ABB ACS560 Hardware Manual
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ABB ACS560 Hardware Manual

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ABB general purpose drives
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ACS560 drives (0.75 to 160 kW, 1.0 to 215 hp)
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  • Page 1 ABB general purpose drives Hardware manual ACS560 drives (0.75 to 160 kW, 1.0 to 215 hp)
  • Page 3 Hardware manual ACS560 drives (0.75 to 160 kW, 1.0 to 215 hp) Table of contents 1. Safety instructions 4. Mechanical installation 6. Electrical installation © 2017 ABB. All Rights Reserved. 3AXD50000044998 B EFFECTIVE: 2016-08-26...

  • Page 5: Table Of Contents

    Table of contents 5 Table of contents 1 Safety instructions Contents of this chapter ................Use of warnings and notes in this manual ............. General safety in installation, start-up and maintenance ........Electrical safety in installation, start-up and maintenance ........Precautions before electrical work ............
  • Page 6 6 Table of contents Unpacking and examining delivery, frames R6…R8 .......... Installing the drive .................. Installing the drive vertically, frames size R0…R2 ......... Installing the drive vertically, frame size R3...R4 .......... Installing the drive vertically, frames size R5…R8 ......... Installing the drive vertically side by side ........... Installing the drive horizontally side by side ..........
  • Page 7 Motor cable .................. Notes for frame R8 ................. Input power cable ................DC connection ..................Connecting the control cables ..............Default control connections for the ABB standard macro ........ Terminal sizes ................... Notes ..................... Switches ..................PNP configuration for digital inputs ............
  • Page 8 8 Table of contents Reinstalling covers, frame size R3, R4 ............Reinstalling side plates and covers, frames size R5…R8 ........ Connecting a PC ................... 7 Installation checklist Contents of this chapter ................Warnings .................... Checklist ..................... 8 Maintenance and hardware diagnostics Contents of this chapter ................
  • Page 9 Table of contents 9 Motor connection data ................EMC compatibility and motor cable length ..........Brake resistor connection data for frames R0…R3 ........... Control connection data ................Auxiliary circuit power consumption ............. Efficiency .................... Degree of protection ................Ambient conditions ................Materials .....................
  • Page 10 10 Table of contents 12 Safe torque off function What this chapter contains ............... Description ..................Compliance with the European Machinery Directive ........Connection principle (R0...R2) ..............Connection with internal +24 V DC power supply ......... Connection with external +24 V DC power supply ........Wiring examples ...................

  • Page 11: Safety Instructions

    Safety instructions 11 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.

  • Page 12: General Safety In Installation, Start-Up And Maintenance

    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 WARNING! Obey these instructions. If you ignore them, injury or death, or damage to the equipment can occur.

  • Page 13: Electrical Safety In Installation, Start-Up And Maintenance

    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 ACS560 standard control program firmware manual (3AXD50000044997 [English]). For the validation of other safety circuits, see the instructions provided with them.

  • Page 14: Additional Instructions And Notes

    14 Safety instructions • 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.

  • Page 15: Grounding

    Safety instructions 15 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. ￭ Grounding These instructions are for all personnel who are responsible for the electrical installation, including the grounding of the drive.

  • Page 16: General Safety In Operation

    16 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 ordeath, 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.

  • Page 17: Introduction To The Manual

    Categorization by frame (size) The ACS560 is manufactured in frames (frame sizes) R0…R8. Some instructions and other information which only concern certain frames are marked with the symbol of the frame (R0…R8). The frame is marked on the type designation label attached to the drive, see...

  • Page 18: Quick Installation And Commissioning Flowchart

    18 Introduction to the manual Quick installation and commissioning flowchart Task Identify the frame of your drive: R0…R8. Type designation la- bel (page 33) Plan the installation: select the cables, etc. Planning the electrical installa- tion (page 49) Check the ambient conditions, ratings and required cooling air flow. Introduction to the manu- al (page 17) Unpack and check the drive.

  • Page 19: Terms And Abbreviations

    Introduction to the manual 19 Task Commission the drive. ACS560 standard control pro- gram firmware manual (3AXD50000044997 [English]) Terms and abbreviations Term/ Description Abbreviation ACS-AP-x Assistant control panel ACS-BP-S Basic control panel Analog input; interface for analog input signals Analog output; interface for analog output signals...

  • Page 20: Related Documents

    Code (English) Code (Hindi) Drive hardware manuals and guides ACS560 standard control program firmware manual 3AXD50000044997 3AXD50000045887 ACS560 (0.75 to 160 kW, 1.0 to 215 hp) hardware manual 3AXD50000044998 3AXD50000045888 ACS560 drives quick installation and start-up guide 3AXD50000042620 (Multi Lingual) ACS-AP-x assistant control panels user’s manual...
  • Page 21 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. ACS560 manuals www.abb.com/drives/documents...

  • Page 23: Operation Principle And Hardware Description

    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. Operation principle The ACS560 is a drive for controlling asynchronous AC induction motors.

  • Page 24: Layout

    24 Operation principle and hardware description The figure below shows the simplified main circuit diagram of the drive. ACS560 T1/U T2/V T3/W R- UDC+ UDC- T1/U T2/V T3/W Rectifier. Converts alternating current and voltage to direct current and voltage. DC link. DC circuit between rectifier and inverter.
  • Page 25 Operation principle and hardware description 25 Installation point (4) EMC filter grounding screw (EMC). R0…R2: on the left side of drive. Cover plate Input voltage connection (L1, L2, L3). Cover plate screw Motor connection (T1/U, T2/V, T3/W) and brake Control panel connection (R-, R+/UDC+, UDC-).

  • Page 26: Frame Size R3

    26 Operation principle and hardware description ￭ Frame size R3 Installation point (4) EMC filter grounding screw (EMC). Cover plate Input voltage connection (L1, L2, L3), motor connection (T1/U, T2/V, T3/W) and brake con- Cover plate screw nection (R-, R+/UDC+, UDC-). Control panel PE connection (power line) Control panel connection...

