| Вид документа | Інструкція з експлуатації |
|---|---|
| Виробник | ABB |
| Код документа | ACH580-01_3AXD50000044839_Instruction_manual |
| Сторінок | 502 |
| Мова документа | англійська |
| Розмір файлу | 84.3 МБ |
О чём документ
Официальное руководство по аппаратной части настенных частотных преобразователей ABB ACH580-01 для HVAC-приложений. Документ охватывает монтаж (механический и электрический, для IEC и North America), пусконаладку, обслуживание и полные технические данные. Предназначен для монтажников, наладчиков и сервисного персонала; работа с приводом требует квалификации по электробезопасности.
Ключевые характеристики
| Параметр | Значение |
|---|---|
| Тип привода | Частотный преобразователь для асинхронных двигателей АС, двигателей с постоянными магнитами и SynRM |
| Классы напряжения | 208…240 В; 380…480 В; 525…600 В (3-фазные), 230/240 В (1-фазные входы для малых типоразмеров) |
| Типоразмеры (frame sizes) | R1…R9, R9e |
| Номинальная мощность | от 0,37 кВт до 355 кВт (IEC, 400 В); до 400 hp (UL, 480 В) |
| Степени защиты | IP21 (UL Type 1), IP55 (UL Type 12), IP66 (UL Type 4X, только R1…R3, опции +B063/+B066) |
| Перегрузочная способность | Light duty: 110 % на 1 мин каждые 10 мин; Heavy duty: 150 % на 1 мин каждые 10 мин |
| Встроенный тормозной ключопер (chopper) | В типоразмерах R1…R3 (клеммы R-, R+); внешние тормозные ключоперы — клеммы UDC+/UDC- в R4…R9 |
| Функция безопасности | Safe torque off (STO) по EN 61800-5-2, встроенная, клеммы X4 |
| Аналоговые входы | AI1: 0(2)…10 В; AI2: 0(4)…20 мА (перенастраивается параметром) |
| Аналоговые выходы | AO1: 0…10 В; AO2: 0…20 мА (0…10 В с резистором 500 Ом) |
| Цифровые входы | DI1…DI6, NPN/PNP, 12/24 В; DI5 — частотный вход (до 16 кГц), DI6 — вход PTC |
| Релейные выходы | RO1…RO3: 250 В AC / 30 В DC, 2 А |
| Встроенная полевая шина | EFB (EIA-485), 9,6…115,2 кбит/с, клеммы X5 |
| Выход +24 В | 24 В DC, макс. 250 мА (6 Вт) |
| Внешнее питание цепей управления | 24 В AC/DC (CCU-24, клеммы 40–41) |
| Панель управления | ACH-AP-H (стандарт), опция ACH-AP-W с Bluetooth; связь EIA-485 RJ-45 до 100 м |
| Панель — ПК | USB Type Mini-B, макс. 3 м |
| Моторные датчики температуры | Pt100, Pt1000, Ni1000, KTY83, KTY84 (через AI1/AI2), PTC (DI6 или модуль CMOD-02/CPTC-02) |
| Питание цепей управления (CCU-23/CCU-24) | 25 Вт / 36 Вт, 24 В AC/DC ±10 % |
| Совместимость с УЗО | Type B RCD |
| Максимальное количество включений | 5 включений за 10 минут |
| Время ожидания после отключения питания | 5 минут до разряда конденсаторов промежуточной цепи |
| Напряжение измерения изоляции двигателя | 1000 В DC, сопротивление для двигателей ABB > 100 МОм |
| Энергопотребление цепей управления CCU-24 | 36 Вт, 1,50 А при 24 В AC/DC ±10 % |
Что внутри документа
- Инструкции по безопасности: электрическая безопасность, заземление, работа с приводами двигателей с постоянными магнитами
- Описание принципа работы, компоновки по типоразмерам, маркировки и ключа типообозначений с кодами опций
- Механический монтаж: вертикальный/горизонтальный/фланцевый монтаж, свободные пространства, распаковка, IP66/UL Type 4X на улице
- Планирование электромонтажа: выбор кабелей, заземление, защита от КЗ и перегрузки, фильтры du/dt и синусные, байпас
- Электромонтаж Global (IEC) и North America: проверка систем заземления, отключение EMC-фильтра и варисторов, подключение силовых и управляющих кабелей с моментами затяжки
- Блок управления CCU-23/CCU-24: схема подключений по умолчанию, цифровые/аналоговые входы-выходы, STO, полевая шина EIA-485
- Пусконаладка, чек-лист монтажа, обслуживание (вентиляторы, конденсаторы, чистка)
- Технические данные: номиналы IEC/UL, derating по температуре/высоте/частоте коммутации, предохранители и автоматы, размеры, потери, стандарты
- Главы по опционным модулям: CAIO-01, CHDI-01, CMOD-01, CMOD-02, фильтры
- Резисторное торможение и функция Safe torque off (сертификат TÜV)
Быстрый старт
- Идентифицируйте типоразмер привода (R1…R9) по шильдику и подберите место монтажа с учётом свободного пространства и вентиляции.
