000 690 170M5813 2
3AXD00000586715.xls F
1)
Minimum short-circuit current of the installation
138 Technical data

Dimensions, weights and free space requirements

Frame Dimensions and weights
size IP21 / UL type 1
H1 H2 H3 H4 W D Weight
mm mm mm mm mm mm kg
R0 -*) -*) 303 330 125 210 4.5
R1 -*) -*) 303 330 125 223 4.6
R2 -*) -*) 394 430 125 227 7.5
R3 -*) -*) 454 490 203 228 14.9
R5 596 598 726 627 203 283 23.0
R6 548 549 726 589 252 369 45.0
R7 600 601 880 641 284 370 55.0
R8 680 677 965 721 300 393 70.0
R9 680 680 955 741 380 418 98.0
3AXD00000586715.xls F
*) Frames with an integrated gland box

Frame Dimensions and weights

size IP55 / UL type 12
H3 H4 W D Weight
mm mm mm mm kg
R0 303 330 125 222 5
R1 303 330 125 233 5
R2 394 430 125 239 7
R3 454 490 203 237 15
R6 726 615 252 380 45
R7 880 641 284 381 55
R8 965 726 300 452 72
R9 955 741 380 477 100
3AXD00000586715.xls F
 Technical data 139

W D W D

H1

H2

H4

H3
Symbols
IP21 / UL type 1
H1 Height back without gland box
H2 Height front without gland box
H3 Height front with gland box
H4 Height back with gland box
W Width
D Depth

Frame Free space

size Vertical mounting Vertical mounting Horizontal mounting
stand alone side by side
Above Below Above Below Between Above Below Between
mm mm mm mm mm mm mm mm
R0 200 200 200 200 0 TBA TBA TBA
R1 200 200 200 200 0 TBA TBA TBA
R2 200 200 200 200 0 TBA TBA TBA
R3 200 200 200 200 0 TBA TBA TBA
R5 200 300 200 300 0 TBA TBA TBA
R6 200 300 200 300 0 TBA TBA TBA
R7 200 300 200 300 0 TBA TBA TBA
R8 200 300 200 300 0 TBA TBA TBA
R9 200 300 200 300 0 TBA TBA TBA
3AXD00000586715.xls F

See the figures in section Checking the installation site on page 38.
140 Technical data

Losses, cooling data and noise

The air flow direction is from bottom to top.
The table below specifies the heat dissipation in the main circuit at nominal load and
in the control circuit with minimum load (I/O, options and panel not in use) and
maximum load (all digital inputs and relays in the ON state, and the panel, fieldbus
and fan in use). The total heat dissipation is the sum of the heat dissipation in the
main and control circuits. Use the maximum losses when designing cabinet or
electrical room cooling needs.
Type Heat dissipation Air flow Noise Frame
ACS580 Main circuit Control Control Main and size
-01- at rated circuit circuit control boards
I1N at IN minimum maximum maximum
W W W W m3/h dB(A)
3-phase UN = 400 or 460 V (380…415 V, 440…480 V)
02A6-4 20 3.5 25 45 TBA TBA R0
03A3-4 30 3.5 25 55 TBA TBA R0
04A0-4 41 3.5 25 66 TBA TBA R0
05A6-4 59 3.5 25 84 TBA TBA R0
07A2-4 81 3.5 25 106 TBA TBA R1
09A4-4 108 3.5 25 133 TBA TBA R1
12A6-4 149 3.5 25 174 TBA TBA R1
017A-4 203 3.5 25 228 TBA TBA R2
025A-4 297 3.5 25 322 TBA TBA R2
032A-4 405 3.5 25 430 TBA TBA R3
038A-4 500 3.5 25 525 TBA TBA R3
045A-4 594 3.5 25 619 TBA TBA R3
061A-4 1117 4.1 36 1153 280 62 R5
072A-4 1117 4.1 36 1153 280 62 R5
087A-4 1120 4.1 36 1156 280 62 R5
105A-4 1295 4.1 36 1331 435 67 R6
145A-4 1440 4.1 36 1476 435 67 R6
169A-4 1940 4.1 36 1976 450 67 R7
206A-4 2310 4.1 36 2346 550 67 R7
246A-4 3300 4.1 36 3336 550 65 R8
293A-4 3900 4.1 36 3936 1150 65 R8
363A-4 4800 4.1 36 4836 1150 68 R9
430A-4 6000 4.1 36 6036 1150 68 R9
3AXD00000586715.xls F
 Technical data 141

Terminal and lead-through data for the power cables

Input, motor, resistor and DC cable lead-throughs, maximum wire sizes (per phase)
and terminal screw sizes and tightening torques (T) are given below.
Frame Cable lead- L1, L2, L3, T1/U, T2/V, T3/W terminals Grounding
size throughs terminals
Per Ø1) Max wire size T (Wire screw) T (Terminal Max wire T
cable (solid/ nut) size
type stranded)
pcs mm mm2 M… N·m M… N·m mm2 N·m
2)
R0 1 30 6/4 0.5…0.6 N/A N/A TBA TBA
2)
R1 1 30 6/4 0.5…0.6 N/A N/A TBA TBA
2)
R2 1 30 16/16 1.2…1.5 N/A N/A TBA TBA
2)
R3 1 30 35/25 2.5…4.1 N/A N/A TBA TBA
R5 1 32 70 M8 5.6 N/A N/A 35 2.9
R6 1 45 150 M10 30 N/A N/A 185 9.8
R7 1 54 240 M10 40 N/A N/A 185 9.8
R8 2 45 2×150 M10 40 M10 24 2×185 9.8
R9 2 54 2×240 M12 70 M10 24 2×185 9.8
3AXD00000586715.xls F
1) Maximum cable diameter accepted. For the lead-through plate hole diameters, see chapter Dimension
drawings on page 161.
2) See the table below.