  • Page 27: Frame R4

    Operation principle and hardware description 27 ￭ Frame R4…R8 The layout of a frame R6 drive is presented below. The frame sizes R7…R8 is similar but have a different structure. Installation point (2 points on the top and 2 points Voltage dependent resistor ground screw (VAR), on the bottom of the frame body) arranged below the control tray.

  • Page 28: Overview Of Power And Control Connections

    28 Operation principle and hardware description Overview of power and control connections The logical diagram below shows the power connections and control interfaces of the drive. Panel port Slot 1 T1/U T2/V T3/W UDC+ UDC- Option slot 1 for optional fieldbus adapter modules Panel port.

  • Page 29: External Control Connecting Terminal, Frame Size R0

    Operation principle and hardware description 29 ￭ External control connecting terminal, Frame size R0…R2 The figure below explains the external control connecting terminal layout of Frame size R0. Layout of the external control connection terminals is identical in frames R1…R2 but the location of the control board with the terminals is different in frames R3.

  • Page 30: External Control Connecting Terminal, Frame Size R3

    30 Operation principle and hardware description ￭ External control connecting terminal, Frame size R3...R5 The figure below explains the external control connecting terminal layout of Frame size R3. Description Analog input and output Auxiliary voltage output Digital input Safety torque cancellation Modbus built-in fieldbus X6…X8 Relay output 1...Relay output 3...

  • Page 31: External Control Connection Terminals, Frames R6

    Operation principle and hardware description 31 ￭ External control connection terminals, frames R6…R8 The layout of the external control connection terminals of frames R6…R8 is shown below. Description Analog input and output Auxiliary voltage output Digital input Safety torque cancellation Modbus built-in fieldbus X6…X8 Relay output 1...Relay output 3...

  • Page 32: Control Panel

    (1b) and push the control panel in at the top edge (1c). For the use of the control panel, see ACS560 standard control program firmware manual (3AXD50000044997 [English]) and ACS-AP-X assistant control panels user’s manual (3AUA0000085685 [English])/ACS-BP-S basic control panel’s user’s manual...

  • Page 33: Type Designation Label

    Operation principle and hardware description 33 Type designation label The type designation label includes IEC 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.

  • Page 34: Locations Of The Labels On The Drive

    34 Operation principle and hardware description ￭ Locations of the labels on the drive...

  • Page 35: Type Designation Key

    +K457. The main selections are described below. Not all The first digits from the left express the basic configuration, for example, ACS560-01-033A-4. The optional selections are given after that, separated by plus signs, for example, +K457.
  • Page 36 36 Operation principle and hardware description CODE DESCRIPTION Full set of printed manuals in selected language. R700 English Hindi 3AXD50000044998...

  • Page 37: Mechanical Installation Contents Of This Chapter

    Mechanical installation 37 Mechanical installation 39 Mechanical installation Mechanical installation Contents of this chapter Contents of this chapter The chapter tells how to check the installation site, unpack, check the delivery and install the drive mechanically. The chapter tells how to check the installation site, unpack, check the delivery and install the drive mechanically.

  • Page 38: Checking The Installation Site

    38 Mechanical installation • Do not install the drive upside down. This can cause damage to the equipment. 40 Mechanical installation Checking the installation site Checking the installation site The drive must be placed in a cabinet and installed on the wall. Drives of frame sizes The drive must be placed in a cabinet and installed on the wall.

  • Page 39: Required Tools

    11.8 Mechanical installation 39 • Vertically side by side • Vertically side by side Frame Vertical installation side by side - c = 0 Vertical installation side by side - size Free space Free space Frame Above (a) Below (b) Between (c) Size Above (a)

  • Page 40: Unpacking And Examining Delivery, Frames R3

    40 Mechanical installation the drive to make sure that the drive is of the correct type. See section Type designation label (page 33). Drive transport package Multi-language quick Installation and startup guide Drive body (the figure shows frame size R1) User manual (if any, adopt additional code for Installation accessories of plastic bag are below ordering)

  • Page 41: Unpacking And Examining Delivery, Frames R5

    Mechanical installation 43 Unpacking and examining delivery, frames R3...R4 Mechanical installation 41 The figure below shows the drive package and its contents. Make sure 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.

  • Page 42: Unpacking And Examining Delivery, Frames R6

    42 Mechanical installation Cable box package. Stopper Drive Cover protecting film In the option box Straps • Multilingual quick installation and start-up guide Pallet • User's manual (if ordered with a plus code) Control panel selected in the order (in a separate •...
  • Page 43 Mechanical installation 43 9 10 11 Cable box. Power and control cable grounding In the option tray shelves in a plastic bag, assembly drawing. • Multilingual quick installation and startup guide • User’s manual (if ordered with a plus code) Drive with factory installed options.

  • Page 44: Installing The Drive

    Installing the drive 44 Mechanical installation Installing the drive vertically, frames size R0…R2 Installing the drive Mechanical installation 47 The figures show frame R0 as an example. ￭ Installing the drive vertically, frames size R0…R2 1. Mark the hole locations with the mounting template included in the package. Installing the drive The figures show frame R0 as an example.

  • Page 45: Installing The Drive Vertically, Frame Size R3

    48 Mechanical installation Mechanical installation 45 4. Position the drive onto the screws on the wall. Tighten the screws in the wall 4. Position the drive onto the screws on the wall. Tighten the screws in the wall securely. securely. Mechanical installation 47 Installing the drive Installing the drive vertically, frames size...