- Смонтируйте привод вертикально на негорючую стену по монтажному шаблону; типоразмеры R5…R9 поднимать такелажем за рымы.
- Если сеть не симметрично заземлённая TN-S — проверьте совместимость системы заземления и при необходимости снимите винты EMC-фильтра и варистора (VAR).
- Измерьте сопротивление изоляции кабеля питания, двигателя и кабеля двигателя (1000 В DC; для двигателей ABB > 100 МОм). Не проводить испытания изоляции самого привода.
- Подключите силовые кабели (L1/L2/L3, T1/U, T2/V, T3/W, PE) с требуемыми моментами затяжки; экран кабеля двигателя заземлите на 360°.
- Подключите управляющие кабели (клеммы X1…X8) с моментом 0,5…0,6 Н·м, экраны заземлите на 360°.
- Проверьте монтаж по чек-листу, затем выполните настройку по руководству по управляющей программе ACH580 (firmware manual) и валидируйте функцию Safe torque off.
Частые вопросы
- Какой кабель использовать между приводом и двигателем?
- Рекомендуется симметричный экранированный кабель ( shielded VFD cable) с экранировкой не менее 1/10 проводимости фазного проводника; для Северной Америки ABB рекомендует металлический кабель-канал и симметричный экранированный VFD-кабель. Экран кабеля двигателя заземляется на 360° с обеих сторон.
- Нужно ли что-то менять при подключении не к сети TN-S?
- Да. На сетях IT, TN с заземлённой фазой (corner-grounded), midpoint-grounded delta и TT может потребоваться выкрутить винты внутреннего EMC-фильтра и/или варистора (VAR) согласно таблицам в руководстве; для установки в систему TT требуется УЗО и отключение EMC-фильтра.
- Что означает функция Safe torque off и как её подключить?
- STO (IEC/EN 61800-5-2) предотвращает создание приводом вращающего момента, не снимая напряжения с силовых цепей. Подключение — клеммы X4 (IN1, IN2), работает только от 24 В DC в PNP-конфигурации; обе цепи должны быть замкнуты для пуска. По умолчанию установлены перемычки — их снимают при подключении внешней цепи STO.
- Какие модули расширения и полевой шины поддерживает привод?
- Слот 1 — адаптеры полевой шины: FPBA-01 (PROFIBUS DP), FENA-21 (EtherNet/IP, Modbus TCP, PROFINET IO), FEIP-21, FBIP-21, FCAN-01, FSCA-01 и др. Слот 2 — модули ввода-вывода: CMOD-01, CMOD-02, CAIO-01, CHDI-01, CPTC-02 (ATEX-сертифицированный модуль термисторной защиты).
- Как часто менять вентиляторы охлаждения?
- Главный вентилятор IP21 типоразмеров R1…R9 — замена каждые 9 лет (интервалы указаны в таблице обслуживания; основные вентиляторы R6…R9 — LONGLIFE, замена каждые 12 лет). Счётчик наработки вентилятора — параметр 05.04.
- Можно ли подключать компенсирующие конденсаторы к кабелю двигателя?
- Нет. Запрещено подключать конденсаторы компенсации реактивной мощности и гармонические фильтры к кабелю двигателя между приводом и двигателем — это может привести к необратимому повреждению привода.
Документ довгий: картка написана за першими 401 тис. знаків його тексту. Повний зміст — у PDF.