Frame Screwdrivers for the terminals of the main circuit

size
R0 Slot 4,5 mm
R1 Slot 4,5 mm
R2 PH1
R3 PH2
3AXD00000586715.xls F

Frame Cable lead- R+, R-, UDC+ and UDC- terminals

size throughs
Per Ø1) Max wire size T (Wire screw) T (Terminal
cable (solid/strand nut)
type ed)
pcs mm mm2 M… N·m M… N·m
2)
R0 1 23 6/4 0.5…0.6 N/A N/A
2)
R1 1 23 6/4 0.5…0.6 N/A N/A
2)
R2 1 23 16/16 1.2…1.5 N/A N/A
2)
R3 1 23 35/25 2.5…4.1 N/A N/A
R5 1 32 70 M8 5.6 N/A N/A
R6 1 45 150 M8 20 N/A N/A
R7 1 54 240 M10 30 N/A N/A
R8 2 45 2×150 M10 40 M10 24
R9 2 54 2×240 M12 70 M10 24
3AXD00000586715.xls F
1)
Maximum cable diameter accepted. For the lead-through plate hole diameters, see
chapter Dimension drawings on page 161.
2)
See the table above.
142 Technical data

Terminal and lead-through data for the control cables

Control cable lead-throughs, wire sizes and tightening torques (T) are given below.
Frame Cable lead- Control cable entries and terminal sizes
size throughs
Holes Max +24V, DCOM, DGND, EXT. 24V DI, AI/O, AGND, RO, STO
cable terminals
size Wire size T Wire size T
pcs mm mm2 N·m mm2 N·m
R0 3 17 0.2…2.5 0.5…0.6 0.14…1.5 0.5…0.6
R1 3 17 0.2…2.5 0.5…0.6 0.14…1.5 0.5…0.6
R2 3 17 0.2…2.5 0.5…0.6 0.14…1.5 0.5…0.6
R3 3 17 0.2…2.5 0.5…0.6 0.14…1.5 0.5…0.6
R5 2 22 0.14…2.5 0.5…0.6 0.14…2.5 0.5…0.6
R6 4 17 0.14…2.5 0.5…0.6 0.14…2.5 0.5…0.6
R7 4 17 0.14…2.5 0.5…0.6 0.14…2.5 0.5…0.6
R8 4 17 0.14…2.5 0.5…0.6 0.14…2.5 0.5…0.6
R9 4 17 0.14…2.5 0.5…0.6 0.14…2.5 0.5…0.6
3AXD00000586715.xls F
 Technical data 143

Electrical power network specification

Voltage (U1) 380 … 480 V AC 3-phase +10%…-15%
Network type Public low voltage networks. TN (grounded), IT
(ungrounded) and corner-grounded TN systems. See
section Checking the compatibility with IT (ungrounded)
and corner-grounded TN systems on page 71.
Rated conditional short-circuit 65 kA when protected by fuses given in the fuse tables
current (IEC 61439-1)
Frequency 47 to 63 Hz
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
Short-circuit protection The motor output is short-circuit proof by IEC/EN 61800-5-
(IEC/EN 61800-5-1, UL 508C) 1 and UL 508C.
Frequency 0.…500 Hz
Frequency resolution 0.01 Hz
Current See section Ratings on page 128.
Switching frequency 2 kHz, 4 kHz, 8 kHz, 12 kHz (depends on the frame and
parameter settings)
144 Technical data

Maximum recommended motor Operational functionality and motor cable length

cable length The drive is designed to operate with optimum performance
with the following maximum motor cable lengths.
Note: Conducted and radiated emissions of these motor
cable lengths do not comply with EMC requirements.

Frame Maximum motor cable length, 4 kHz

size Scalar control Vector control
m ft m ft
Standard drive, without external options
R0 100 330 100 330
R1 100 330 100 330
R2 200 660 200 660
R3 300 990 300 990
R5 300 990 300 990
R6 300 990 300 990
R7 300 990 300 990
R8 300 990 300 990
R9 300 990 300 990

Note: In multimotor systems, the calculated sum of all

motor cable lengths must not exceed the maximum motor
cable length given in the table.
 Technical data 145

EMC compatibility and motor cable length

To comply with the European EMC Directive (standard
EN 61800-3), use the following maximum motor cable
lengths at 4 kHz switching frequency.

Frame Maximum motor cable length, 4 kHz

size
m ft
EMC limits for Category C2 1)
Standard drive with an internal EMC filter. See notes 2,
3 and 5.
R0 100 330
R1 100 330
R2 100 330
R3 100 330
R5 100 330
R6 150 492
R7 150 492
R8 150 492
R9 150 492
EMC limits for Category C3 1)
Standard drive with an internal EMC filter. See notes 3
and 4.
R0 100 330
R1 100 330
R2 100 330
R3 100 330
R5 100 330
R6 150 492
R7 150 492
R8 150 492
R9 150 492
3AXD00000586715.xls F
1)
See the terms in section Definitions on page 156.
146 Technical data

Note 2: Radiated emissions are according to C2 with an

internal EMC filter.
Note 3: The internal EMC filter must be connected.
Note 4: Radiated and conducted emissions are according
to category C3 with an internal filter and these cable
lengths.
Note 5: Categories C1 and C2 meet requirements for
connecting equipment to the public low-voltage networks.

Brake resistor connection data

Short-circuit protection The brake resistor output is conditionally short-circuit proof
(IEC/EN 61800-5-1, IEC 60439-1, by IEC/EN 61800-5-1 and UL 508C. For correct fuse
UL 508C) selection, contact your local ABB representative. Rated
conditional short-circuit current as defined in IEC 60439-1.

Control connection data

External power supply Maximum power:
Frames R0…R3: 25 W, 1.04 A at 24 V AC/DC ±10%
with an optional module
Frames R5…R9: 36 W, 1.50 A at 24 V AC/DC ±10% as
standard
Supplied from an external power supply through optional
module CMOD-01 or CMOD-02 with frames R0…R3. With
frames R5…R9 no options are needed.
Terminal size:
Frames R0…R3: 0.2…2.5 mm2
Frames R5…R9: 0.14…2.5 mm2
+24 V DC output Total load capacity of this outputs is 6.0 W (250 mA / 24 V)
(Term. 10) minus the power taken by the option modules installed on
the board.
Terminal size:
Frames R0…R3: 0.2…2.5 mm2
Frames R5…R9: 0.14…2.5 mm2
Digital inputs DI1…DI6 Input type: NPN/PNP
(Term. 13…18) Terminal size:
Frames R0…R3: 0.14…1.5 mm2
Frames R5…R9: 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)
 Technical data 147

Relay outputs RO1…RO3 250 V AC / 30 V DC, 2 A

(Term. 19…27) Terminal size:
Frames R0…R3: 0.14…1.5 mm2
Frames R5…R9: 0.14…2.5 mm2
See sections Isolation areas, R0…R3 (CCU-11): on page
148 and Isolation areas, R5…R9 (CCU-12): on page 149.
Analog inputs AI1 and AI2 Current/voltage input mode selected with a dip switch, see
(Term. 2 and 5) page 94.
Current input: 0(4)…20 mA, Rin: 100 ohm
Voltage input: 0(2)…10 V, Rin: > 200 koh
Terminal size:
Frames R0…R3: 0.14…1.5 mm2
Frames R5…R9: 0.14…2.5 mm2
Inaccuracy: typical ±1%, max. ±1.5% of full scale
Analog outputs AO1 and AO2 Current/voltage output mode for AO1 selected with a dip
(Term. 7 and 8) switch, see page 94.
Current output: 0…20 mA, Rload: < 500 ohm
Voltage input: 0…10 V, Rload: > 100 kohm (AO1 only)
Terminal size:
Frames R0…R3: 0.14…1.5 mm2
Frames R5…R9: 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 IN1 24 V DC logic levels: “0” < 5 V, “1” > 13 V
and IN2 Rin: 2.47 kohm
(Term. 37 and 38) Terminal size:
Frames R0…R3: 0.14…1.5 mm2
Frames R5…R9: 0.14…2.5 mm2
Control panel - drive connection EIA-485, male RJ-45 connector, max. cable length 100 m
Control panel - PC connection USB Type Mini-B, max. cable length 2 m
148 Technical data

