Académique Documents
Professionnel Documents
Culture Documents
Hardware Manuals
ACS5X0-07 Drives (1.1 ~ 110 kW)
ACS 5X0 Drive Manuals*
* ACS5X0 represents ACS550 or ACS510 in this Manual.
• Safety instructions
• Mechanical installtion planning
• Electrical installation planning
• Mechanical and electrical installation
• Maintenance
• Technical data
• Dimensional darwings
• Resistor braking
General Manuals
ACS 550-01 User Manual 1.1 ~110 kW
ACS 510-01 User Manual 1.1 ~110 kW
Hardware Manuals
3ABD00019153 Rev A EN
PDM Code: 30024246
EFFECTIVE: 7.2006
Safety instructions
Safety instructions
6
Installation and maintenance work
These warnings are intended for all who work on the drive, motor cable or motor.
Ignoring the instructions can cause physical injury or death.
WARNING!
• Only qualified electricians are allowed to install and maintain the drive.
• Never work on the drive, motor cable or motor when main power is applied. After
switching off the power, always wait for 5 minutes to let the intermediate circuit
capacitors discharge before you start working on the drive, the motor or the motor
cable.
Always ensure by measuring with a multimeter (impedance at least 1 Mohm) that:
1. Voltage between drive input phases U1, V1 and W3 and the frame is close to
0 V.
2. Voltage between terminals UDC+ and UDC- and the frame is close to 0 V.
• Do not work on the control cables when power is applied to the drive or to the
external control circuits. Externally supplied control circuits may cause dangerous
voltages inside the drive even when the main power on the drive is switched off.
• Do not make any insulation or voltage withstand tests on the drive or drive
modules.
• When reconnecting the motor cable, always check that the phase order is correct.
Note:
• The disconnecting device (means) of the drive does not isolate the input cables
and busbars from the main AC supply. Before working inside the cabinet, isolate
the input cables and busbars from the main supply with the disconnecting device
at the distribution board or with the disconnector of the supply transformer.
• The motor cable terminals on the drive are at a dangerously high voltage when the
input power is on, regardless of whether the motor is running or not.
• The brake control terminals (UDC+, UDC-, BRK+, BRK- terminals) carry a
dangerous DC voltage (over 500 V).
WARNING!
• Cover the drive when installing to ensure that dust from drilling or foreign
objects do not enter the drive. Electrically conductive dust inside the unit may
cause damage or lead to malfunction.
• Ensure sufficient cooling.
• When removing the module from the cabinet and manoeuvring it outside the
cabinet, prevent it from toppling over by securing it. The drive module is heavy
and has a high centre of gravity.
Safety instructions
7
Grounding
These instructions are intended for all who are responsible for the grounding of the
drive. Incorrect grounding can cause physical injury, death or equipment malfunction
and increase electromagnetic interference.
WARNING!
• Ground the drive, the motor and adjoining equipment to ensure personnel
safety in all circumstances, and to reduce electromagnetic emission and pick-
up.
• Power cable shields are suitable for equipment grounding conductors only
when adequately sized to meet safety regulations.
Operation
These warnings are intended for all who plan the operation of the drive or operate
the drive. Ignoring the instructions can cause physical injury or death or damage the
equipment.
WARNING!
• Before adjusting the drive and putting it into service, make sure that the motor
and all driven equipment are suitable for operation throughout the speed range
provided by the drive. The drive can be adjusted to operate the motor at
speeds above and below the speed provided by connecting the motor directly
to the power line.
• Do not control the motor with the disconnecting device (disconnecting means);
instead, use the control panel keys and , or commands via the I/O
board of the drive. The maximum allowed number of charging cycles of the DC
capacitors (i.e. power-ups by applying power) is five in ten minutes.
Note:
Safety instructions
8
• If an external source for start command is selected and it is ON, the drive will
start immediately after fault reset unless the drive is configured for 3-wire (a
pulse) start/stop.
• When the control location is not set to Local (REM shown on the left of the top
row of the LCD screen), the stop key on the control panel will not stop the
drive. To stop the drive using the control panel, press the LOC/REM key and
then the stop key .