Текст документа
—
ABB DRIVES FOR HVAC
ACH580-01 drives
Hardware manual
ACH580-01 drives
Hardware manual
Table of contents
1. Safety instructions
4. Mechanical installation
6. Electrical installation –
Global (IEC)
7. Electrical installation – North
America
10. Start-up
3AXD50000044839 Rev G
EN
Original instructions
EFFECTIVE: 2025-06-25
Table of contents 5
Table of contents
1 Safety instructions
Contents of this chapter.......................................................................................... 21
Safety messages........................................................................................................ 21
General safety in installation, start-up and maintenance................................. 22
Electrical safety in installation, start-up and maintenance.............................. 24
Electrical safety precautions........................................................................... 24
Additional instructions and notes.................................................................. 25
Printed circuit boards........................................................................... 25
Grounding............................................................................................................ 26
General safety in operation..................................................................................... 27
Additional instructions for permanent magnet motor drives......................... 27
Safety in installation, start-up, maintenance............................................... 27
Safety in operation............................................................................................ 28
2 Introduction to the manual
Contents of this chapter.......................................................................................... 29
Applicability................................................................................................................ 29
Target audience......................................................................................................... 29
Categorization by frame size.................................................................................. 29
Quick installation and commissioning flowchart............................................... 30
Terms and abbreviations......................................................................................... 31
Related documents................................................................................................... 33
3 Operation principle and hardware description
Contents of this chapter.......................................................................................... 35
Operation principle................................................................................................... 36
Layout.......................................................................................................................... 36
Overview of power and control connections....................................................... 50
External control connection terminals, frames R1…R5.............................. 51
External control connection terminals, frames R6…R9............................. 52
Control panel.............................................................................................................. 53
Control panel door mounting kits.................................................................. 54
Control panel mounting platform cover (option +J424)............................ 54
Type designation label............................................................................................. 54
Locations of the labels on the drive............................................................... 56
Type designation key................................................................................................ 57
Option codes....................................................................................................... 57
Manual kit ordering codes....................................................................................... 60
6 Table of contents
4 Mechanical installation
Contents of this chapter.......................................................................................... 61
Safety........................................................................................................................... 61
Cabinet installation (options +P940 and +P944)................................................ 61
Examining the installation site............................................................................... 62
Installation alternatives............................................................................................ 63
Necessary tools.......................................................................................................... 68
Moving the drive........................................................................................................ 68
Unpacking and examining delivery, frames R1 and R2....................................... 69
Frames R1 and R2 cable box (IP21, UL Type 1).............................................. 71
Unpacking and examining delivery, frame R3...................................................... 72
Unpacking and examining delivery, frames R1…R3, IP66 (UL Type 4X)......... 74
Unpacking and examining delivery, frames R4.................................................... 76
Unpacking and examining delivery, frame R5 and R6........................................ 78
Frame R5 cable box (IP21, UL Type 1)............................................................. 79
Frame R6 cable box (IP21, UL Type 1)............................................................. 80
Unpacking and examining delivery, frame R7...................................................... 81
Frame R7 cable box (IP21, UL Type 1).............................................................. 83
Unpacking and examining delivery, frames R8 and R9...................................... 84
Frame R8 cable box (IP21, UL Type 1)............................................................. 86
Frame R9 cable box (IP21, UL Type 1)............................................................. 87
Unpacking and examining delivery, frame R9e.................................................... 88
Frame R8 cable box (IP21, UL Type 1)............................................................. 90
Frame R9 cable box (IP21, UL Type 1)............................................................. 91
Installing the drive..................................................................................................... 92
Installing the drive vertically, frames R1…R4................................................ 92
Installing the cable box, frames R1…R2............................................. 93
Installing the drive vertically, frame R5.......................................................... 94
IP21 (UL Type 1)....................................................................................... 95
IP21 (UL Type 1), IP55 (UL Type 12)...................................................... 96
Installing the drive vertically, frames R6…R9............................................... 97
IP21 (UL Type 1)....................................................................................... 98
IP55 (UL Type 12).................................................................................... 99
Installing the drive vertically, frame R9e........................................................ 99
Remove the front cover........................................................................ 100
Remove the EMC cover plates............................................................. 101
Remove the side plates......................................................................... 102
Remove the EMC side plate................................................................. 103
Remove the control cable entry plate................................................ 103
Remove the clamping shelves............................................................. 104
Remove the terminals........................................................................... 105
Installing the drive vertically side by side...................................................... 105
Installing the drive horizontally, frames R1…R5.......................................... 105
Installing the IP66 (UL Type 4X) drive outdoors.......................................... 105
Flange mounting........................................................................................................ 106
Table of contents 7
Strut channel installation (US only)....................................................................... 106
Installation instructions.................................................................................... 106
5 Guidelines for planning the electrical installation
Contents of this chapter.......................................................................................... 107
Limitation of liability................................................................................................. 107
North America..................................................................................................... 107