Isolation areas, R0…R3 (CCU-11):

Panel port

X1
AI/AO Power unit
connection

X2
24 V
GND

X3
DI

SLOT1
X4 FBA
STO
X8
RO

SLOT3 X7
EFB RO

X6
RO

SLOT2
I/O extension

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

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

Below altitudes 2000 m (6562 ft): The terminals on the control board fulfil
the Protective Extra Low Voltage (PELV) requirements (EN 50178):
There is adequate insulation between the user terminals which only
accept ELV voltages and terminals that accept higher voltages (relay
outputs).
Between altitudes 2000 m (6562 ft) … 4000 m (13123 ft): If you connect
higher than ELV voltage to one relay output, no relay output meets the
Protective Extra Low Voltage (PELV) requirements (EN 50178), because
there is only functional insulation between the individual relay outputs.
 Technical data 149

Isolation areas, R5…R9 (CCU-12):

SLOT1
FBA
X1:1…3
AI1

X1:4…6
AI2
X1:7…8
AO
Power unit
X2 connection
24 V
GND
X3:1…3
DI

X3:4…6
DI SLOT3
EFB
X4
STO
X10
Ext. 24 V
SLOT2
X8
I/O extension
RO1

X7
RO2
Panel port X6
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.
150 Technical data

Grounding of frames R0…R3 (CCU-11)

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

Ground

*) Jumper installed at factory

 Technical data 151

Grounding of frames R5…R9 (CCU-12)

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

Ground

*) Jumper installed at factory

152 Technical data

Auxiliary circuit power consumption

Maximum external power supply:
Frames R0…R3: 25 W, 1.04 A at 24 V AC/DC (with
optional modules CMOD-01, CMOD-02)
Frames R5…R9: 36 W, 1.50 A at 24 V AC/DC (as
standard, terminals 40…41)

Efficiency
Approximately 98% at nominal power level

Degree of protection
IP21 (UL type 1)
IP55 (UL type 12)
Ambient conditions
Environmental limits for the drive are given below. The drive is to be used in a heated, indoor,
controlled environment. All printed circuit boards are conformal coated.
Operation Storage Transportation
installed for in the protective in the protective
stationary use package package
Installation site altitude • 0 to 4000 m - -
(13123 ft)
above sea level
1)

• 0 to 2000 m
(6561 ft) above
sea level 2)
Above 1000 m
(3281 ft), see
page 134.
Air temperature -15 to +50 °C (5 to -40 to +70 °C (-40 -40 to +70 °C (-40
122 °F). to +158 °F) to +158 °F)
0 to -15 °C (32 to
5 °F): No frost
allowed.
See section
Ratings.
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, IEC 60721-3-2, Chemical gases: Chemical gases: Chemical gases:
IEC 60721-3-1) Class 3C2 Class 1C2 Class 2C2
Solid particles: Solid particles: Solid particles:
Class 3S2 Class 1S3 Class 2S2
 Technical data 153

Atmospheric pressure 70 to 106 kPa 70 to 106 kPa 60 to 106 kPa

0.7 to 1.05 0.7 to 1.05 0.6 to 1.05
atmospheres atmospheres atmospheres
Vibration (IEC 60068-2) Max. 1 mm (0.04 - -
in.)
(5 to 13.2 Hz),
max. 7 m/s2 (23
ft/s2)
(13.2 to 100 Hz)
sinusoidal
Vibration (ISTA) - R0…R5 (ISTA 1A): Displacement,
25 mm peak to peak, 14200 vibratory
impacts
R6…R9 ISTA 3E): Random, overall
Grms level of 0.52
Shock/Drop (ISTA) Not allowed R0…R5 (ISTA 1A): Drop, 6 faces, 3
edges and 1 corner
Weight range mm in
0…10 kg (0…22 lb) 760 29.9
10…19 kg (22…42 lb) 610 24.0
19…28 kg (42…62 lb) 460 18.1
28…41 kg (62…90 lb) 340 13.4
R6…R9 (ISTA 3E): Shock, incline
impact: 1.1 m/s (3.61 ft/s)
Shock, rotational edge drop: 200 mm
(7.9 in)
1)
For neutral-grounded TN and TT systems and non-corner grounded IT systems.
See also section Limiting relay output maximum voltages at high installation altitudes on
page 68.
2) For corner-grounded TN, TT and IT systems

Materials
Drive enclosure • PC/ABS 3 mm, color NCS 1502-Y (RAL 9002 / PMS 1C
Cool Grey) and RAL 9017
• PC+10%GF 3.0mm, Color RAL 9017 (in frames
R0…R3 only)
• hot-dip zinc coated steel sheet 1.5 to 2.5 mm, thickness
of coating 100 micrometers, color NCS 1502-Y
Package Plywood, cardboard and moulded pulp. Foam cushions
PP-E, bands PP.
154 Technical data

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. The compliance with the European Low
Voltage Directive is verified according to standard EN 61800-5-1.
EN 60204-1:2006 + AC: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.
IEC/EN 60529:1992 + A2: 2013 Degrees of protection provided by enclosures (IP code)
EN 61000-3-12:2011 Electromagnetic compatibility (EMC) - Part 3-12: Limits -
Limits for harmonic currents produced by equipment
connected to public low-voltage systems with input current
IEC/EN 61800-3:2004 + A1:2012 Adjustable speed electrical power drive systems. Part 3:
EMC requirements and specific test methods
IEC/EN 61800-5-1:2007 Adjustable speed electrical power drive systems. Part 5-1:
Safety requirements – electrical, thermal and energy
 Technical data 155

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

 Compliance with the European Low Voltage Directive

The compliance with the European Low Voltage Directive has been verified according
to standard EN 61800-5-1:2007. Declaration (3AXD10000302784) is available on the
Internet. See section Document library on the Internet on the inside of the back cover.

 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 + A1:2012) covers requirements stated for drives. See section Compliance
with the EN 61800-3:2004 + A1:2012 below. The declaration (3AXD10000302784) is
available on the Internet. See section Document library on the Internet on the inside
of the back cover.

 Compliance with the European ROHS Directive 2011/65/EU

The RoHS Directive defines the restriction of the use of certain hazardous
substances in electrical and electronic equipment. The declaration
(3AXD10000302785) is available on the Internet. See section Document library on
the Internet on the inside of the back cover.

