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)