Selecting the main supply disconnecting device................................................ 107
Selecting the main contactor.................................................................................. 108
Examining the compatibility of the motor and drive......................................... 108
Protecting the motor insulation and bearings............................................. 108
Requirements tables.......................................................................................... 109
Requirements for ABB motors, Pn < 100 kW (134 hp)..................... 110
Requirements for ABB motors, Pn > 100 kW (134 hp)..................... 111
Requirements for non-ABB motors, Pn < 100 kW (134 hp)............. 112
Requirements for non-ABB motors, Pn > 100 kW (134 hp)............. 113
Abbreviations.......................................................................................... 114
Availability of du/dt filter and common mode filter by drive
type........................................................................................................... 114
Additional requirements for explosion-safe (EX) motors............. 114
Additional requirements for ABB motors of types other than M2_,
M3_, M4_, HX_ and AM_......................................................................... 114
Additional requirements for braking applications.......................... 114
Additional requirements for ABB high-output and IP23 motors... 114
Additional requirements for non-ABB high-output and IP23
motors...................................................................................................... 115
Additional data for calculating the rise time and the peak
line-to-line voltage................................................................................. 116
Additional note for sine filters............................................................ 117
Selecting the power cables...................................................................................... 118
General guidelines.............................................................................................. 118
Typical power cable sizes................................................................................. 118
Power cable types.............................................................................................. 119
Preferred power cable types................................................................ 119
Alternate power cable types................................................................ 120
Not allowed power cable types........................................................... 121
Additional guidelines – North America.......................................................... 121
Metal conduit.......................................................................................... 122
Power cable shield............................................................................................. 122
Grounding requirements.......................................................................................... 123
Additional grounding requirements – IEC..................................................... 124
Additional grounding requirements – UL (NEC).......................................... 125
Selecting the control cables.................................................................................... 125
Shielding.............................................................................................................. 125
Signals in separate cables................................................................................ 125
8 Table of contents
Signals that can be run in the same cable..................................................... 126
Relay cable........................................................................................................... 126
Control panel to drive cable............................................................................. 126
PC tool cable........................................................................................................ 126
FPBA-01 PROFIBUS DP adapter module connectors................................... 126
Routing the cables..................................................................................................... 127
General guidelines – IEC.................................................................................... 127
General guidelines – North America............................................................... 128
Continuous motor cable shield/conduit and metal enclosure for
equipment on the motor cable........................................................................ 129
Separate control cable ducts........................................................................... 129
Implementing short-circuit and thermal overload protection......................... 129
Protecting the drive and the input power cable in short-circuits............ 129
Protecting the motor and motor cable in short-circuits............................ 130
Protecting the motor cables against thermal overload............................. 130
Protecting the motor against thermal overload.......................................... 131
Protecting the motor against overload without thermal model or
temperature sensors......................................................................................... 131
Protecting the drive against ground faults.......................................................... 132
Residual current device compatibility............................................................ 132
Implementing the emergency stop function....................................................... 132
Implementing the Safe torque off function......................................................... 132
Using power factor compensation capacitors with the drive.......................... 132
Controlling a contactor between drive and motor............................................. 133
Implementing an ATEX-certified motor thermal protection............................ 133
Implementing the power loss ride-through function........................................ 134
Using a safety switch between the drive and the motor.................................. 135
Implementing a bypass connection....................................................................... 135
Example bypass connection............................................................................ 135
Switching the motor power supply from drive to direct-on-line.. 136
Switching the motor power supply from direct-on-line to drive.. 136
Protecting the contacts of relay outputs............................................................. 136
Limiting relay output maximum voltages at high installation altitudes........ 137
Implementing a motor temperature sensor connection................................... 137
Connecting a motor temperature sensor to the drive through an option
module.................................................................................................................. 138
6 Electrical installation – Global (IEC)
Contents of this chapter.......................................................................................... 141
Necessary tools.......................................................................................................... 141
Grounding the motor cable shield at the motor end......................................... 141
Measuring the insulation......................................................................................... 142
Measuring the insulation resistance of the drive........................................ 142
Measuring the insulation resistance of the input power cable................ 142
Measuring the insulation resistance of the motor and motor cable....... 142
Table of contents 9
Brake resistor assembly for R1…R3................................................................ 143
Grounding system compatibility check................................................................ 143
EMC filter............................................................................................................. 143
Ground-to-phase varistors............................................................................... 144
When to disconnect EMC filter or ground-to-phase varistor: TN-S, IT,
corner-grounded delta and midpoint-grounded delta systems.............. 144
Guidelines for installing the drive to a TT system....................................... 146
Identifying the grounding system of the electrical power network........ 147
Disconnecting internal EMC filter or ground-to-phase varistor - frames
R1…R3................................................................................................................... 147
Disconnecting internal EMC filter or ground-to-phase varistor - frames
R4…R9.................................................................................................................. 148
Connecting the power cables................................................................................. 150
Connection diagram.......................................................................................... 151
Connection procedure, frames R1…R4.......................................................... 152