  • Page 46: Installing The Drive Vertically, Frames Size R5

    46 Mechanical installation 6.30 6.30 18.62 24.37 6.30 6.30 6.30 6.30 Weight 18.62 24.37 18.62 24.37 Weight Weight 14.86 32.77 23.0 50.72 14.9 32.84 19.0 41.89 14.86 32.77 23.0 50.72 ￭ Installing the drive vertically, frames size R5…R8 1. Mark the punch positions for the six mounting holes with the mounting template included in the package.
  • Page 47 1. Mark the punch positions for the six mounting holes with 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, see chapter Dimension drawings on page 149.

  • Page 48: Installing The Drive Vertically Side By Side

    Mechanical installation 51 Mechanical installation 51 Mechanical installation 51 48 Mechanical installation 6. Remove the front cover as follows: • Remove the fastening screws (a). 6. Remove the front cover as follows: 6. Remove the front cover as follows: • Move the cover to the top side and then up •...

  • Page 49: Planning The Electrical Installation

    Planning the electrical installation 49 Planning the electrical installation Contents of this chapter This chapter contains instructions for planning the electrical installation of the drive, for example, for checking the compatibility of the motor and drive, selecting cables, protections, and cable routing. Note: The installation must always be designed and made according to applicable local laws and regulations.

  • Page 50: Other Regions

    50 Planning the electrical installation ￭ Other regions The disconnecting device must conform to the applicable local safety regulations. Checking the compatibility of the motor and drive Use an asynchronous AC induction motor with the drive. Several induction motors can be connected to the drive at a time.

  • Page 51: Alternative Power Cable Types

    Planning the electrical installation 51 Drive type Framesize ACS560 Cu cable type Cu cable type AI cable type AI cable type AWG/kcmil AWG/kcmil 3-phase U = 400 V (380…480 V) 02A6-4 3×1.5 + 1.5 03A3-4 3×1.5 + 1.5 04A0-4 3×1.5 + 1.5 05A6-4 3×1.5 + 1.5...

  • Page 52: Recommended Power Cable Types

    52 Planning the electrical installation Recommended power cable types Symmetrical shielded cable with three phase conductors and a concentric PE conductor as the shield. The shield must meet the requirements of IEC 61439-1, see General rules (page 50). Check with local/state/country electrical codes for allowance. Symmetrical shielded cable with three phase conductors and a concentric PE conductor as the shield.

  • Page 53: Conduit

    shield conductivity must be at least 1/10 of the phase conductor conductivity. The requirements are easily met with a copper or aluminum shield. The minimum requirement of the motor cable shield of the drive is shown below. It consists of a concentric layer of copper wires with an open helix of copper tape or copper wire.

  • Page 54: Signals In Separate Cables

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

  • Page 55: Separate Control Cable Ducts

    Planning the electrical installation 55 Drive min 300 mm (12 in.) 90 ° min 200 mm (8 in.) min 500 mm (20 in.) Motor cable Input power cable Power cable Control cable Separate control cable ducts Lead 24 V and 230 V (120 V) control cables in separate ducts unless the 24 V cable is insulated for 230 V (120 V) or insulated with an insulation sleeving for 230 V (120 V).

  • Page 56: Protecting The Motor And Motor Cable In Short-Circuits

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

  • Page 57: Implementing The Safe Torque Off Function

    147). Implementing the undervoltage control (power-loss ride-through) See ACS560 standard control program firmware manual (3AXD50000044997 [English]. Using a contactor between the drive and the motor Implementing the control of the output contactor depends on how you select the drive to operate.

  • Page 58: Switching The Motor Power Supply From Drive To Direct-On-Line

    58 Planning the electrical installation Main switch for the drive Drive main contactor on/off control Bypass circuit breaker Motor power supply selection (drive or direct-on- line) Drive main contactor Start when the motor is connected direct-on-line Bypass contactor Stop when the motor is connected direct-on-line Drive output contactor Drive Switching the motor power supply from drive to direct-on-line...

  • Page 59: Switching The Motor Power Supply From Direct-On-Line To Drive

    Planning the electrical installation 59 Switching the motor power supply from direct-on-line to drive 1. Stop the motor with S42. 2. Switch the motor power supply from direct-on-line to the drive with S40. 3. Close the main contactor of the drive with switch S11 (-> turn to position ST for two seconds and leave at position 1).

  • Page 61: Electrical Installation

    Electrical installation 61 Electrical installation Contents of this chapter The chapter describes how to check the insulation of the assembly and the compatibility with IT (ungrounded) and corner-grounded TN systems. It then shows how to connect the power and control cables, install optional modules and connect a PC. Warnings WARNING! Obey the instructions in chapter...

  • Page 62: Input Power Cable

    62 Electrical installation Also, there are voltage-limiting circuits inside the drive which cut down the testing voltage automatically. ￭ Input power cable Check the insulation of the input cable according to local regulations before connecting it to the drive. ￭ Motor and motor cable Check the insulation of the motor and motor cable as follows: 1.

  • Page 63: Checking The Compatibility With It (Ungrounded) And Corner-Grounded Tn Systems

    Electrical installation 63 1000 V DC, > 1 Mohm Checking the compatibility with IT (ungrounded) and corner-grounded TN systems ￭ EMC filter The internal EMC filter is not suitable for use on an IT (ungrounded) system or on a corner-grounded TN system. Disconnect the EMC filter before connecting the drive to the supply network.

  • Page 64: Frames R0

    64 Electrical installation Frame sizes EMC filter Ground- to- Symmetrically Corner groun- IT systems (un- phase varistor grounded TN ded TN systems grounded or (EMC) systems (TN-S high-resistance (VAR) systems) grounded [>30 ohms]) R0…R3 EMC (1 screw) Do not discon- Disconnect Disconnect nect...

  • Page 65: Frames R4

    Electrical installation 65 4. To disconnect the ground-to-phase varistor, remove the varistor grounding screw. Electrical installation 75 Frames R4…R8 To disconnect the internal EMC filter or ground-to-phase varistor, if needed, do as ￭ Frames R4…R8 follows: To disconnect the internal EMC filter or ground-to-phase varistor, if needed, do as follows: 1.
  • Page 66 66 Electrical installation...