Safety instructions
9
Table of contents
Safety instructions
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Use of warnings and notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
nstallation and maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Table of contents
ACS5X0-07
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
ACS5X0-07 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Type code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Main circuit and control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Door switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Diagram of the main circuit and the control circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Motor control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Mechanical installation
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Moving the unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Before installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Delivery check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Type designation lable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Requirements for the installation site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Cooling air flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Cable channel in the floor below the cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Fastening the cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Nonstandard methods to fastening the cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Electric welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Table of contents
10
To which products this chapter applies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Motor selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Supply connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Disconnecting device (means) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Thermal overload and short-circuit protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Mains cable (AC line cable) short-circuit protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Operating time of the fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Circuit breakers (TBD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Ground fault protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Emergency stop devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Selecting the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
General rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Motor cable shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Recommendation for Conductor Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Conduit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Armored cable / shielded power cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Equipment connected to the motor cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Installation of safety switches, contactors, connection boxes, etc. . . . . . . . . . . . . . . . . . . . . .28
Bypass connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Protecting the relay output contacts and attenuating disturbances in case of inductive loads . . . . .28
Selecting the control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Relay cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Control panel cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Connection of a motor temperature sensor to the drive I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Routing the cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Control cable ducts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Electrical installation
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Before installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
IT (ungrounded) systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Checking the insulation of the assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Warning sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Example wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Power cable connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Connecting the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Addtional instructions for frame size R6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Connecting the control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Routing the cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
360 degrees grounding at the cable entry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Special for top entry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Cabling of I/O and fieldbus modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Installation of optional modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Layout drawing of factory installed optional equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Installation of brake resistors (units with brake chopper option) . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Table of contents
11
Maintenance
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Required tools for maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Cabinet layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
2xR1/R2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
R3/R4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
R5/R6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Replacing the air filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
IP 42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
IP 54 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Heatsink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Frame size R1 ~ R4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Frame size R5 ~ R6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Replacing the drive module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Technical data
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Rating capacitance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Cable types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Cabinet power cabling terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Dimensions and weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Free space around the unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Input power connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Motor connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Degrees of protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Applicable standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
CE marking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Equipment warranty and liability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Dimensional drawings
Frame type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Resistor braking
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Availability of brake choppers and resistors for the ACS 5X0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Select the brake resistor (Frame size R1and R2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Optional brake chopper and resistor(s) (Frame size R3~R6) . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Resistor installation and wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
ACS5X0-07 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Diagram for resistor connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Table of contents
12
Table of contents
13
About this manual
Target audience
This manual is intended for people who plan the installation, install, commission, use
and service the drive. Read the manual before working on the drive. The reader is
expected to know the fundamentals of electricity, wiring, electrical components and
electrical schematic symbols.
Contents
The chapters of this manual are briefly described below.
Safety instructions give safety instructions for the installation, commissioning,
operation and maintenance of the drive.
About this manual introduces this manual.
ACS5X0-07 describes the drive.
Mechanical installation shows how to move and unpack the delivery and how to
fasten the cabinet to the floor.
Planning the electrical installation instructs on the motor and cable selection, the
protections and the cable routing.
Electrical installation instructs how to wire the drive.
Installation checklist and start-up helps in checking the mechanical and electrical
installation of the drive.
Maintenance contains preventive maintenance instructions.
Technical data contains the technical specifications of the drive, e.g. the ratings,
sizes and technical requirements, provisions for fulfilling the requirements for CE
and other markings and warranty policy.
Dimensional drawings contains the dimensional drawings of the drive.
Resistor braking describes how to select, protect and wire optional brake choppers
and resistors. The chapter also contains technical data.
Task See
Check the insulation of the motor and the motor Electrical installation
cable.
Install the drive. Connect the power cables. Connect Mechanical installation, Electrical installation,
the control and the auxiliary control cables. Resistor braking (optional)
Inquiries
Address any inquiries about the product to the local ABB representative, quoting the
type code and the serial number of the unit. If the local ABB representative cannot
be contacted, address inquiries to the manufacturing facility.(See the back cover of
this manual for the detailed address and the phone number.)
ACS5X0-07
ACS5X0-07 is a cabinet-installed drive of ACS5X0 series
IP 21
*Line contactor
Drive module
Side plate,
For layout of optional
equipment on the side
plate ,see
Electrical installation
U1,V1,W1Cable terminals
U2,V2,W2Cable terminals
ACS5X0-07
16
Type code
The type code contains information on the specifications and configuration of the
drive.