Motor cable............................................................................................. 153
Input power cable.................................................................................. 155
Grounding shelf...................................................................................... 158
Brake resistor cable (if used)............................................................... 158
Finalization.............................................................................................. 160
Connection procedure, frame R5.................................................................... 160
IP21 (UL Type 1)....................................................................................... 160
IP55 (UL Type 12).................................................................................... 160
Connection procedure, frames R6…R9......................................................... 166
Motor cable............................................................................................. 167
Input power cable.................................................................................. 168
Detaching and reinstalling the connectors...................................... 168
Connection procedure, frame R9e.................................................................. 170
Connect the power cables.................................................................... 171
Install the control cable entry plate.................................................... 177
Install the EMC plates and side plates............................................... 177
DC connection............................................................................................................ 177
Connecting the control cables................................................................................ 178
Connection diagram.......................................................................................... 178
Control cable connection procedure, frames R1…R9................................. 178
Control cable connection procedure, frame R9e......................................... 183
Installing option modules........................................................................................ 184
Option slot 1 (fieldbus adapter modules)..................................................... 184
Option slot 2 (I/O extension modules).......................................................... 185
Wiring the optional modules............................................................................ 186
Reinstalling grommets............................................................................................. 187
Reinstalling covers.................................................................................................... 188
Reinstalling cover, frames R1…R4.................................................................. 188
Reinstalling covers, frame R5, R5 v2............................................................... 189
IP21 (UL Type 1)....................................................................................... 189
10 Table of contents
IP55 (UL Type 12).................................................................................... 189
Reinstalling side plates and covers, frames R6…R9................................... 190
IP21 (UL Type 1)....................................................................................... 190
IP55 (UL Type 12).................................................................................... 190
Reinstalling covers, frame R9e........................................................................ 191
Installing IP66 (UL Type 4X) sun shield................................................................. 191
Connecting a PC......................................................................................................... 191
Connecting a remote panel, or chaining one panel to several drives............. 192
7 Electrical installation – North America
Contents of this chapter.......................................................................................... 193
Necessary tools.......................................................................................................... 194
Grounding the motor cable shield at the motor end......................................... 194
Measuring the insulation......................................................................................... 194
Measuring the insulation resistance of the drive........................................ 194
Measuring the insulation resistance of the input power cable................ 194
Measuring the insulation resistance of the motor and motor cable....... 194
Brake resistor assembly for R1…R3................................................................ 195
Grounding system compatibility check................................................................ 196
EMC filter............................................................................................................. 196
Ground-to-phase varistors (VAR).................................................................... 196
When to connect EMC filter or disconnect ground-to-phase varistor:
TN-S, IT, corner-grounded delta and midpoint-grounded delta systems. 197
Replacement screws.............................................................................. 198
Guidelines for installing the drive to a TT system....................................... 199
Identifying the grounding system of the electrical power network........ 200
Disconnecting internal EMC filter or ground-to-phase varistor - frames
R1…R3................................................................................................................... 200
Disconnecting internal EMC filter or ground-to-phase varistor - frames
R4…R9.................................................................................................................. 202
Connecting the power cables................................................................................. 204
Connection diagram.......................................................................................... 204
Connection procedure, frames R1…R4.......................................................... 206
Motor cabling.......................................................................................... 207
Input power cabling............................................................................... 210
Brake resistor cabling (if used)........................................................... 212
Finalization.............................................................................................. 213
Connection procedure, frame R5.................................................................... 214
IP21 (UL Type 1)....................................................................................... 214
IP55 (UL Type 12).................................................................................... 214
Connection procedure, frames R6…R9......................................................... 218
Motor cabling.......................................................................................... 219
Input power cabling............................................................................... 220
Detaching and reinstalling the connectors...................................... 220
DC connection............................................................................................................ 222
Table of contents 11
Connecting the control cables................................................................................ 222
Connection diagram.......................................................................................... 222
Control cable connection procedure R1…R9................................................ 222
Installing option modules........................................................................................ 228
Reinstalling grommets............................................................................................. 228
Reinstalling covers.................................................................................................... 229
Reinstalling cover, frames R1…R4.................................................................. 229
Reinstalling covers, frame R5........................................................................... 230
IP21 (UL Type 1)....................................................................................... 230
IP55 (UL Type 12).................................................................................... 230
Reinstalling side plates and covers, frames R6…R9................................... 231
IP21 (UL Type 1)....................................................................................... 231
IP55 (UL Type 12).................................................................................... 231
Installing UL Type 12 hood....................................................................................... 232
Installing IP66 (UL Type 4X) sun shield................................................................. 232
Connecting a PC......................................................................................................... 232