 Compliance with the European WEEE Directive 2002/96/EC

The WEEE Directive defines the regulated disposal and recycling of electric and
electrical equipment.

 Compliance with the European Machinery Directive

2006/42/EC 2nd Edition – June 2010
The drive is a machinery component that can be integrated into a wide range of
machinery categories as specified in European Commission’s Guide to application of
the Machinery Directive 2006/42/EC 2nd Edition – June 2010. The declaration
(3AXD10000302783) is available on the Internet. See section Document library on
the Internet on the inside of the back cover.

Validating the operation of the Safe torque off function

See chapter Safe torque off function on page 187.
156 Technical data

Compliance with the EN 61800-3:2004 + A1:2012

 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 directly
supplying domestic premises.
Drive of category C1: drive of rated voltage less than 1000 V and intended for use in
the first environment.
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, intended for use in the
second environment and not intended for use in the first environment.

 Category C1
The emission limits are complied with the following provisions:
1. The optional EMC filter is selected according to the ABB documentation and
installed as specified in the EMC filter manual.
2. The motor and control cables are selected as specified in this manual.
3. The drive is installed according to the instructions given in this manual.
4. For the maximum motor cable length with 4 kHz switching frequency, see page
144.

WARNING! In a domestic environment, this product may cause radio inference, in

which case supplementary mitigation measures may be required.
 Technical data 157

 Category C2
The emission limits are complied with the following provisions:
1. The motor and control cables are selected as specified in this manual.
2. The drive is installed according to the instructions given in this manual.
3. For the maximum motor cable length with 4 kHz switching frequency, see page
144.

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

Note: Do not install a drive with the internal EMC filter connected on IT (ungrounded).
The supply network becomes connected to ground potential through the internal
EMC filter capacitors which may cause danger or damage to the drive. For
disconnecting the EMC filter see page 72.
Note: Do not install a drive with internal EMC filter connected on corner-grounded TN
systems; otherwise the drive will be damaged. For disconnecting the internal EMC
filter see page 72.

 Category C3
The drive complies with the standard with the following provisions:
1. The motor and control cables are selected as specified in this manual.
2. The drive is installed according to the instructions given in this manual.
3. For the maximum motor cable length with 4 kHz switching frequency, see page
144

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.
158 Technical data

 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 this manual.
4. The drive is installed according to the instructions given in this 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.

EAC marking
EAC marking is required in Russia, Belarus and Kazakhstan. The EAC certificate of
conformity (3AXD10000312900) is available on the Internet. See section Document
library on the Internet on the inside of the back cover.

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
 Technical data 159

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.
160 Technical data
 Dimension drawings 161

10
Dimension drawings
Contents of this chapter
This chapter shows the dimension drawings of the ACS580. The dimensions are
given in millimeters and [inches].
162 Dimension drawings

Frame R0, IP21

3AXD10000257110
 Dimension drawings 163

Frame R0, IP55

3AXD10000341562
164 Dimension drawings

Frame R1, IP21

3AXD10000257188
 Dimension drawings 165

Frame R1, IP55

3AXD10000336766
166 Dimension drawings

Frame R2, IP21

3AXD10000257203
 Dimension drawings 167

Frame R2, IP55

3AXD10000336766
168 Dimension drawings

Frame R3, IP21

3AXD10000257219
 Dimension drawings 169

Frame R3, IP55

3AXD10000335424
170 Dimension drawings

Frame R5, IP21

3AXD10000258138
 Dimension drawings 171

Frame R6, IP21

3AXD10000258705
172 Dimension drawings

Frame R6, IP55

3AXD10000330667
 Dimension drawings 173

Frame R7, IP21

3AXD10000258995
174 Dimension drawings

Frame R7, IP55

3AXD10000330932
 Dimension drawings 175

Frame R8, IP21

3AXD10000287670
176 Dimension drawings

Frame R8, IP55

3AXD10000332446
 Dimension drawings 177

Frame R9, IP21

3AXD10000287428
178 Dimension drawings

Frame R9, IP55

3AXD10000334310
 Resistor braking 179

11
Resistor braking
Contents of this chapter
The chapter describes how to select the brake resistor and cables, protect the
system, connect the brake resistor and enable resistor braking.

Operation principle and hardware description

The brake chopper handles the energy generated by a decelerating motor. The
chopper connects the brake resistor to the intermediate DC circuit whenever the
voltage in the circuit exceeds the limit defined by the control program. Energy
consumption by the resistor losses lowers the voltage until the resistor can be
disconnected.
For frame R0…R3 internal brake choppers and resistors, see below. For R5…R9
external brake choppers and resistors, see Resistor braking, frames R5…R9 on page
186.
180 Resistor braking

Resistor braking, frames R0…R3

 Planning the braking system
Selecting the brake resistor
Frames R0…R3 have an built-in brake chopper as standard equipment. The brake
resistor is selected using the table and equations presented in this section.
1. Determine the required maximum braking power PRmax for the application. PRmax
must be smaller than PBRmax given in the table on page 181 for the used drive
type.
2. Calculate resistance R with Equation 1.
3. Calculate energy ERpulse with Equation 2.
4. Select the resistor so that the following conditions are met:
• The rated power of the resistor must be greater than or equal to PRmax.
• Resistance R must be between Rmin and Rmax given in the table for the used
drive type.
• The resistor must be able to dissipate energy ERpulse during the braking
cycle T.
Equations for selecting the resistor:
450000 ton
Eq. 1. UN = 400 V: R = PRmax
PRmax

615000 PRave
UN = 460 V: R =
PRmax T
Eq. 2. ERpulse = PRmax · ton
ton
Eq. 3. PRave = PRmax · For conversion, use 1 hp = 746 W.
T

where
R = calculated brake resistor value (ohm). Make sure that: Rmin < R < Rmxx.
PRmax = maximum power during the braking cycle (W)
PRave = average power during the braking cycle (W)
ERpulse = energy conducted into the resistor during a single braking pulse (J)
ton = length of the braking pulse (s)
T = length of the braking cycle (s).
 Resistor braking 181

The table shows reference resistor types for the maximum braking power.
Type Rmin Rmax PBRmax Reference resistor types
ACS580-01 ohm ohm kW hp Danotherm
3-phase UN = 400 or 460 V (380…415 V, 440…480 V)
0246-4 54 690 0.6 0.8 CBH 360 C T 406 210R or
CAR 200 D T 406 210R
03A3-4 54 465 0.9 1.2 CBH 360 C T 406 210R or
CAR 200 D T 406 210R
04A0-4 54 313 1.3 1.7 CBH 360 C T 406 210R or
CAR 200 D T 406 210R
05A6-4 54 223 1.9 2.6 CBH 360 C T 406 210R or
CAR 200 D T 406 210R
07A2-4 54 153 2.6 3.5 CBR-V 330 D T 406 78R UL
09A4-4 54 112 3.5 4.7 CBR-V 330 D T 406 78R UL
12A6-4 54 83 4.9 6.6 CBR-V 330 D T 406 78R UL
017A-4 32 60 6.8 9.0 CBR-V 560 D HT 406 39R UL
025A-4 23 42 10 13.6 CBR-V 560 D HT 406 39R UL
032A-4 16 29 14 18.5 CBT-H 560 D HT 406 19R
038A-4 11 21 17 22.8 CBT-H 760 D HT 406 16R
045A-4 11 17 20 27.4 CBT-H 760 D HT 406 16R
3AXD00000586715.xls F

Symbols
Rmin = minimum allowed brake resistor that can be connected to the brake chopper
Rmax = maximum allowed brake resistor that allows PBRmax
PBRmax = maximum braking capacity of the drive, must exceed the desired braking power.

