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ACS530-04
ABB ACS530-04 User Manual
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146 Safe torque off function
Multiple drives (ext
ernal power supply)
STO
Control unit
Control unit
Control unit
STO
OUT2
OUT1
+ 24
V
DC
IN1
IN2
SGND
+ 24
V
DC
34
35
36
37
38
STO
OUT2
OUT1
+ 24
V
DC
IN1
IN2
SGND
+ 24
V
DC
34
35
36
37
38
24
V DC
–+
K
OUT2
OUT1
+ 24
V
DC
IN1
IN2
SGND
+ 24
V
DC
34
35
36
37
38
ACS53
0-04
ACS530-04
ACS530-04
145
147
Table of Contents
Default Chapter
5
Table of Contents
5
1 Safety Instructions
13
Contents of this Chapter
13
Use of Warnings and Notes
13
General Safety in Installation, Start-Up and Maintenance
14
Electrical Safety in Installation, Start-Up and Maintenance
16
Precautions before Electrical Work
16
Additional Instructions and Notes
17
Grounding
18
Additional Instructions for Permanent Magnet Motor Drives
19
Safety in Installation, Start-Up and Maintenance
19
2 Introduction to the Manual
21
Contents of this Chapter
21
Target Audience
21
Contents of the Manual
22
Categorization by Frame Size and Option Code
23
Quick Installation, Commissioning and Operating Flowchart
23
Terms and Abbreviations
25
3 Operation Principle and Hardware Description
27
Contents of this Chapter
27
Product Overview
27
Layout
28
Standard Drive Module Configuration
28
Drive Module Configuration with Option +B051
29
Control Panel
31
Overview of Power and Control Connections
32
Control Connection Terminals
33
Type Designation Label
34
Type Designation Key
34
4 Guidelines for Planning the Cabinet Installation
37
Contents of this Chapter
37
Limitation of Liability
37
Installation Positions of the Drive Module
37
Basic Requirements for the Cabinet
37
Planning the Layout of the Cabinet
38
Layout Example, Door Closed
38
Layout Example, Door Open (Standard Drive Module Configuration)
39
Layout Example, Door Open (Option +B051)
40
Arranging the Grounding Inside the Cabinet
41
Selecting the Busbar Material and Preparation of the Joints
41
Tightening Torques
41
Planning the Fastening of the Cabinet
41
Planning the Cabinet Placement on a Cable Channel
42
Planning the Electromagnetic Compatibility (EMC) of the Cabinet
42
Planning the Cooling
44
Preventing the Recirculation of Hot Air
45
Standard Drive Module Configuration
46
Drive Module with Option +B051
48
Required Free Space
49
Free Space at the Top of the Drive Module
49
Free Space Around the Drive Module
49
Other Installation Positions
49
Drive Module on Its Back
49
Planning the Placement of the Control Panel
50
Planning the Use of Cubicle Heaters
50
Arc Welding
50
5 Guidelines for Planning the Electrical Installation
51
Contents of this Chapter
51
Selecting the Supply Disconnecting Device
52
European Union
52
Other Regions
52
Selecting the Main Contactor
52
Examining the Compatibility of the Motor and Drive
52
Protecting the Motor Insulation and Bearings
52
Requirements Table
53
Selecting the Power Cables
55
General Rules
55
Sufficient Conductivity of the Protective Conductor
56
Typical Power Cable Sizes
57
Alternative Power Cable Types
58
Motor Cable Shield
58
Selecting the Control Cables
59
Shielding
59
Signals in Separate Cables
59
Signals Allowed to be Run in the same Cable
59
Relay Cable Type
59
Control Panel Cable Length and Type
59
Routing the Cables
60
Separate Control Cable Ducts
60
Continuous Motor Cable Shield or Enclosure for Equipment in the Motor Cable
61
Implementing Thermal Overload and Short-Circuit Protection
61
Protecting the Drive and Input Power Cable in Short-Circuits
61
Protecting the Motor and Motor Cable in Short-Circuits
61
Protecting the Drive and the Input Power and Motor Cables
62
Against Thermal Overload
62