Connecting a remote panel, or chaining one panel to several drives............. 233
8 Control unit
Contents of this chapter.......................................................................................... 235
Layout.......................................................................................................................... 236
Default control connection diagram..................................................................... 238
Additional information on the control connections........................................... 242
Embedded EIA-485 fieldbus connection....................................................... 242
Connecting motor temperature sensors to the drive................................ 243
PNP configuration for digital inputs (DIGITAL IN)....................................... 244
NPN configuration for digital inputs (DIGITAL IN)...................................... 245
Connection for obtaining 0…10 V from analog output 2 (AO2)............... 245
Connection examples of two-wire and three-wire sensors to analog
input (AI2)............................................................................................................ 245
DI5 as frequency input...................................................................................... 246
DI6 as PTC input................................................................................................. 246
AI1 and AI2 as Pt100, Pt1000, Ni1000, KTY83 and KTY84 sensor inputs
(X1)......................................................................................................................... 246
Safe torque off (X4)........................................................................................... 247
Technical data............................................................................................................ 248
9 Installation checklist
Contents of this chapter.......................................................................................... 257
Checklist...................................................................................................................... 257
10 Start-up
Contents of this chapter.......................................................................................... 261
12 Table of contents
Reforming the capacitors........................................................................................ 261
Start-up procedure.................................................................................................... 261
11 Maintenance
Contents of this chapter.......................................................................................... 263
Maintenance intervals............................................................................................... 263
Description of symbols..................................................................................... 263
Recommended maintenance intervals after start-up................................. 264
Cleaning the exterior of the drive, IP21 and IP55 (UL Type 1 and UL Type 12). 266
Cleaning the exterior of the drive, IP66 (UL Type 4X)........................................ 267
Cleaning the heatsink, IP21, IP55 (UL Type 1, UL Type 12)................................. 268
Cleaning the heatsink, IP 66 (UL Type 4X)............................................................ 269
Fans.............................................................................................................................. 270
Replacing the main cooling fan, IP21, IP55 and IP66 (UL Type 1, UL Type 12
and UL Type 4X) frames R1…R4 and R5 v2.................................................... 271
R1…R3....................................................................................................... 271
R4, R4 v2, R5 v2....................................................................................... 272
Replacing the main cooling fan, IP21 and IP55 (UL Type 1 and UL Type 12)
frames R5…R8.................................................................................................... 273
Replacing the main cooling fans, IP21 and IP55 (UL Type 1 and UL Type 12)
frame R9............................................................................................................... 274
Replacing the auxiliary cooling fan, IP21 and IP55 (UL Type 1 and
UL Type 12) frames R6…R9.............................................................................. 275
Replacing the auxiliary cooling fan, IP55 (UL Type 12) frames R1…R2..... 276
Replacing the auxiliary cooling fan, IP55 and IP66 (UL Type 12 and
UL Type 4X) frame R3........................................................................................ 278
Replacing the auxiliary cooling fan, IP55 (UL Type 12) frame R4; IP21 and
IP55 (UL Type 1 and UL Type 12) frame R5..................................................... 280
Replacing the auxiliary cooling fan, IP21 (UL Type 1) frame R5 v2............ 282
Replacing the second auxiliary cooling fan, IP55 (UL Type 12) frames
R8…R9.................................................................................................................. 283
Replacing the auxiliary cooling fans in the IP55 (UL Type 12) cover, frame
R9 (drive types -490A-4 and -454A-4)............................................................ 284
Replacing the internal cooling fan, IP21 (UL Type 1) frame R9e................ 286
Capacitors................................................................................................................... 287
Reforming the capacitors................................................................................. 287
Control panel.............................................................................................................. 287
LEDs.............................................................................................................................. 288
Drive LEDs............................................................................................................ 288
Control panel LEDs............................................................................................. 289
Functional safety components............................................................................... 290
12 Technical data
Contents of this chapter.......................................................................................... 291
Table of contents 13
Electrical ratings........................................................................................................ 292
IEC......................................................................................................................... 292
Definitions............................................................................................... 297
UL (NEC)............................................................................................................... 298
Definitions............................................................................................... 301
UL listed multiple ratings..................................................................... 302
Conversion tables for IEC and North American type codes...................... 302
Sizing.................................................................................................................... 304
Deratings............................................................................................................. 304
Surrounding air temperature derating, IP21 (UL Type 1)............... 306
Surrounding air temperature derating, IP55 (UL Type 12)............. 308
Surrounding air temperature derating, IP66 (UL Type 4X)............ 309
Altitude derating.................................................................................... 310
Switching frequency derating............................................................. 311
Output frequency derating.................................................................. 314
Fuses (IEC).................................................................................................................. 314
gG fuses............................................................................................................... 314
uR and aR fuses................................................................................................... 316
Calculating the short-circuit current of the installation............................ 320
Calculation example.............................................................................. 320
Circuit breakers (IEC)................................................................................................ 322
Fuses (UL)................................................................................................................... 324
Circuit breakers (UL)................................................................................................. 327
Dimensions, weights and free space requirements........................................... 333
Dimensions with flange.................................................................................... 338
Losses, cooling data and noise............................................................................... 344
Cooling air flow, heat dissipation and noise for stand-alone drives....... 344