  • Page 67: Connecting The Power Cables

    Electrical installation 67 R6...R8 R6…R8 Electrical installation 77 Connecting the power cables Connecting the power cables ￭ Connection diagram Connection diagram ACS560-01 UDC+ T1/U T2/V T3/W 3 ~ M (PE) (PE) For alternatives, see section Selecting the supply disconnecting device on page...

  • Page 68: Connection Procedure, Frames R0

    68 Electrical installation 360-degree grounding is required. External brake resistor. Use a separate grounding cable if the shield does not meet the requirements of IEC 61439-1 (see lecting the power cables (page 50)) and there is no symmetrically constructed grounding conductor in the cable (see Motor cable shield (page 52)).

  • Page 69: Input Power Cable

    Motor cable Motor cable 2. Prepare the ends of the cable as illustrated in the figure. Two different motor cable 2. Prepare the ends of the cable as illustrated in the figure. Two different motor cable types are shown in the figures (2a.and 2b). types are shown in the figures (2a.and 2b).
  • Page 70 70 Electrical installation The bare shield will be grounded 360 degrees. Mark the pigtail made from the shield as a PE conductor with yellow-and-green color 80 Electrical installation 5. Connect the input power cable as follows: 5. Connect the input power cable as follows: •...

  • Page 71: Finalization

    N·m lbf·ft N·m lbf·ft L1. L2. L3 0.5…0.6 1.2…1.5 0.9…1.1 6. Connect the braking resistor cable as the motor cable in step 4. Electrical installation 71 7. Ground the shield 360 degrees (6a). 8. Connect the twisted shield to the grounding terminal (6b) and the conductors to 8.

  • Page 72: Motor Cable

    1. Remove the front cover as follows: 1. Remove the front cover as follows: 1. Remove the front cover as follows: • Loosen the retaining screw with a screwdriver (1a). • Loosen the retaining screw with a screwdriver (1a). • Loosen the retaining screw with a screwdriver (1a).

  • Page 73: Notes

    the grounding shelf. • Ground the shield 360 degrees by tightening the clamp of the power cable grounding shelf onto the stripped part of the cable (4a). Electrical installation 73 • Connect the twisted shield of the cable to the grounding terminal (4b). •...

  • Page 74: Finalization

    5. Connect the input power cable as follows: • Ground the shield 360 degrees by tightening the clamp of the power cable 5. Connect the input power cable as follows: grounding shelf onto the stripped part of the cable (6a). •...

  • Page 75: Connection Procedure, Frames R5

    11. Install the grounding shelf for the control cables (included with the mounting Finalization screws in a plastic bag in the delivery) onto the grounding shelf for the power cables. 11. Install the grounding shelf for the control cables (included with the mounting screws in a plastic bag in the delivery) onto the grounding shelf for the power Electrical installation 75 cables.

  • Page 76: Motor Cable

    86 Electrical installation 86 Electrical installation 86 Electrical installation 1. Attach the residual voltage warning sticker next to the control board. 2. Remove the side plates of the cable box as follows: Connection procedure, frames R6…R8 Connection procedure, frames R6…R8 Connection procedure, frames R6…R8 76 Electrical installation •...

  • Page 77: Notes For Frame R8

    Motor cable 6. Cut an adequate hole into the rubber grommet. Slide the grommet onto the cable. figure. If you use aluminum cables, put grease to the peeled aluminum cable 7. Prepare the ends of the input power cable and motor cable as illustrated in the 6.
  • Page 78 under the upper pressure plate. under the upper pressure plate. • The connectors are detachable but we do not recommend that you detach them. • The connectors are detachable but we do not recommend that you detach them. If you do, detach and reinstall the connectors as follows. If you do, detach and reinstall the connectors as follows.
  • Page 79 Terminals L1, L2 and L3 Terminals L1, L2 and L3 • • Remove the combi screw that attaches the connector to its terminal post, and Remove the combi screw that attaches the connector to its terminal post, and pull the connector off. pull the connector off.

  • Page 80: Dc Connection

    See section Default control connections for the ABB standard macro (page 81) for the default I/O connections of the ABB standard macro. For other macros, see ACS560 firmware manual (3AXD50000044997 [English]). Connect the cables as described under Control cable connection procedure R0…R8 (page...

  • Page 81: Default Control Connections For The Abb Standard Macro

    Electrical installation 81 ￭ Default control connections for the ABB standard macro Reference voltage and analog inputs Signal cable shield (screen) External frequency reference: 1…10 kohm 1) 4)10) 0…10 V AGND Analog input circuit, common +10V 10 V DC reference voltage...

  • Page 82: Notes

    82 Electrical installation ￭ Notes Current [0(4)…20 mA, R < 500 ohm] or voltage [ 0(2)…10 V, R > 200 kohm] input as selected with parameter 12.15 AI1 unit selection. Current [0(4)…20 mA, R = 100 ohm] or voltage[ 0(2)…10 V, R >...

  • Page 83: Pnp Configuration For Digital Inputs

    Electrical installation 83 Switch Description Position S100 Modbus link termination. Must be set to the ter- BUS not terminated (default) minated (ON) position when the drive is the first (TERM) or last unit on the link. BUS terminated S200 Switches on the biasing voltages to the bus. One BIAS off (default) (and only one) device, preferably at the end of (BIAS)

  • Page 84: Connection For Obtaining 0

    ￭ Connection examples of two-wire and three-wire sensors PID macros (see ACS560 firmware manual (3AXD50000016097 [English])) use analog input 2 (AI2). The macro wiring diagrams on these pages use an externally powered sensor (connections not shown). The figures below give examples of connections using a two-wire or three-wire sensor/transmitter supplied by the drive auxiliary voltage output.