WARNING! Do not use a brake resistor with a resistance below the minimum
value specified for the particular drive. The drive and the internal chopper are
not able to handle the overcurrent caused by the low resistance.
182 Resistor braking

Selecting and routing the brake resistor cables

Use a shielded cable with the conductor size specified in section Terminal and lead-
through data for the power cables on page 141.

Minimizing electromagnetic interference

Follow these rules in order to minimize electromagnetic interference caused by the
rapid current changes in the resistor cables:
• Install the cables away from other cable routes.
• Avoid long parallel runs with other cables. The minimum parallel cabling
separation distance should be 0.3 meters.
• Cross the other cables at right angles.
• Keep the cable as short as possible in order to minimize the radiated emissions
and stress on chopper IGBTs. The longer the cable the higher the radiated
emissions, inductive load and voltage peaks over the IGBT semiconductors of the
brake chopper.

Maximum cable length

The maximum length of the resistor cable(s) is 10 m (33 ft).

EMC compliance of the complete installation

Note: ABB has not verified that the EMC requirements are fulfilled with external user-
defined brake resistors and cabling. The EMC compliance of the complete installation
must be considered by the customer.
 Resistor braking 183

Placing the brake resistor

Install the resistors outside the drive in a place where they will cool.
Arrange the cooling of the resistor in a way that:
• no danger of overheating is caused to the resistor or nearby materials
• the temperature of the room the resistor is located in does not exceed the allowed
maximum.
Supply the resistor with cooling air/water according to the resistor manufacturer’s
instructions.

WARNING! The materials near the brake resistor must be non-flammable. The
surface temperature of the resistor is high. Air flowing from the resistor is of
hundreds of degrees Celsius. If the exhaust vents are connected to a ventilation
system, ensure that the material withstands high temperatures. Protect the resistor
against physical contact.

Protecting the system in brake circuit fault situations

Protecting the system in cable and brake resistor short-circuit situations

The input fuses will also protect the resistor cable when it is identical with the input
cable.

Protecting the system against thermal overload

Equipping the drive with a main contactor is highly recommended for safety reasons.
Wire the contactor so that it opens in case the resistor overheats. This is essential for
safety since the drive will not otherwise be able to interrupt the main supply if the
chopper remains conductive in a fault situation. An example wiring diagram is shown
below. We recommend that you use resistors equipped with a thermal switch (1)
inside the resistor assembly. The switch indicates overtemperature and overload.
184 Resistor braking

We recommend that you also wire the thermal switch to a digital input of the drive.

L1 L2 L3

OFF
2

1 3 5 13 3

ON
2 4 6 14 4

Θ 1 ACS580
ACS580
L1 L2 L3
10 +24V

x DIx
K1

 Mechanical installation
All brake resistors must be installed outside the drive. Follow the resistor
manufacturer’s instructions.

 Electrical installation
Checking the insulation of the assembly
Follow the instructions given in section Brake resistor assembly on page Brake
resistor assembly.

Connection diagram
See section Connection diagram page 74.

Connection procedure
See section Brake resistor cable (if used) on page 79.
Connect the thermal switch of the brake resistor as described in section Protecting
the system against thermal overload on page 183.
 Resistor braking 185

 Start-up
Note: Protective oil on the brake resistors will burn off when the brake resistor is used
for the first time. Make sure that the airflow is sufficient.
Set the following parameters:
1. Disable the overvoltage control of the drive with parameter 30.30 Overvoltage
control.
2. Set the source of parameter 31.01 External event 1 source to point to the digital
input where the thermal switch of the brake resistor is wired.
3. Set parameter 31.02 External event 1 type to Fault.
4. Enable the brake chopper by parameter 43.06 Brake chopper enable. If Enabled
with thermal model is selected, set also the brake resistor overload protection
parameters 43.08 and 43.09 according to the application.
5. Check the resistance value of parameter 43.10 Brake resistance.
With these parameter settings, the drive generates a fault and coasts to a stop on
brake resistor overtemperature.

WARNING! If the drive is equipped with a brake chopper but the chopper is not
enabled by the parameter setting, the internal thermal protection of the drive
against resistor overheating is not in use. In this case, the brake resistor must be
disconnected.
186 Resistor braking

Resistor braking, frames R5…R9

To be added
 Safe torque off function 187

12
Safe torque off function
What this chapter contains
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. 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.
Note: The Safe torque off function does not disconnect the voltage from the drive,
see the warning on page 194.
When activated, the Safe torque off function disables the control voltage of the power
semiconductors of the drive output stage (A, see diagram on page 190), 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.
188 Safe torque off function

The Safe torque off function of the drive complies with these standards:
Standard Name
EN 60204-1:2006 + Safety of machinery – Electrical equipment of machines – Part 1:
AC:2010 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 –
AC:2009 Part 1: General principles for design
EN ISO 13849-2:2012 Safety of machinery – Safety-related parts of control systems – Part
2: Validation

The function also corresponds to Prevention of unexpected start-up as specified by

EN 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 2006/42/EC 2nd
Edition – June 2010 on page 155.
 Safe torque off function 189

Connection principle
 Connection with internal +24 V DC power supply

Control unit Drive

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

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

UDC-

 Connection with 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
A T2/V,
T3/W

UDC-
190 Safe torque off function

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 Safe PLC

power 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

For information on the specifications of the STO input, see chapter Control
connection data (page 146).

 Activation switch
In the wiring diagram above (page 190), 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.
• If a manually operated activation switch is used, the switch must be of a type that
can be locked out to the open position.
• Inputs IN1 and IN2 must open/close within 200 ms of each other.
 Safe torque off function 191

 Cable types and lengths

• Double-shielded twisted-pair cable is recommended.
• Maximum cable length 300 m (984 ft) between activation switch (K) and drive
control unit.
Note: A short-circuit in the wiring between the switch and an STO terminal causes a
dangerous fault and therefore it is recommended to use a safety relay (including
wiring diagnostics), or a wiring method (shield grounding, channel separation) which
reduces or eliminates the risk caused by the short-circuit.
Note: The voltage at the INx terminals of each drive must be at least 13 V DC to be
interpreted as “1”. Pulse tolerance of input channels is 1 ms.