IEC - IP21 and IP55 (UL Type 1 and 12)................................................ 344
IEC - IP66 (UL Type 4X).......................................................................... 346
UL (NEC) - IP21 and IP55 (UL Type 1 and UL Type 12)...................... 347
UL (NEC) - IP66 (UL Type 4X)............................................................... 350
Cooling air flow and heat dissipation for flange mounting (option
+C135)................................................................................................................... 351
IEC - IP21 and IP55 (UL Type 1 and UL Type 12)................................ 351
IEC - IP66 (UL Type 4X).......................................................................... 352
UL (NEC) - IP21 and IP55 (UL Type 1 and UL Type 12)...................... 353
UL (NEC) - IP66 (UL Type 4X)............................................................... 354
Terminal and entry data for the power cables.................................................... 356
IEC......................................................................................................................... 356
UL (NEC)............................................................................................................... 359
Power cables............................................................................................................... 364
Typical power cables, IEC................................................................................. 364
IP66 (UL Type 4X) with disconnect option (+F253)......................... 366
Typical power cables UL (NEC)........................................................................ 367
14 Table of contents
Terminal and entry data for the control cables................................................... 369
IEC......................................................................................................................... 369
UL (NEC)............................................................................................................... 371
Electrical power network specification................................................................. 371
Motor connection data............................................................................................. 373
Brake resistor connection data for frames R1…R3............................................. 377
Auxiliary circuit power consumption..................................................................... 377
Efficiency..................................................................................................................... 377
Energy efficiency data (ecodesign)....................................................................... 378
Protection classes..................................................................................................... 378
Ambient conditions................................................................................................... 379
Storage conditions.................................................................................................... 381
Colors........................................................................................................................... 381
Materials...................................................................................................................... 381
Drive...................................................................................................................... 381
Package materials for small wall-mounted drives and converter
modules................................................................................................................ 382
Package materials for large wall-mounted drives and converter
modules................................................................................................................ 382
Package materials for options, accessories and spare parts................... 382
Materials of manuals......................................................................................... 382
Disposal....................................................................................................................... 382
Applicable standards................................................................................................ 383
Markings...................................................................................................................... 384
CE marking.................................................................................................................. 386
Compliance with the European Low Voltage Directive.............................. 386
Compliance with the European EMC Directive............................................. 386
Compliance with the European ROHS II Directive 2011/65/EU................ 387
Compliance with the European WEEE Directive 2002/96/EC................... 387
Compliance with the European Machinery Directive 2006/42/EC
2nd Edition – June 2010..................................................................................... 387
Validating the operation of the Safe torque off function............. 387
Compliance with the EN 61800-3:2004 + A1:2012............................................... 387
Definitions........................................................................................................... 387
Category C1......................................................................................................... 388
Category C2......................................................................................................... 388
Category C3......................................................................................................... 389
Category C4......................................................................................................... 389
UL checklist................................................................................................................. 390
Design lifetime expectancy..................................................................................... 391
Disclaimers.................................................................................................................. 392
Generic disclaimer.............................................................................................. 392
Cyber security disclaimer................................................................................. 392
Declarations of conformity...................................................................................... 392
Table of contents 15
13 Dimension drawings
Contents of this chapter.......................................................................................... 395
Frame R1, IP21 (UL Type 1)........................................................................................ 396
Frame R1, IP55 (UL Type 12)..................................................................................... 397
Frame R1, IP55+F278 (UL Type 12).......................................................................... 398
Frame R1, IP66 (UL Type 4X) +B066....................................................................... 399
Frame R1, IP66 (UL Type 4X) +B063....................................................................... 400
Frame R1, IP66 (UL Type 4X) +C193........................................................................ 401
Frame R2, IP21 (UL Type 1)....................................................................................... 402
Frame R2, IP55 (UL Type 12)..................................................................................... 403
Frame R2, IP55+F278 (UL Type 12).......................................................................... 404
Frame R2, IP66 (UL Type 4X) +B066....................................................................... 405
Frame R2, IP66 (UL Type 4X) +B063....................................................................... 406
Frame R2, IP66 (UL Type 4X) +C193....................................................................... 407
Frame R3, IP21 (UL Type 1)....................................................................................... 408
Frame R3, IP55 (UL Type 12)..................................................................................... 409
Frame R3, IP55+E223 (UL Type 12).......................................................................... 410
Frame R3, IP55+F278/F316 (UL Type 12)............................................................... 411
Frame R3, IP66 (UL Type 4X) +B066....................................................................... 412
Frame R3, IP66 (UL Type 4X) +B063....................................................................... 413
Frame R3, IP66 (UL Type 4X) +C193....................................................................... 414
Frame R4, IP21 (UL Type 1)....................................................................................... 415
Frame R4, IP55 (UL Type 12).................................................................................... 416
Frame R4, IP55+E223 (UL Type 12)......................................................................... 417
Frame R4, IP55+F278/F316 (UL Type 12)............................................................... 418