  • Page 85: Di5 As Frequency Input

    PID macros (see ACS560 firmware manual (3AXD50000016097 [English])) use PID macros (see ACS560 firmware manual (3AXD50000016097 [English])) use analog input 2 (AI2). The macro wiring diagrams on these pages use an externally analog input 2 (AI2). The macro wiring diagrams on these pages use an externally powered sensor (connections not shown).

  • Page 86: Safe Torque Off (X4)

    One, two or three Pt100 sensors for motor temperature measurement can be connected between an analog input and output as shown below. Do not connect both ends of the cable shields directly to ground, nor connect the capacitor at one end to 86 Electrical installation the ground and another end directly to ground.
  • Page 87 Electrical installation 87 The figures for frames R0...R2 (page 88), R3...R5 (page 89) R6...R8 (page 90) show an example of connecting a cable. Make the connections according to the macro in use. 3. Frames R4...R8: Cut an adequate hole into the rubber grommet and slide the grommet onto the cable.

  • Page 88: R0...R2

    The shield can also be grounded directly at both ends if they are in the same ground line with no significant voltage drop between the end points. • Keep any signal wire pairs twisted as close to the terminals as possible. Twisting 88 Electrical installation the wire with its return wire reduces disturbances caused by inductive coupling.

  • Page 89: R3...R5

    y capacitor with a few nanofarads, eg, 3.3 nF / 630 V. nded directly at both ends if they are in the same nt voltage drop between the end points. Electrical installation 89 wisted as close to the terminals as possible. Twisting educes disturbances caused by inductive coupling.

  • Page 90: Installing Optional Modules

    Electrical installation 101 90 Electrical installation R6…R8 R6...R8 0.5...0.6 N·m (0.4 lbf·ft) 0.5...0.6 N·m (0.4 lbf·ft) M4×20 Installing optional modules Note: If you are installing the FPBA-01 module, see section (page 54) for suitable connector types. ￭ Mechanical installation of option modules See section Overview of power and control connections (page 28) for the available slots...

  • Page 91: Option Slot 1 (Fieldbus Adapter Modules)

    Electrical installation 91 1. Remove the front cover(s) if not already removed. See Connection procedure, frames R0…R2 (page 68), Connection procedure, frames R3...R4 (page 71) Connection procedure, frames R5…R8 (page 75). 2. Put the module carefully into its position on the control board. 3.

  • Page 92: Reinstalling Covers, Frame Size R3, R4

    104 Electrical installation 92 Electrical installation Reinstalling covers, frame size R3, R4 ￭ Reinstalling covers, frame size R3, R4 1. Reinstall the module cover. Put the tabs on the cover top in their counterparts on 1. Reinstall the module cover. Put the tabs on the cover top in their counterparts on the the housing and then press the cover.
  • Page 93 106 Electrical installation 106 Electrical installation 106 Electrical installation Connecting a PC Connecting a PC Connecting a PC Electrical installation 93 To be able to connect a PC to the drive, you need a control panel To be able to connect a PC to the drive, you need a control panel To be able to connect a PC to the drive, you need a control panel Connect a PC to the drive with a USB data cable (USB Type A <->...

  • Page 95: Installation Checklist

    Installation checklist 95 Installation checklist Contents of this chapter This chapter contains an installation checklist which you must complete before you start up the drive. Warnings WARNING! Obey the instructions in chapter Safety instructions (page 11). If you ignore them, injury or death, or damage to the equipment can occur.
  • Page 96 96 Installation checklist Check that …. There is an adequately sized protective earth (ground) conductor between the drive and the switchboard. There is an adequately sized protective earth (ground) conductor between the motor and the drive. All protective earth (ground) conductors have been connected to the appropriate terminals and the terminals have been tightened (pull conductors to check).

  • Page 97: Maintenance And Hardware Diagnostics

    For more information, consult your local ABB Service representative (www.abb.com/searchchannels). Maintenance and component replacement intervals are based on the assumption that the equipment is operated within the specified ratings and ambient conditions. ABB recommends annual drive inspections to ensure the highest reliability and optimum performance. Note: Long term operation near the specified maximum ratings or ambient conditions may require shorter maintenance intervals for certain components.

  • Page 98: Recommended Annual Maintenance Actions By The User

    Recommended maintenance action by the user The table below shows the intervals for the preventive maintenance tasks allowed for the customer. For other maintenance tasks, consult your local ABB Service representative, or see the complete maintenance schedule on the Internet.

  • Page 99: Heatsink

    * Ambient temperature constantly over 40 °C, especially dusty or humid ambient conditions, cyclic heavy load, or continuous rated (full) load. To maintain the best possible performance and reliability of the drive, inspect the drive annually. Contact ABB Service at least once in three years for replacement of aging components.

  • Page 100: Replacing The Cooling Fan, Frames Size R0

    average operation conditions. In a speed-controlled fan, the speed of the fan matches the cooling needs. This increases the life span of the fan. 100 Maintenance and hardware diagnostics Replacement fans are available from the manufacturer. Do not use other than specified spare parts.

  • Page 101: Replacing The Main Cooling Fan, Frames Size R6

    WARNING! Obey the instructions in chapter Safety instructions on page 11. Ignoring the instructions can cause physical injury or death, or damage to the equipment. Maintenance and hardware diagnostics 101 1. Stop the drive and disconnect it from the power line. Wait for 5 minutes and then make sure by measuring that there is no voltage.

  • Page 102: Replacing The Auxiliary Cooling Fan, Frames R6

    3. Pull the fan mounting plate down from the side edge. 4. Unplug fan power supply wires from the drive. 5. Lift the fan mounting plate off. 102 Maintenance and hardware diagnostics 6. Remove the fan from the mounting plate. 7.