For example: ACS550-07-04A1/023A-4+B055
ACS550-07-04A1/023A-4 denotes the basic configuration. The optional selections
are given thereafter, separated by + signs (e.g. +B055, denotes IP54).
The main selections are described below.
Selection Alternatives
Product series ACS 5X0 product series
Type -07 Cabinet built.
Main function: 400mm cabinet ( R5/R6:600mm cabinet ), When
no options are selected: IP 21, switch fuse with gG fuses, main
cable input/output terminals, control panel ACS-CP-D, bottom
entry and exit of cables, one set of manuals.
Size For example:-04A1/023A (denotes the rating output current of the two drive
module are 4.1A and 23A ) For more information, refer to Technical data:
IEC rating and ACS5X0 Ordering Information
Voltage range -4 380~480V
+ options
Degree of protection +B053 IP 22 (When selected, cabinet R3-R6 with a cooling fan duct )
+B054 IP 42 (When selected, cabinet R3-R6 with a cooling fan duct )
+B055 IP 54 (When selected, all type of cabinets are with a cooling fan
duct )
Resistor braking +D150 Brake chopper +braking resistor
+D151 When selected, a 400mm cabinet will be added
This option is noneffective for IP54
This option is noneffective for cabinet R1/R2
Filter +E205 Du/dt filter (When selected, cabinet R3-R6 with a cooling fan
duct)
Line options +F250 Line contactor + emergency stop (immediate removal of power)
+Q951
+F255 Moulded case circuit breaker( type Tmax, instead of switch OS
and fuse link)
Cabinet options +G300 Cabinet heater (defend low temperature, moistureproof, external
supply)
+G307 Terminals for external control voltage (UPS)
+G313 Output for motor heater (external supply)
Cabling +H351 Top entry + top exit
+H353
Fieldbus +K451 DeviceNet adapter RDNA-01
+K452 LONWorks adapter RLON-01
+K454 Profibus-DP adapter RPBA-01
+K457 CANOpen adapter RCAN-01
+K462 ControlNet adapter RCNA-01
I/O expand +L511 Relay output expand module OREL-01
+L504 Additional I/O terminal
+L502 Pulse encoder interface OTAC-01
Language of manual +R700 English document
Control panel +J404 Basic control panel ACS-CP-C
Starter for auxiliary motor +M600 1...1.6 A
fan +M601 1.6...2.5 A
+M602 2.5...4 A
+M603 4...6.3 A
+M604 6.3...10 A
+M605 10...16 A
ACS5X0-07
17
In the table above, not all selections are available for all types. For more information,
refer to ACS 5X0 Ordering Information or available on request.
Door switches
The following switches are mounted on the cabinet door:
output relay
extension
module
Drive module
(OREL)
Motor
control and Optional module 1: relay output
I/O board extension option module(OREL) and
(RMIO) pulse encoder interface OREL-01 or
OTAC-01
External control via Optional module 2: communication
analogue/digital option module cabling RDNA, RLON,
inputs and outputs RPBA, RCAN, RCNA,
Input power
= ~ Output power
~ =
Brake chopper
(R1-R2 embeded,R3-R6
optional)
R- UDC+ UDC-
R+
ACS5X0-07
18
Operation
This table describes the operation of the main circuit in short.
Component Description
capacitor bank energy storage which stabilizes the intermediate circuit DC voltage
six-pulse IGBT inverter converts the DC voltage to AC voltage and vice versa. The motor
operation is controlled by switching the IGBTs.
ACS5X0-07
19
Mechanical installation
Max 30°
Move the cabinet by pallet truck
Earth
WARNING! Lift the drive by the upper part only using the lifting lugs/bars attached to
the top of the unit.
Before installation
Delivery check
The drive delivery contains:
factory installed options, residual voltage warning stickers, hardware manual, user’s
manual, appropriate optional module manuals, delivery documents.
Check that there are no signs of damage. Before attempting installation and
operation, check the information on the type designation label of the drive to verify
Mechanical installation
20
that the unit is of the correct type.The label includes the technical data of the drive,
Type designation lable
The type designation label is located on the front cover and the serial number label
inside the unit. Example labels are shown below.
Mechanical installation
21
Prevent the cooling air flow from the cable channel to the
cabinet by bottom plates. To ensure the degree of cables
25
Mechanical installation
22
Planform
L-bracket
M16 bolt > 600 mm
cabinet top
Electric welding
Welding of the cabinet frame is not recommended by ABB.