Frame R5, IP21 (UL Type 1)....................................................................................... 419
Frame R5, IP55 (UL Type 12).................................................................................... 420
Frame R5, IP55+E223 (UL Type 12).......................................................................... 421
Frame R5, IP55+F278/F316 (UL Type 12)............................................................... 422
Frame R5 v2, IP21 (UL Type 1).................................................................................. 423
Frame R5 v2, IP55 (UL Type 12)................................................................................ 424
Frame R6, IP21 (UL Type 1)....................................................................................... 425
Frame R6, IP55 (UL Type 12).................................................................................... 426
Frame R7, IP21 (UL Type 1)....................................................................................... 427
Frame R7, IP55 (UL Type 12)..................................................................................... 428
Frame R8, IP21 (UL Type 1)....................................................................................... 429
Frame R8, IP55 (UL Type 12).................................................................................... 430
Frame R9, IP21 (UL Type 1)....................................................................................... 431
Frame R9, IP55 (UL Type 12).................................................................................... 432
Frame R9, IP55 (UL Type 12)*................................................................................... 433
Frame R9e, IP21 (UL Type 1)..................................................................................... 434
14 Resistor braking
Contents of this chapter.......................................................................................... 435
16 Table of contents
Operation principle................................................................................................... 435
Resistor braking, frames R1…R3............................................................................ 435
Planning the braking system........................................................................... 435
Selecting the brake resistor................................................................. 435
Selecting and routing the brake resistor cables.............................. 439
Placing the brake resistor.................................................................... 439
Protecting the system in brake circuit fault situations................. 440
Mechanical installation..................................................................................... 441
Electrical installation......................................................................................... 441
Start-up................................................................................................................ 441
Start-up.................................................................................................... 441
Resistor braking, frames R4…R9........................................................................... 442
Planning the braking system........................................................................... 442
IEC............................................................................................................. 442
UL (NEC)................................................................................................... 443
Parameter settings for external braking chopper and resistor................ 444
15 The Safe torque off function
Contents of this chapter.......................................................................................... 445
Description.................................................................................................................. 445
Compliance with the European Machinery Directive and the UK Supply
of Machinery (Safety) Regulations.................................................................. 446
Wiring........................................................................................................................... 447
Connection principle......................................................................................... 447
Single ACH580-01 drive, internal power supply............................... 447
Single ACH580-01 drive, external power supply.............................. 448
Wiring examples................................................................................................. 448
Single ACH580-01 drive, internal power supply............................... 448
Single ACH580-01 drive, external power supply.............................. 449
Multiple ACH580-01 drives, internal power supply......................... 450
Multiple ACH580-01 drives, external power supply........................ 451
Activation switch................................................................................................ 452
Cable types and lengths.................................................................................... 452
Grounding of protective shields..................................................................... 452
Operation principle................................................................................................... 453
Start-up including validation test.......................................................................... 454
Competence........................................................................................................ 454
Validation test reports...................................................................................... 454
Validation test procedure................................................................................. 454
Use................................................................................................................................ 456
Maintenance............................................................................................................... 458
Competence........................................................................................................ 458
Fault tracing................................................................................................................ 459
Safety data.................................................................................................................. 460
Terms and abbreviations.................................................................................. 463
Table of contents 17
TÜV certificate.................................................................................................... 464
16 CAIO-01 bipolar analog I/O adapter module
Contents of this chapter.......................................................................................... 465
Product overview....................................................................................................... 465
Layout.......................................................................................................................... 466
Mechanical installation............................................................................................. 467
Necessary tools.................................................................................................. 467
Unpacking and examining the delivery.......................................................... 467
Installing the module......................................................................................... 467
Electrical installation................................................................................................. 467
Necessary tools.................................................................................................. 467
Wiring.................................................................................................................... 467
Start-up........................................................................................................................ 468
Setting the parameters..................................................................................... 468
Diagnostics................................................................................................................. 469
LEDs...................................................................................................................... 469
Technical data............................................................................................................ 469
Isolation areas..................................................................................................... 470
Dimension drawings................................................................................................. 471
17 CHDI-01 115/230 V digital input extension module
Contents of this chapter.......................................................................................... 473
Product overview....................................................................................................... 473
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