 Grounding of protective shields

• Ground the shield in the cabling between the activation switch and the control
board at the control board.
• Ground the shield in the cabling between two control boards at one control board
only.

Operation principle
1. The Safe torque off activates (the activation switch is opened, or safety relay
contacts open).
2. The STO inputs IN1 and IN2 on the drive control board de-energize.
3. The STO cuts off the control voltage from the drive IGBTs.
4. The control program generates an indication as defined by parameter 31.22 STO
indication run/stop.
The parameter selects which indications are given when one or both Safe torque
off (STO) signals are switched off or lost. The indications also depend on whether
the drive is running or stopped when this occurs.
Note: This parameter does not affect the operation of the STO function itself. The
STO function will operate regardless of the setting of this parameter: a running
drive will stop upon removal of one or both STO signals, and will not start until
both STO signals are restored and all faults reset.
Note: The loss of only one STO signal always generates a fault as it is interpreted
as a malfunction of STO hardware or wiring.
5. Motor coasts to a stop (if running). The drive cannot restart while the activation
switch or safety relay contacts are open. After the contacts close, a new start
command is required to start the drive.
192 Safe torque off function

Start-up including acceptance test

To ensure the safe operation of a safety function, validation is required. The final
assembler of the machine must validate the function by performing an acceptance
test. The acceptance test must be performed
• at initial start-up of the safety function
• after any changes related to the safety function (circuit boards, wiring,
components, settings, etc.)
• after any maintenance work related to the safety function.

 Authorized person
The acceptance test of the safety function must be carried out by an authorized
person with expertise and knowledge of the safety function. The test must be
documented and signed by the authorized person.
An authorized person is an individual with authorization from the machine builder or
end user to carry out, report and sign off the safety function validation / acceptance
testing on behalf of the machine builder or end user.

 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 193

 Acceptance test procedure

After wiring the Safe torque off function, validate its operation as follows.

Action

WARNING! Follow the Safety instructions, page 11. Ignoring the

instructions can cause physical injury or death, or damage to the
equipment.

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 wiring 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 the
‘stopped’ state in parameter 31.22 STO indication run/stop. For the description of
the warning, see ACS580 firmware manual (3AXD50000016097 [English]).
• Give a start command to verify that the STO function blocks the drive’s operation.
The drive displays a warning. The motor should not start.
• Close the STO circuit.
• Reset any active faults. Restart the drive and check that the motor runs normally.

Test the operation of the STO function when the motor is running.
• Start the drive and ensure the motor is running.
• Open the STO circuit. The motor should stop. The drive generates an indication if
one is defined for the ‘running’ state in parameter 31.22 STO indication run/stop.
For the description of the warning, see ACS580 firmware manual
(3AXD50000016097 [English]).
• 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.
194 Safe torque off function

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 STO
indication run/stop.
4. The motor coasts to a stop (if running). The drive will not restart while the
activation switch or safety relay contacts are open.
5. Deactivate the STO by closing the activation switch, or resetting the safety
functionality that is wired to the STO connection.
6. Reset any faults before restarting.

WARNING! The Safe torque off function does not disconnect the voltage of
the main and auxiliary circuits from the drive. Therefore maintenance work
on electrical parts of the drive or the motor can only be carried out after
isolating the drive from the 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 a running drive is stopped by using the Safe torque off function, the drive will cut
off the motor supply voltage and the motor will coast to a stop. If this causes
danger or is not otherwise acceptable, stop the drive and machinery using the
appropriate stop mode before activating the Safe torque off function.
• The Safe torque off function overrides all other functions of the drive unit.
• 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.
 Safe torque off function 195

Maintenance
After the operation of the circuit is validated at start-up, the STO function shall be
maintained by periodic proof testing. In high demand mode of operation, the
maximum proof test interval is 20 years. In low demand mode of operation, the
maximum proof test interval is 2 years. The test procedure is given in section
Acceptance test procedure (page 193).
In addition to proof testing, it is a good practice to check the operation of the function
when other maintenance procedures are carried out on the machinery.
Include the Safe torque off operation test described above in the routine maintenance
program of the machinery that the drive runs.
If any wiring or component change is needed after start up, or the parameters are
restored, follow the test given in section Acceptance test procedure (page 193).
Use only ABB approved spare parts.

Fault tracing
The indications given during the normal operation of the Safe torque off function are
selected by parameter 31.22 STO indication run/stop.
The diagnostics of the Safe torque off function cross-compare the status of the two
STO channels. In case the channels are not in the same state, a fault reaction
function is performed and the drive trips on an “STO hardware failure” fault. An
attempt to use the STO in a non-redundant manner, for example activating only one
channel, will trigger the same reaction.
See the 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.
196 Safe torque off function

Safety data
The safety data for the Safe torque off function is given below.
Note: The safety data is calculated for redundant use, and does not apply if both STO
channels are not used.

Frame IEC 61508 and IEC/EN 61800-5-2

size SIL PFHd HFT SFF T1 PFD
(1/h) (%) (a)
R0 3 2.68E-09 1 99.8 20 2.8E-06
R1 3 2.68E-09 1 99.8 20 2.8E-06
R2 3 2.68E-09 1 99.8 20 2.8E-06
R3 3 2.68E-09 1 99.8 20 2.8E-06
R5 3 7.09E-10 1 99.9 20 5.91E-05
R6 3 1.06E-09 1 99.8 20 8.85E-05
R7 3 1.06E-09 1 99.8 20 8.85E-05
R8 3 1.4E-09 1 99.7 20 9.04E-05
R9 3 1.4E-09 1 99.7 20 9.04E-05

Frame EN ISO 13849-1 IEC/EN IEC 61511

size 62061
1 2
PL CCF MTTFd DC Category SILCL SIL
(%) (a) (%)
R0 e 80 2938.483 >90 3 3 3
R1 e 80 2938.483 >90 3 3 3
R2 e 80 2938.192 >90 3 3 3
R3 e 80 2938.192 >90 3 3 3
R5 e 80 16033.9 >90 3 3 3
R6 e 80 10876.08 >90 3 3 3
R7 e 80 10876.08 >90 3 3 3
R8 e 80 2490.467 >90 3 3 3
R9 e 80 2490.467 >90 3 3 3
1
100 years must be used for calculation of a safety loop. 3AXD00000586715.xls F
2 According to standard EN ISO 13849-1 table E.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.
 Safe torque off function 197

• 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
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
• Maximum cable length 300 m (984 ft) between activation switch (K) and drive
control unit.
• The voltage at the INx terminals of each drive must be at least 13 V DC to be
interpreted as “1”. Pulse tolerance of input channels is 1 ms.
198 Safe torque off function

 Abbreviations
Abbr. Reference Description
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
STO IEC/EN 61800-5-2 Safe torque off
T1 IEC 61508 Proof test interval

 Declaration of conformity
Declaration of conformity (3AXD10000302783) is available on the Internet. See
section Document library on the Internet on the inside of the back cover.