WARNING! If the welding return wire is connected improperly, the welding circuit
may damage electronic circuits in the cabinet.
Mechanical installation
25
Planning the electrical installation
Motor selection
Select the three-phase AC induction motor must according to the rating tables in
chapter Technical Data.
WARNING! The running is forbidden if the motor rating input voltage less than the
1/2 drive rating voltage. The nominal current is 0 ... 2 · I2hd.
Supply connection
Fuses
See section Thermal overload and short-circuit protection.
General rules
Dimension the mains (input power) and motor cables according to local
regulations:
• The cable must be able to carry the drive load current. See chapter Technical
data for the rated currents.
• The cable must be rated for at least 70°C maximum permissible temperature of
conductor in continuous use. For US, see section Additional US requirements.
• The inductance and impedance of the PE conductor/cable (grounding wire) must
be rated according to permissible touch voltage appearing under fault conditions
(so that the fault point voltage will not rise excessively when a ground fault
occurs).
Cable core
Shield
Not allowed for motor cables (CE & C-Tick)
A four-conductor system: three phase
conductors and a protective conductor, without a
shield. Allowed for motor cables: with phase
conductor cross section up to 10 mm2.
PE
L1
Braided Metallic Screen L3
Conduit
Where conduits must be coupled together, bridge the joint with a ground conductor
bonded to the conduit on each side of the joint. Bond the conduits also to the drive
enclosure. Use separate conduits for input power, motor, brake resistors, and control
wiring. Do not run motor wiring from more than one drive in the same conduit.
Armored cable / shielded power cable
The motor cables can be run in the same cable tray as other 460 V or 600 V power
wiring. Control and signal cables must not be run in the same tray as power cables.
Bypass connection
WARNING! Never connect the supply power to the drive output terminals U2, V2
and W2. If frequent bypassing is required, employ mechanically connected switches
or contactors. Mains (line) voltage applied to the output can result in permanent
damage to the unit.
Relay
output
230 VAC
RCFilter
Relay
output
230 VAC
Diode
Relay
output
24 VDC
a b
A double-shielded twisted A single-shielded twisted
pair cable multipair cable
Relay cable
The cable type with braided metallic screen is recommended.
WARNING! IEC 60664 requires double or reinforced insulation between live parts
and the surface of accessible parts of electrical equipment which are either non-
conductive or conductive but not connected to the protective earth.
Motor cable
Drive
min 300 mm (12 in.)
Power cable
control cable
WARNING! The work described in this chapter may only be carried out by a qualified
electrician. Follow the Safety instructions on the first pages of this manual. Ignoring
the safety instructions can cause injury or death.
Make sure that the drive is disconnected from the mains (input power) during
installation. If the drive is already connected to the mains, wait for 5 min after
disconnecting mains power.
Electrical installation
34
WARNING! Check the insulation before connecting the drive to the mains. Make
sure that the drive is disconnected from the mains (input power).
Warning sticker
A multi-language sticker is attached onto the drive module cover. Attach the warning
sticker in the local language onto the cover of the drive module.
Electrical installation
35
Power cable connection diagram
Drive
INPUT OUTPUT
PE U1 V1 W1 BRK- BRK+ U2 V2 W2
1)
2)
PE
See page 23 V1
Disconnecting U1 W1
External brake
device resistor 3 ~
(optional) Motor
L1 L2 L3
1) Ground the other end of the PE conductor at the distribution board.
2)
Use a separate grounding cable if the conductivity of the cable shield is not good (less than the conductivity of the phase
conductor) and there is no symmetrically constructed grounding conductor in the cable (see page24 Selecting the power
cables).
Note:
Do not use an asymmetrically constructed motor cable.
f there is a symmetrically constructed grounding conductor in the motor cable in addition to the conductive shield, connect
the grounding conductor to the grounding terminal at the drive and motor ends.
Electrical installation
36
PE terminal
cable ties
EMC sleeve
strain relief
Base plate
Lead-through plate
Electrical installation
37
Connecting the control cables
1 1
Lead-through
plate
Grommet
3. Strip off the cable plastic sheath above the lead-through plate just enough to
ensure proper connection of the bare shield.
4. Tighten the two fastening screws (1) so that the EMI conductive cushions press
tightly round the bare shield.
Note: If the outer surface of the shield is non-conductive:
• Cut the shield at the midpoint of the bare part. Be careful not to cut the conductors
or the grounding wire (if present).