Protecting the Motor against Thermal Overload
62
Protecting the Drive against Ground Faults
62
Residual Current Device Compatibility
62
Implementing the Emergency Stop Function
63
Implementing the Safe Torque off Function
63
Implementing the Power Loss Ride-Through Function
63
Using Power Factor Compensation Capacitors with the Drive
63
Implementing a Safety Switch between the Drive and the Motor
63
Using a Contactor between the Drive and the Motor
64
Implementing a Bypass Connection
64
Example Bypass Connection
65
Protecting the Contacts of Relay Outputs
66
Connecting a Motor Temperature Sensor to the Drive I/O
67
Example Circuit Diagram
67
6 Installation Instructions
69
Contents of this Chapter
69
Safety
69
Checking the Installation Site
69
Moving and Unpacking the Unit
70
Checking the Delivery
74
Installing the Motor Cable at the Motor End
74
Checking the Insulation of the Assembly
75
Drive
75
Input Cable
75
Motor and Motor Cable
75
Installation Alternatives
75
Standard Drive Module Configuration and Option +B051
75
Drive Module Without Output Cable Connection Terminals (Option +0H371)
76
Drive Module Without Pedestal (Option +0H354)
76
Attaching the Drive Module to a Mounting Plate or Wall
77
Alternatives for Grounding the Drive Module
77
Installing the Bottom Grille (for IP20 Degree Protection)
78
Connecting the Power Cables
79
Connection Diagram
79
Power Cable Connection Procedure
80
DC Connection
81
Connecting the Control Cables
82
Default I/O Connection Diagram (ABB Standard Macro)
84
Connecting a Control Panel
89
Installing Option Modules
90
Option Slot 2 (I/O Extension Modules)
90
Option Slot 1 (Fieldbus Adapter Modules)
90
Wiring the Optional Modules
90
Connecting a PC
91
7 Installation Example of Drive Module with IP20 Shrouds (Option +B051)
93
Contents of this Chapter
93
Limitation of Liability
93
Safety
93
Required Parts
94
Required Tools
94
Overall Flowchart of the Installation Process
94
Installing the Drive Module into a Cabinet
95
Connecting the Power Cables and Installing the Shrouds
95
Installing the Roof and Door
97
Miscellaneous
98
Input Power Cable Lead-Through from Top
98
Attaching the Drive Module to a Mounting Plate
98
IP20 Shrouds
98
8 Installation Checklist
99
Contents of this Chapter
99
9 Start-Up
103
Contents of this Chapter
103
Start-Up Procedure
103
10 Fault Tracing
105
Contents of this Chapter
105
Warning and Fault Messages
105
11 Maintenance
107
Contents of this Chapter
107
Maintenance Intervals
107
Descriptions of Symbols
108
Recommended Annual Maintenance Actions by the User
108
Recommended Maintenance Intervals after Start-Up
108
Cabinet
108
Cleaning the Interior of the Cabinet
108
Heatsink
109
Cleaning the Interior of the Heatsink
109
Fans
110
Replacing the Circuit Board Compartment Cooling Fan
110
Replacing the Main Cooling Fans
111
Replacing the Drive Module
112
Capacitors
113
Reforming the Capacitors
113
Control Panel
114
Cleaning the Control Panel
114
Replacing the Battery in the Assistant Control Panel
114
12 Technical Data
117
Contents of this Chapter
117
Ratings
117
IEC Ratings
117
Output Derating
118
Fuses (IEC)
119
Dimensions, Weights and Free Space Requirements
119
Losses, Cooling Data and Noise
120
Terminal and Lead-Through Data for the Power Cables
120
Terminal Data for the Control Cables
120
Electrical Power Network Specification
121
Motor Connection Data
121
DC Connection Data
121
Control Unit (CCU-24) Connection Data
121
Control Panel Type
123
Efficiency (EU Ecodesign)
123
Degree of Protection
123
Ambient Conditions
124
CE Marking
125
Compliance with the European Low Voltage Directive
125
Materials
125
Applicable Standards
125
Compliance with the European EMC Directive
126
Compliance with the European Rohs Directive