  • Page 103: Capacitors

    For information on reforming the capacitors, see Converter module capacitor reforming instructions (3BFE64059629 [English]), available on the Internet (go to http://www.abb.com and enter the code in the Search field). Control panel ￭...

  • Page 104: Leds

    Note: The battery is NOT required for any control panel or drive functions, except the clock. 1. Remove the control panel from the drive. See section Control panel on page 34. 104 Maintenance and hardware diagnostics 2. To remove the battery, use a coin to rotate the battery cover on the back of the control panel.
  • Page 105 Maintenance and hardware diagnostics 105 Control panel LED, at the left edge of the control panel LED off LED lit and steady LED blinking/flickering Panel has no Green Drive functioning normally. Green Blinking: power. Active warning in the drive Connection between the drive and control panel may be faulty Flickering: or lost, or the panel and drive...

  • Page 107: Technical Data

    CE, UL and other approval marks. Ratings ￭ IEC ratings Drive Type Nomin- Max. current Output ratings Output ratings Frame ACS560 al In size Nominal use Heavy-duty use (Continu- ous) 3 phases U = 400 V (380…480 V) 02A6-4 0.75 0.55...

  • Page 108: Definitions

    108 Technical data Drive Type Nomin- Max. current Output ratings Output ratings Frame ACS560 al In size Nominal use Heavy-duty use (Continu- ous) 025A-4 30.6 033A-4 44.3 24.6 039A-4 56.9 18.5 31.6 046A-4 67.9 37.7 18.5 062A-4 44.6 073A-4 088A-4...

  • Page 109: Sizing

    110): The derating factor for 1500 m is 1 - 1/10 000 m · (1500 - 1000) m = 0.95. The minimum size required becomes then I = 18.18 A / 0.95 = 19.14 A. Referring to I in the ratings tables (starting from i484355), drive type ACS560-01-025A-4 exceeds the I requirement of 19.24 A. ￭...

  • Page 110: Switching Frequency Derating

    110 Technical data 1.00 0.95 0.90 R0…R8 0.85 0.80 … °C 5.00 +104.00 °C +122.00 °C -59 °F +104 °F +122 °F ￭ Switching frequency derating The output current is calculated by multiplying the current given in the rating table by the derating factor given in the table below.

  • Page 111: Fuses (Iec)

    ￭ uR and aR fuse Drive type Input cur- uR and aR Minimum ACS560 rent short cir- Rated cur- Rated Bussmann IEC 60269...

  • Page 112: Gg Fuses

    112 Technical data Drive type Input cur- uR and aR Minimum ACS560 rent short cir- Rated cur- Rated Bussmann IEC 60269 cuit cur- rent I voltage designation size rent type 246A-4 2050 145000 170M5809 293A-4 2200 275000 170M5810 minimum short-circuit current of the device ￭...

  • Page 113: Gr Fuses

    Technical data 113 Drive type Input cur- gG (IEC 60269) Minimum ACS560 rent short cir- Rated cur- Rated ABB designa- IEC 60269 cuit cur- rent I voltage tion type size rent 293A-4 7800 1300000 OFAF000H425 minimum short-circuit current of the device ￭...

  • Page 114: Circuit Breakers

    114 Technical data Circuit breakers The table below lists MCB circuit breakers that can be used with the drive. Type MCBs ACS560 ABB type Max. short- Tmax Tmax rat- Electronic SACE ordering circuit frame XT / release code for breaker...

  • Page 115: Dimensions, Weights And Free Space Requirements

    Technical data 115 Dimensions, weights and free space requirements Framesize Dimensions and weight IP20 Weight 14.9 28.3 42.4 Standard frame size (R0-R8)

  • Page 116: Thermal Losses, Cooling Data And Noise

    Use the maximum heat dissipation when designing cabinet or electrical room cooling needs. Desig. Thermal losses Air flow Noise Frame size ACS560 Main cir- Control cir- Control cir- Main circuit cuit nomin- cuit Min.

  • Page 117: Terminal And Lead-Through Data For The Power Cables

    Technical data 117 Desig. Thermal losses Air flow Noise Frame size ACS560 Main cir- Control cir- Control cir- Main circuit cuit nomin- cuit Min. cuit Max. and control al I load load circuit Max. load dB(A) 03A3-4 63.10 04A0-4 63.10 05A6-4 63.10...

  • Page 118: Terminal And Lead-Through Data For The Control Cables

    2x150 2x300MCM 29.5 2x50 Terminal and lead-through data for the control cables Control cable lead-throughs, wire sizes and tightening torques (T) are given below. Desig. ACS560 Control Terminal +24V. DCOM.DGND DI. AI/O. AGND. RO. STO size T (N·m) T (N·m) 3 phases U = 400V (380…480V)

  • Page 119: Electrical Power Network Specification

    Technical data 119 Electrical power network specification Voltage (U Input voltage range 3~ 380…480 V AC. This is indicated in the type designa- tion label as typical input voltage levels 3~ 400/480 V AC. Network type Public low voltage networks. TN (grounded), IT (ungrounded) and corner- grounded TN systems.

  • Page 120: Emc Compatibility And Motor Cable Length

    120 Technical data Maximum recommended mo- Operational functionality and motor cable length tor cable length The drive is designed to operate with optimum performance with the following maximum motor cable lengths. Frame size Maximum motor cable length, 4 kHz Scalar control Vector control Standard drive, without external options 3AXD10000561047.xls...