• Turn the shield inside out to expose its conductive surface.
• Cover the turned shield and the stripped cable with copper foil to keep the
shielding continuous.
Copper foil
Cable shield
Shielded twisted pair
Grounding wire
Electrical installation
38
2. Sort the cables going to the left into one group and the cables going to the right
into another group to avoid unnecessary crossing of cables inside the cabinet.
3. Sort the cables in each group according to size.
4. Group the cables for each grommet as follows ensuring that each cable has a
proper contact to the cushions on both sides.
Cable diameter in mm Max. number of cables per grommet
< 13 4
< 17 3
< 25 2
> 25 1
5. Divide the bunches so that cables will be arranged according to size between the
EMI conductive cushions.
EMI conductive cushions.
6. If more than one cable go through a grommet, the grommet must be sealed by
Loctite 5221 .
Apply Loctite
Side view 5221 inside the
grommet.
Attach control
cables to the
supporting plate.
Electrical installation
39
grounded directly at both ends if they are in the same ground line with no significant
voltage drop between the end points.
Keep the signal wire pairs twisted as close to the terminals as possible. Twisting the
wire with its return wire reduces disturbances caused by inductive coupling.
Electrical installation
40
Layout drawing of factory installed optional equipment
*cabinet heaters
*control loop
transformer
* X1
* motor auxiliary * X5
fan supply
* X6
* X1.1
* X9
* X2
Electrical installation
41
Electrical installation
42
Electrical installation
43
Installation checklist and start-up
Checklist
Check the mechanical and electrical installation of the drive before start-up. Go
through the checklist below together with another person. Read the Safety
instructions on the first pages of this manual before you work on the unit.
Check
MECHANICAL INSTALLATION
The ambient operating conditions are allowed. See Mechanical installation, Technical data: Ratings capacitance,
Ambient conditions.
The unit is fixed properly on floor and a vertical non-flammable wall. See Mechanical installation.
The motor and the driven equipment are ready for start. See Planning the electrical installation: Motor selection
and compatibility, Technical data: Motor connection.
The EMC filter capacitors are disconnected by removing EMC screws.(EM1. EM3. F1. F2.) See page 33, if the
drive is connected to an IT (ungrounded) system.
The mains (input power) voltage matches the drive nominal input voltage.
The mains (input power) connections at U1, V2 and W3 and their tightening torques are OK. See Technical data
/ Cable entries.
The motor connections at U2, V2 and W2 and their tightening torques are OK. See Technical data / Cable entries.
There are no tools, foreign objects or dust from drilling inside the drive.
Mains (input power) voltage cannot be applied to the output of the drive (with bypass connection).
Safety
WARNING! Read the Safety instructions on the first pages of this manual before
performing any maintenance on the equipment. Ignoring the safety instructions can
cause injury or death.
Maintenance intervals
If installed in an appropriate environment, the drive requires very little maintenance.
This table lists the routine maintenance intervals recommended by ABB.
Maintenance
46
Cabinet layout
2XR1/R2
Q1 * Q2 *
F1.1-3 F2.1-3
K2 A49.1-2
K1
S20.1-2
U1 U2
S11.1-2
F20
F10.1-2 K31.2
F50
F31.2
F11
U1,V1,W1 U2,V2,W2
Q20
Q50
F31.1 Z2.1 Z2.2
K31.1
T10 E1
R3/R4
Q1 * K1
F1.1-3 A49
Y3.2 S20
U1 S11
Electric
al option
layout is
same as U1,V1,W1
R1/R2 U2,V2,W2
Z2
E1
T10
Maintenance
47
R5/R6
A49
Q1 * K1
F1.1-3 S20
Y3.2
S11
Electric U1
al option
layout is
same as
R1/R2 U2,V2,W2
U1,V1,W1
Z2
T10
E1
IP 42
IP 54
Change the air filter mat of the IP54 unit every year:
• removing the fastener(s) at the top of the grating.
• moving the grating.
• Changing the air filter mat
Maintenance
48
Heatsink
Check the cleanliness of the cabinet and the surroundings. When necessary, clean
the interior of the cabinet with a soft brush and a vacuum cleaner.
The heatsink fins accumulate dust from the cooling air. Since a dusty heatsink is less
efficient at cooling the drive, overtemperature faults become more likely. In a
“normal” environment (not dusty, not clean) check the heatsink annually, in a dusty
environment check more often.