126
Compliance with the European Machinery Directive
126
Compliance with en 61800-3:2004
126
Definitions
126
Category C3
127
Category C4
127
China Rohs Marking
128
WEEE Marking
128
Cybersecurity Disclaimer
128
Disclaimer
128
13 Dimension Drawings
129
Contents of this Chapter
129
R10 Standard Configuration
130
R10 with Options +E208+0H354+H356+0H370+0H371
131
R10 with Option +B051
132
R11 Standard Configuration
133
R11 with Options +E208+0H354+H356+0H370+0H371
134
R11 with Option +B051
135
Air Baffles for the Drive Module with Option +B051
136
14 Example Circuit Diagram
137
Contents of this Chapter
137
15 Safe Torque off Function
139
Contents of this Chapter
139
Description
139
Compliance with the European Machinery Directive
140
Wiring
140
Activation Switch
141
Cable Types and Lengths
141
Grounding of Protective Shields
141
Single Drive (Internal Power Supply)
141
Single Drive (External +24 V DC Power Supply)
142
Dual-Channel Connection
142
Single-Channel Connection
143
Wiring Examples
143
Multiple Drives (Internal Power Supply)
145
Multiple Drives (External Power Supply)
146
Operation Principle
147
Start-Up Including Acceptance Test
147
Competence
147
Acceptance Test Reports
147
Acceptance Test Procedure
147
Use
148
Maintenance
149
Competence
150
Fault Tracing
150
Safety Data
150
Declaration of Conformity
152
16 Optional I/O Extension Modules
153
Contents of this Chapter
153
CHDI-01 115/230 V Digital Input Extension Module
153
Safety Instructions
153
Hardware Description
153
Product Overview
153
Layout
154
Mechanical Installation
154
Necessary Tools and Instructions
154
Unpacking and Checking the Delivery
154
Installing the Module
154
Electrical Installation
155
Warnings
155
Terminal Designations
155
Wiring
155
Start-Up
156
Setting the Parameters
156
Diagnostics
156
Faults and Warning Messages
156
Leds
157
Technical Data
157
Dimension Drawing
157
CMOD-01 Multifunction Extension Module (External 24 V AC/DC and Digital I/O)
159
Safety Instructions
159
Hardware Description
159
Product Overview
159
Layout
160
Mechanical Installation
160
Necessary Tools and Instructions
160
Unpacking and Checking the Delivery
160
Installing the Module
160
Electrical Installation
161
Warnings
161
Necessary Tools and Instructions
161
Terminal Designations
161
General Cabling Instructions
161
Wiring
161
Start-Up
163
Setting the Parameters
163
Diagnostics
163
Faults and Warning Messages
163
Leds
164
Technical Data
164
Dimension Drawing
164
CMOD-02 Multifunction Extension Module (External 24 V AC/DC and Isolated PTC Interface)
166
Safety Instructions
166
Hardware Description
166
Product Overview
166
Layout
167
Mechanical Installation
167
Unpacking and Checking the Delivery
167
Installing the Module
167
Electrical Installation
168
Warnings
168
Terminal Designations
168
General Cabling Instructions
168
Wiring
168
Start-Up
169
Setting the Parameters
169
Diagnostics
170
Faults and Warning Messages
170
Leds
170
Technical Data
170
CPTC-02 ATEX-Certified Thermistor Protection Module, (External 24 V AC/DC and Isolated PTC Interface)
172
17 Du/Dt Filters
173
Contents of this Chapter
173
When Is Du/Dt Filter Needed
173
Selection Table
173
Ordering Codes
173
Description, Installation and Technical Data of the FOCH Filters
173
18 Step-By-Step Drawings for an Installation Example of Drive Module with Options
179
Further Information
179
Product and Service Inquiries
179
Product Training
179
Providing Feedback on ABB Manuals
179
Document Library on the Internet
179
4
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ABB ACS530-04 Specifications
General
Brand
ABB
Model
ACS530-04
Category
Controller
Language
English
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