  • Page 121: Brake Resistor Connection Data For Frames R0

    Technical data 121 Frame size Maximum motor cable length, 4 kHz See the terms in section Definitions (page 129). Applicable for frames R4...R8. Frames R0...R2 require external EMC filter to meet the category 2 standards. Note 2: Radiated emissions are according to C3 with an internal EMC filter. Note 3: The internal EMC filter must be connected.
  • Page 122 122 Technical data Analog outputs AO1 and AO2 a dip switch or see section Switches (page 82). (Term. 7 and 8) Current output: 0…20 mA, R : < 500 ohm load Voltage output: 0…10 V, R : > 100 kohm (AO1 only) load Inaccuracy: ±1% of full scale (in voltage and current modes) Reference voltage output for...
  • Page 123 Technical data 123 Grounding of frames R0…R2 X2 & X3 Slot 2 Slot 1 +24V DGND DCOM RO1C RO1A RO1B OUT1 SGND Ground *) Installed with jumpers at the factory.
  • Page 124 124 Technical data Grounding of frames R3…R5 Slot 1 AGND +10V AGND AGND X2 & X3 +24V DGND DCOM X6. X7. X8 RO1C RO1A RO1B RO2C RO2A RO2B RO3C RO3A RO3B DGND OUT1 OUT2 SGND Ground Installed with jumpers at the factory.

  • Page 125: Auxiliary Circuit Power Consumption

    Technical data 125 Grounding of frames R6…R8 Slot 1 Slot 2 AGND +10V AGND AGND X2 & X3 +24V DGND DCOM X6, X7, X8 RO1C RO1A RO1B RO2C RO2A RO2B RO3C RO3A RO3B DGND OUT1 OUT2 SGND 24VAC/DC+in 24VAC/DC-in Ground Jumper installed at factory Auxiliary circuit power consumption Maximum external power supply:...

  • Page 126: Degree Of Protection

    126 Technical data Degree of protection Ambient conditions Environmental limits for the drive are given below. The drive is to be used in a heated, indoor, controlled environment. All printed circuit boards are conformal coated. Operation installed Storage in the pro- Transportation in for stationary use tective package...

  • Page 127: Materials

    Technical data 127 Shock/Drop (ISTA) Not allowed R0…R5 (ISTA 1A): Drop, 6 faces, 3 edges and 1 corner Weight range 0...10 kg 29.9 (0...22 lb) 10...19 kg 24.0 (22...42 lb) 19...28 kg 18.1 (42...62 lb) 28...41 kg 13.4 (62...90 lb) R6…R8 (ISTA 3E): Shock, incline impact: 1.1 m/s (3.61 ft/s) Shock, rotational edge drop: 200 mm (7.9...

  • Page 128: Ce Marking

    128 Technical data EN 61000-3-12:2011 Electromagnetic compatibility (EMC) - Part 3-12: Limits - Limits for harmonic currents produced by equipment connected to public low-voltage systems with input current IEC/EN 61800-3:2004 + Adjustable speed electrical power drive systems. Part 3: EMC requirements A1:2012 and specific test methods IEC/EN 61800-5-1:2007...

  • Page 129: Compliance With The En 61800-3:2004 + A1:2012

    Technical data 129 Compliance with the EN 61800-3:2004 + A1:2012 ￭ Definitions EMC stands for Electromagnetic Compatibility. It is the ability of electrical/electronic equipment to operate without problems within an electromagnetic environment. Likewise, the equipment must not disturb or interfere with any other product or system within its locality. First environment includes establishments connected to a low-voltage network which supplies buildings used for domestic purposes.

  • Page 130: Category C3

    130 Technical data WARNING! The drive may cause radio interference if used in residential or domestic environment. The user is required to take measures to prevent interference, in association to the requirements for the CE compliance listed above, if necessary. Note: •...
  • Page 131 Technical data 131 Medium voltage network Supply transformer Neighbouring network Static screen Point of measurement Low voltage Low voltage Equipment Drive (victim) Equipment Equipment 2. An EMC plan for preventing disturbances is drawn up for the installation. A template is available from the local representative.

  • Page 133: Dimension Drawings

    Dimension drawings 133 Dimension drawings Contents of this chapter This chapter shows the dimension drawings of the ACS560. The dimensions are given in millimeters and [inches].

  • Page 134: Frame R0, Ip20

    134 Dimension drawings Frame R0, IP20...

  • Page 135: Frame R1, Ip20

    Dimension drawings 135 Frame R1, IP20 Frame R2, IP20...

  • Page 136: Frame R3, Ip20

    136 Dimension drawings Frame R3, IP20 Frame R4, IP20...

  • Page 137: Frame R5 Ip20

    Dimension drawings 137 Frame R5, IP20...

  • Page 138: Frame

    138 Dimension drawings Frame R6, IP20...

  • Page 139: Frame R7, Ip20

    Dimension drawings 139 Frame R7, IP20...

  • Page 140: Frame R8, Ip20

    140 Dimension drawings Frame R8, IP20...

  • Page 141: Resistor Braking

    Resistor braking 141 Resistor braking Contents of this chapter The chapter describes how to select the brake resistor and cables, protect the system, connect the brake resistor and enable resistor braking. Operation principle and hardware description The brake chopper handles the energy generated by a decelerating motor. The chopper connects the brake resistor to the intermediate DC circuit whenever the voltage in the circuit exceeds the limit defined by the control program.
  • Page 142 = length of the braking cycle (s). The table shows reference resistor types for the maximum braking power. Type Part No. Energy (KJ) cont ACS560 400 sec. 3-phase U = 380 or 480V, 1 min/5 min duty use 02A6-4 03A3-4...

  • Page 143: Selecting And Routing The Brake Resistor Cables

    Resistor braking 143 Type Part No. Energy (KJ) cont ACS560 400 sec. 039A-4 3AYNSBR-RES10 4400 046A-4 3AXD10000561047.xls Type Part No. Energy (KJ) cont ACS560 400 sec. 3-phase U = 380 or 480V, 10 sec / 2 min duty use 02A6-4...

  • Page 144: Placing The Brake Resistor

    The maximum length of the resistor cable(s) is 10 m (33 ft). EMC compliance of the complete installation Note: ABB has not verified that the EMC requirements are fulfilled with external user-defined brake resistors and cabling. The EMC compliance of the complete installation must be considered by the customer.