Clean the heatsink as follows:
1. Remove the cooling fan (see section Fans).
2. Blow dry clean compressed air from bottom to top and simultaneously use a
vacuum cleaner at the air outlet to trap the dust. Note: Prevent dust from entering
adjoining equipment.
3. Replace the cooling fan.
Fans
The drive’s main cooling fan has a life span of about 60,000 operating hours at
maximum rated operating temperature and drive load. The expected life span
doubles for each 10 °C (18 °F) drop in the fan temperature (fan temperature is a
function of ambient temperatures and drive loads).
Fan failure can be predicted by the increasing noise from fan bearings and the
gradual rise in the heatsink temperature in spite of heatsink cleaning. If the drive is
operated in a critical part of a process, fan replacement is recommended once these
symptoms start appearing. Replacement fans are available from ABB. Do not use
other than ABB specified spare parts.
6. Restore power.
Maintenance
49
Frame Sizes R5 and R6
Bottom View (R5)
To replace the fan:
1. Remove power from drive. 3
2
2. Remove the screws attaching the fan.
3. Remove the fan: X5023
• R5: Swing the fan out on its hinges. Bottom View (R6) 4
• R6: Pull the fan out.
4. Disconnect the fan cable.
2
5. Install the fan in reverse order.
6. Restore power.
7. Restart the power. X0022
Capacitors
The drive intermediate circuit employs several electrolytic capacitors. Their life span
is from 35,000…90,000 hours depending on drive loading and ambient temperature.
Capacitor life can be prolonged by lowering the ambient temperature.
It is not possible to predict a capacitor failure. Capacitor failure is usually followed by
a input power fuse failure or a fault trip. Contact ABB if capacitor failure is suspected.
Do not use other than ABB specified spare parts.
Control Panel
Cleaning
Use a soft damp cloth to clean the control panel. Avoid harsh cleaners which could
scratch the display window.
Battery
A battery is only used in Assistant control panels that have the clock function
available and enabled. The battery keeps the clock operating in memory during
power interruptions.
The expected life for the battery is greater than ten years. To remove the battery, use
a coin to rotate the battery holder on the back of the control panel. Replace the
battery with type CR2032.
Note! The battery is NOT required for any control panel or drive function, except the
clock.
Maintenance
50
6. Pull the module from the cabinet
7. Install the new module in reverse order to the above.
5
4
b b
3
5
2 1
a a
外形规格 R4 的照片
Maintenance
51
LEDs
This table describes LEDs of the drive.
Maintenance
52
Maintenance
53
Technical data
Rating capacitance
ACS550/ACS510 drive’s rating capacitance, includes:
• IEC ratings
• Frame size
See technical data of ACS550 User manual or ACS510 User manual.
Fuses
For the fuses restrict drive damage and prevent damage to adjoining equipment in
case of a short-circuit inside the drive, see ACS550 User’s manual or ACS510 User
manual.
Cable types
copper and aluminium cable types please refer to of ACS550 User manual or
ACS510 User manual.Technical data: Input power connection.
U1, V1, W1
U2, V2, W2
Frame Min. Max.
size wire wire Max.
size size Torque currr
ent
mm2 mm2 Nm A
R1 1.5 16 1.2...2.4(M4) 76
R2 1.5 16 1.2...2.4(M4) 76
R3 1.5 25 2.0...4.0(M5) 101
R4 2.5 50 2.5...5.0(M6) 150
R51 10 95 6.0...10(M8) 232
R61 6 150 10...20 309
Technical data
54
Dimensions and weights
Frame size Height Width Depth Weight
IP 21/22/42 IP 54
mm mm mm mm kg
R1 2130 2315 430 689 161.5
R2 2130 2315 430 689 164
R3 2130 2315 430 689 171
R4 2130 2315 430 689 179
R5 2130 2315 630 689 224
R6 2130 2315 630 689 259
Motor connection
Voltage (U2) 0 to U1, 3-phase symmetrical, Umax at the field weakening point
Voltage (U2) 0 ~500Hz
Frequency resolution 0.1 Hz
Current See Rating capacitance
Field weakening point 10 ~500 Hz
Switching frequency Options: 1, 4, 8 or 12kHz
Technical data
55
Maximum recommended Frame size Max. motor cable length
motor cable length fsw=1 or 4kHz fsw=8 or 12kHz
R1 100 m 100 m
R2...R4 200 m 100 m
R5...R6 300m 150m
* With longer motor cables may cause the permanent destroy to the units.