 Certificate
TÜV certificate (3AXD10000302787) is available on the Internet. See section
Document library on the Internet on the inside of the back cover.
 Optional I/O extension modules 199

13
Optional I/O extension
modules
What this chapter contains
This chapter describes how to install and start up the optional CMOD-01 and
CMOD-01 multifunction extension modules. The chapter also contains diagnostics
and technical data.

CMOD-01 multifunction extension module (external

24 V AC/DC and digital I/O)
 Safety instructions

WARNING! Obey the safety instructions for the drive. If you ignore the safety
instructions, injury or death can occur.

 Hardware description
Product overview
The CMOD-01 multifunction extension module (external 24 V AC/DC and digital I/O)
expands the outputs of the drive control unit. It has two relay outputs and one
transistor output, which can function as a digital or frequency output.
In addition, the extension module has an external power supply interface, which can
be used to power up the drive control unit in case the drive power supply fails. If you
do not need the back-up power supply, you do not have to connect it because the
module is powered from the drive control unit by default.
200 Optional I/O extension modules

Note: In frames R5…R9, you do not need a CMOD-01 module to use external
24 V AC/DC supply. The external supply is connected directly to terminals 40 and 41
on the control unit.

Layout

5
3

6
4 3

Item Description Additional

information
1 Grounding screw Page 200
2 Hole for mounting screw Page 200
3 3-pin terminal blocks for relay outputs Page 201
4 3-pin terminal block for transistor output Page 201
5 2-pin terminal block for external power supply Page 201
6 Diagnostic LED Page 205

 Mechanical installation
Necessary tools and instructions
• Screwdriver and a set of suitable bits.
 Optional I/O extension modules 201

Unpacking and checking the delivery

1. Open the option package.
2. Make sure that the package contains:
• CMOD-01 multifunction extension module
• mounting screw.
3. Make sure that there are no signs of damage.

Installing the module

See chapter Installing option modules on page 104.

 Electrical installation
Warnings

WARNING! Obey the instructions in chapter Safety instructions on page 11. If

you ignore them, injury or death, or damage to the equipment can occur. If you
are not a qualified electrician, do not do electrical work.
Make sure that the drive is disconnected from the input power during
installation. If the drive is already connected to the input power, wait for
5 minutes after disconnecting the input power.

Necessary tools and instructions

• Screwdriver and a set of suitable bits
• Cabling tools

Terminal designations
For more detailed information on the connectors, see section Technical data on
page 205.

Relay outputs
Marking Description
50 RO4C Common, C
51 RO4A Normally closed, NC
52 RO4B Normally open, NO
53 RO5C Common, C
54 RO5A Normally closed, NC
55 RO5B Normally open, NO
202 Optional I/O extension modules

Transistor output
Marking Description
42 DO1 SRC Source input
43 DO1 OUT Digital or frequency output
44 DO1 SGND Ground (earth) potential

External power supply6

The external power supply is needed only if you want to connect an external back-up
power supply for the drive control unit
Note: Only frames R0…R3 need CMOD-01 (or CMOD-02) for connecting external
power supply, frames R5…R9 have corresponding terminals 40 and 41 on the control
unit.
Marking Description
40 24V AC/DC + in External 24 V (AC/DC) input
41 24V AC/DC - in External 24 V (AC/DC) input

General cabling instructions

Obey the instructions given in chapter Planning the electrical installation on page 53.

Wiring
Connect the external control cables to the applicable module terminals. Ground the
outer shield of the cables 360 degrees under a grounding clamp on the grounding
shelf of the control cables.

Relay output connection example

RO4C
50
RO4A
24 V DC 51
RO4B
52

CMOD-01
 Optional I/O extension modules 203

Digital output connection example

42 DO1 SRC
24 V DC
43 DO1 OUT
44 DO1 SGND
CMOD-01

Frequency output connection example

1) 42 DO1 SRC
43 DO1 OUT
44 DO1 SGND
CMOD-01

1) An externally supplied frequency indicator which provides, for example:

• a 40 mA / 12 V DC power supply for the sensor circuit (CMOD frequency output)
• suitable voltage pulse input (10 Hz … 16 kHz).

External power supply connection example

+
1) 40 24V AC/DC - in
- 41 24V AC/DC + in
CMOD-01

1)
External power supply, 24 V AC/DC

 Start-up
Setting the parameters
1. Power up the drive.
2. If no warning is shown,
• make sure that the value of both parameter 15.02 Detected extension module
and parameter 15.01Extension module type is CMOD-01.
If warning A7AB Extension I/O configuration failure is shown,
• make sure that the value of parameter 15.02 Detected extension module is
CMOD-01.
• set parameter 15.01 Extension module type to CMOD-01.
204 Optional I/O extension modules

You can now see the parameters of the extension module in parameter group 15
I/O extension module (page 252).
3. Set the parameters of the extension module to applicable values.
Examples are given below.

Parameter setting example for relay output

This example shows how make relay output RO4 of the extension module indicate
the reverse direction of rotation of the motor with a one-second delay.
Parameter Setting
15.07 RO4 source Reverse
15.08 RO4 ON delay 1s
15.09 RO4 OFF delay 1s

Parameter setting example for digital output

This example shows how to make digital output DO1 of the extension module indicate
the reverse direction of rotation of the motor with a one-second delay.
Parameter Setting
15.22 DO1 configuration Digital output
15.23 DO1 source Reverse
15.24 DO1 ON delay 1s
15.25 DO1 OFF delay 1s

Parameter setting example for frequency output

This example shows how to make digital output DO1 of the extension module indicate
the motor speed 0... 1500 rpm with a frequency range of 0...10000 Hz.
Parameter Setting
15.22 DO1 configuration Frequency output
15.33 Freq out 1 source 01.01
15.34 Freq out 1 src min 0
15.35 Freq out 1 src max 1500.00
15.36 Freq out 1 at src min 1000 Hz
15.37 Freq out 1 at src max 10000 Hz

 Diagnostics
Faults and warning messages
Warning A7AB Extension I/O configuration failure, see page 429.
 Optional I/O extension modules 205

LEDs
The extension module has one diagnostic LED.
Color Description
Green The extension module is powered up.

 Technical data
Dimension drawing:
The dimensions are in millimeters and [inches].