  • Page 145: Mechanical Installation

    Resistor braking 145 L1 L2 L3 Θ ACS560 ACS560 L1 L2 L3 +24V ￭ Mechanical installation All brake resistors must be installed outside the drive. Follow the resistor manufacturer’s instructions. ￭ Electrical installation Checking the insulation of the assembly Follow the instructions given in section Resistor braking, frames R0…R3 (page...

  • Page 146: Resistor Braking, Frames R4

    For more information, see NBRA-6xx Braking Choppers Installation and start-up guide (3AFY58920541 [English]) and ACS-BRK Brake Units Installation and start-up guide (3AFY61514309 [English]). Type Brakechopper Reference resistor types ACS560 3-phase UN = 380 or 480V 062A-4 ACS-BRK-D 18.1 40.2 Built in with the brake chopper...

  • Page 147: Safe Torque Off Function

    Safe torque off function 147 Safe torque off function What this chapter contains This chapter describes the Safe torque off (STO) function of the drive and gives instructions for its use. Description The Safe torque off function can be used, for example, to construct safety or supervision circuits that stop the drive in case of danger.

  • Page 148: Compliance With The European Machinery Directive

    148 Safe torque off function Standard Name IEC 61326-3-1:2008 Electrical equipment for measurement, control and laboratory use – EMC require- ments – Part 3-1: Immunity requirements for safety-related systems and for equipment intended to perform safety-related functions (functional safety) – Gen- eral industrial applications IEC 61508-1:2010 Functional safety of electrical/electronic/programmable electronic safety-related...

  • Page 149: Connection Principle (R0

    Safe torque off function 149 Connection principle (R0...R2) ￭ Connection with internal +24 V DC power supply Control unit OUT1 + 24 V DC SGND UDC+ T1/U. Control logic T2/V. T3/W UDC- ￭ Connection with external +24 V DC power supply 24 V DC OUT 1 + 24 V DC...
  • Page 150 150 Safe torque off function OUT1 SGND Safety relay +24 V DC safety PLC Drives external power supply OUT1 SGND Safety relay For information on the specifications of the STO input, see chapter Control connection data (page 121).

  • Page 151: Connection Principle (R3-R8)

    Safe torque off function 151 Connection principle (R3-R8) ￭ Connection with built-in +24V DC power supply Drive Control unit OUT1 + 24VDC OUT2 + 24VDC SGND UDC+ T1/U, Control logic T2/V, T3/W UDC- ￭ Connection with external +24VDC power supply 24VDC Drive Control unit...

  • Page 152: Activation Switch

    152 Safe torque off function Drive Safety PLC OUT1 OUT2 36 SGND Safety relay STO line example of external +24V DC power supply is shown as follows. +24V DC external Drive Safety PLC power supply OUT1 OUT2 36 SGND Safety relay For the information of STO input specification, see Chapter Control connection data (page...

  • Page 153: Grounding Of Protective Shields

    Safe torque off function 153 a wiring method (shield grounding, channel separation) which reduces or eliminates the risk caused by the short-circuit. Note: The voltage at the INx terminals of each drive must be at least 13 V DC to be interpreted as “1”.

  • Page 154: Acceptance Test Reports

    • Start the drive and ensure the motor is running. • Open the STO circuit. The motor should stop. The drive generates an indication if one is defined for the ‘running’ state in parameter. For the description of the warning,see ACS560 standard control program firmware manual (3AXD50000044997[English]).

  • Page 155: Maintenance

    Safe torque off function 155 6. Reset any faults before restarting. WARNING! The Safe torque off function does not disconnect the voltage of the main and auxiliary circuits from the drive. Therefore maintenance work on electrical parts of the drive or the motor can only be carried out after isolating the drive from the main supply.

  • Page 156: Safety Data

    Any failures of the Safe torque off function must be reported to ABB. Safety data The safety data for the Safe torque off function is given below.

  • Page 157: Abbreviations

    Safe torque off function 157 • 30 on/off cycles per year with ΔT = 10.0 °C • 32 °C board temperature at 2.0% of time • 60 °C board temperature at 1.5% of time • 85 °C board temperature at 2.3% of time. •...

  • Page 158: Declaration Of Conformity

    158 Safe torque off function Declaration of conformity Declaration of conformity (3AXD10000302783) is available on the Internet. See section Document library on the Internet on the inside of the back cover. Certificate TUV certificate (3AXD10000302787) can be found on the Internet. Please see section Document library on the Internet of inside page of back cover.

  • Page 159: Du/Dt Filters

    ￭ Where is a du/dt filter needed? See section Checking the compatibility of the motor and drive. ￭ du/dt filter types Drive type ACS560- du/dt filter type 3 phases U = 400 V (380…480 V) 02A6-4 NOCH0016-6X 03A3-4 NOCH0016-6X...

  • Page 160: Description, Installation And Technical Data Of The Foch Filters

    160 du/dt filters Drive type ACS560- du/dt filter type 046A-4 NOCH0070-6X 062A-4 NOCH0070-6X 073A-4 NOCH0120-6X 088A-4 NOCH0120-6X 106A-4 NOCH0120-6X 145A-4 FOCH0260-7X 169A-4 FOCH0260-7X 206A-4 FOCH0260-7X 246A-4 FOCH0260-7X 293A-4 FOCH0260-7X ￭ Description, installation and technical data of the FOCH filters See FOCH du/dt filters hardware manual (3AFE68577519 [English]).

  • Page 163: Further Information

    Product and service inquiries Address any inquiries about the product to your local ABB representative, quoting the type designation and serial number of the unit in question. A listing of ABB sales, support and service contacts can be found by navigating to www.abb.com/searchchannels.
  • Page 164 Contact us www.abb.com/drives 3AXD50000044998 B (EN) EFFECTIVE 2016-08-26 3AXD50000044998B...

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