Efficiency
Approximately 98% at nominal power level.
Cooling
Method Internal fan, flow direction from front to top
Filter material Inlet (door) Outlet (roof)
IP22 / IP 42 units 318 mm x 540 mm(R1-R4) -
518 mm x 540 mm(R5-R6)
IP 54 units 318 mm x 540 mm (R1-R4) 2 pcs: 398 mm x 312 mm
518 mm x 540 mm(R5-R6)
Free space around the unit See Free space around the unit.
Cooling air flow See ACS550 User’s Manual or ACS510 User’s Manual, chapter Technical data.
Degrees of protection
IP 21, IP 22, IP 42 , IP 54
Ambient conditions
Operation Storage Transportation
installed for stationary use in the protective package in the protective package
Installation site altitude • 0 ~ 1000 m - -
• 1000~ 2000m ,every rises
100 m the PN and I2
Derating 1% 。
Technical data
56
Shock (IEC 60068-2-29) Not allowed Max.100 m/s2 (330 ft./s2), Max. 100 m/s2 (330 ft./s2),
11 ms 11 ms
Free fall Not allowed 100 mm (4 in.) for weight 100 mm (4 in.) for weight
over 100 kg (220 lb) over 100 kg (220 lb)
Materials
Drive enclosure • PC/ABS 2.5 mm,colour NCS 1502-Y (RAL 90021 / PMS 420 C and 425 C)
• hot-dip zinc coated steel sheet 1.5 to 2 mm, thickness of coating 20 micrometres
• cast aluminium AlSi
• extruded aluminium AlSi
Package Corrugated cardboard, expanded polystyrene, plywood, Wood. (heat up drying)
Plastic covering of the package: PE-LD, bands PP or steel.
Disposal The drive contains raw materials that should be recycled to preserve energy and natural
resources. The package materials are environmentally compatible and recyclable. All
metal parts can be recycled. The plastic parts can either be recycled or burned under
controlled circumstances, according to local regulations. Most recyclable parts are
marked with recycling marks.
If recycling is not feasible, all parts excluding electrolytic capacitors and printed circuit
boards can be landfilled. The DC capacitors contain electrolyte and the printed circuit
boards contain lead, both of which will be classified as hazardous waste within the EU.
They must be removed and handled according to local regulations.
For further information on environmental aspects and more detailed recycling
instructions, please contact your local ABB distributor.
Applicable standards
Refer to ACS550 User’s Manual or ACS510 User’s Manual Technical data:Application standard.
CE marking
Refer to ACS550 User’s Manual or ACS510User’s Manual Technical data:Application standard.
Technical data
57
Dimensional drawings
Dimensional drawings
58
Frame size R1 - R4
Dimensional drawings
59
Dimensional drawings
60
Frame size R5/R6
Dimensional drawings
61
Brake chopper +Brake resistor
3ABD00015132 A
Dimensional drawings
62
Dimensional drawings
63
Resistor braking
R Resistance value for the listed resistor assembly. Note: This is also the minimum allowed resistance for the brake resistor.
ER Short energy pulse that the resistor assembly withstands every 400 seconds. This energy will heat the resistor element from 40 °C
(104 °F) to the maximum allowable temperature.
PRcont Continuous power (heat) dissipation of the resistor when placed correctly. Energy ER dissipates in 400 seconds.
Resistor braking
64
WARNING! The materials near the brake resistor must be non-flammable. The
surface temperature of the resistor is high. Air flowing from the resistor is of
hundreds of degrees Celsius. Protect the resistor against contact.
To ensure that the input fuses protect the resistor cable, use resistor cables with the
same rating as used for the power input to the drive.
The maximum length of the resistor and brake chopper cable(s) is 10 m (33 ft). See
the Power Connection Diagrams on page page 15 for the resistor cable connection
points.
ACS5X0-07
If ordered, the resistors and brake chopper are factory installed in a cubicle(400mm)
next to the drive cabinet.
1 3 5 13 3
On
2 4 6 14 4
ACS510
U1 V1 W1
Thermal switch (standard in
Q
ABB resistors)
K1
Parameter Set-up
To enable dynamic braking, switch off the drive’s overvoltage control (Set parameter
2005 = 0 (DISABLE))
Resistor braking
3ABD00019153 Rev B EN PDM: 30024246
EFFECTIVE: 7.2006