Installation: Into an option slot on the drive control unit

Degree of protection: IP20
Ambient conditions: See the drive technical data.
206 Optional I/O extension modules

Package: Cardboard
Isolation areas:

CMOD-01

Plugged to
24 Vin drive SLOT2 RO4

DO1 RO5

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

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

Relay outputs (50…52, 53…55):

• Wire size max. 1.5 mm2
• Minimum contact rating: 12 V / 10 mA
• Maximum contact rating: 250 V AC / 30 V DC / 2 A
• Maximum breaking capacity: 1500 VA
Transistor output (42…44):
• Wire size max. 1.5 mm2
• Type: Transistor output PNP
• Maximum switching voltage: 30 V DC
• Maximum switching current: 100 mA / 30 V DC, short-circuit protected
• Frequency: 10 Hz … 16 kHz
• Resolution: 1 Hz
• Accuracy: 0.2%
 Optional I/O extension modules 207

External power supply (40…41):

• Wire size max. 1.5 mm2
• 24 V AC / V DC ±10% (GND, user potential)
• Maximum current consumption: 25 W, 1.04 A at 24 V DC
208 Optional I/O extension modules

CMOD-02 multifunction extension module

(external 24 V AC/DC and isolated PTC interface)
 Safety instructions

WARNING! Obey the safety instructions for the drive. If you ignore the safety
instructions, injury or death can occur.

 Hardware description
Product overview
The CMOD-02 multifunction extension module (external 24 V AC/DC and isolated
PTC interface) has a motor thermistor connection for supervising the motor
temperature and one relay output, which indicates the thermistor status. To trip the
drive, the user must connect this overtemperature indication back to the drive, for
example, to its Safe torque off input.
In addition, the extension module has an external power supply interface, which can
be used to power up the drive control unit in case the drive power supply fails. If you
do not need the back-up power supply, you do not have to connect it because the
module is powered from the drive control unit by default.
There is reinforced insulation between the motor thermistor connection, the relay
output and the drive control unit interface. Thus, you can connect a motor thermistor
to the drive through the extension module.
Note: In frames R5…R9, you do not need a CMOD-01 module to use external
24 V AC/DC supply. The external supply is connected directly to terminals 40 and 41
on the control unit.
 Optional I/O extension modules 209

Layout

5 4

6 3

Item Description Additional

information
1 Grounding screw Page 209
2 Hole for mounting screw Page 209
3 2-pin terminal block for motor thermistor connection Page 210
4 2-pin terminal block for relay output Page 210
5 2-pin terminal block for external power supply Page 210
6 Diagnostic LED Page 213

 Mechanical installation
Necessary tools and instructions
• Screwdriver and a set of suitable bits
210 Optional I/O extension modules

Unpacking and checking the delivery

1. Open the option package.
2. Make sure that the package contains:
• CMOD-02 multifunction extension module
• mounting screw
3. Make sure that there are no signs of damage.

Installing the module

See chapter Installing option modules on page 104.

 Electrical installation
Warnings

WARNING! Obey the instructions in chapter Safety instructions on page 11. If

you ignore them, injury or death, or damage to the equipment can occur. If you
are not a qualified electrician, do not do electrical work.
Make sure that the drive is disconnected from the input power during
installation. If the drive is already connected to the input power, wait for
5 minutes after disconnecting the input power.

Necessary tools and instructions

• Screwdriver and a set of suitable bits
• Cabling tools

Terminal designations
For more detailed information on the connectors, see section Technical data on
page 214.

Motor thermistor connection

Marking Description
60 PTC IN PTC connection
61 PTC IN Ground (earth) potential

Relay output
Marking Description
62 RO PTC C Common, C
63 RO PTC B Normally open, NO
 Optional I/O extension modules 211

External power supply

The external power supply is needed only if you want to connect an external back-up
power supply for the drive control unit.
Note: Only frames R0…R3 need CMOD-01 (or CMOD-02) for connecting external
power supply, frames R5…R9 have corresponding terminals 40 and 41 on the control
unit.
Marking Description
40 24V AC/DC + in External 24 V (AC/DC) input
41 24V AC/DC - in External 24 V (AC/DC) input

General cabling instructions

Obey the instructions given in chapter Planning the electrical installation on page 53.

Wiring
Connect the external control cables to the applicable module terminals. Ground the
outer shield of the cables 360 degrees under a grounding clamp on the grounding
shelf of the control cables

Motor thermistor connection example

1)
60 PTC IN
61 PTC IN
CMOD-02

1)
One or 3…6 PTC thermistors connected in series.
212 Optional I/O extension modules

Relay output connection example

CMOD-02
RO PTC C
62
63
RO
PTC B

X4 CCU
34 OUT1
35 OUT2
36 SGND
37 IN1
38 IN2

Power supply connection example

+
1) 40 24V AC/DC - in
- 41 24V AC/DC + in
CMOD-02

1) External power supply, 24 V AC/DC

 Start-up
Setting the parameters
1. Power up the drive.
2. If no warning is shown,
• make sure that the value of both parameter 15.02 Detected extension module
and parameter 15.01Extension module type is CMOD-02.
If warning A7AB Extension I/O configuration failure is shown,
• make sure that the value of parameter 15.02 Detected extension module is
CMOD-02.
• set parameter 15.01 Extension module type to CMOD-02.
You can now see the parameters of the extension module in parameter group 15
I/O extension module (page 252).
 Optional I/O extension modules 213

 Diagnostics
Faults and warning messages
Warning A7AB Extension I/O configuration failure, see page 429.

LEDs
The extension module has one diagnostic LED.
Color Description
Green The extension module is powered up.
214 Optional I/O extension modules

 Technical data
Dimension drawing:
The dimensions are in millimeters and [inches].

Installation: Into an option slot on the drive control unit

Degree of protection: IP20
Ambient conditions: See the drive technical data.
Package: Cardboard
 Optional I/O extension modules 215

Isolation areas:

CMOD-02

Plugged to
24 Vin drive SLOT2 RO PTC

PTCin

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

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

Motor thermistor connection (60…61):

• Wire size max. 1.5 mm2
• Supported standards: DIN 44081 and DIN 44082
• Number of PTC thermistor relays: 1 or 3…6 in series
• Triggering threshold: 3.6 kohm
• Recovery threshold: 1.6 kohm
• PTC terminal voltage: < 5.0 V
• PTC terminal current: < 1 mA
• Short-circuit detection: < 50 ohm
Relay output (62…63):
• Wire size max. 1.5 mm2
• Maximum contact rating: 250 V AC / 30 V DC / 5 A
• Maximum breaking capacity: 1000 VA
External power supply (40…41):
• Wire size max. 1.5 mm2
• 24 V AC / V DC ±10% (GND, user potential)
• Maximum current consumption: 25 W, 1.04 A at 24 V DC
216 Optional I/O extension modules
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
Training courses.

Providing feedback on ABB Drives manuals

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Document Library – Manuals feedback form (LV AC drives).

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3AXD50000018826 Rev C (EN) 2014-10-21

3AXD50000018826C