ABB ACH580 Series Installation, Operation And Maintenance Manual

ABB ACH580 Series Installation, Operation And Maintenance Manual

Ultra-low harmonic drives
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ACH580 Ultra-Low Harmonic Drives
Installation, Operation and Maintenance Manual (I, O & M)
ACH580 HVAC Drives (4...355 kW, 5...400 HP)
ACH580-BCR/BDR/ E-Clipse Bypass Drives (4...355 kW, 5...400 HP)
ACH580-PCR/PDR Packaged Drives with Disconnect (4...355 kW,
5...400 HP)
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Summary of Contents for ABB ACH580 Series

  • Page 1 ACH580 Ultra-Low Harmonic Drives Installation, Operation and Maintenance Manual (I, O & M) ACH580 HVAC Drives (4…355 kW, 5…400 HP) ACH580-BCR/BDR/ E-Clipse Bypass Drives (4…355 kW, 5…400 HP) ACH580-PCR/PDR Packaged Drives with Disconnect (4…355 kW, 5…400 HP)
  • Page 2 ACH580 Ultra-Low Harmonic Drives Installation, Operation and Maintenance Manual Safety instructions These are the safety instructions which you • Handle the drive carefully. must obey when you install and operate the • Lift the drive with a lifting device. Use the drive and do maintenance on the drive.
  • Page 3 ACH580 Ultra-Low Harmonic Drives Installation, Operation and Maintenance Manual • Before you connect voltage to the drive, • Frame R3: Do not attempt to repair a make sure that the drive covers are on. malfunctioning drive; contact your local Keep the covers on during the operation. representative for replacement or repair by authorized persons.
  • Page 4 ACH580 Ultra-Low Harmonic Drives Installation, Operation and Maintenance Manual 6. Measure that the installation is you must disconnect the varistor. See de-energized. sections When to disconnect EMC filter or ground-to-phase varistor: TN-S, IT, 7. Confirm the multimeter is working by testing Corner-grounded delta, and a known source.
  • Page 5 ACH580 Ultra-Low Harmonic Drives Installation, Operation and Maintenance Manual Grounding • install a device which automatically disconnects the supply if the protective These instructions are for all personnel who are earth conductor breaks. responsible for the electrical installation, including the grounding of the drive. Additional instructions for Safety Functions WARNING! Obey these instructions.
  • Page 6 ABB and its affiliates are not liable General safety in operation for damages and/or losses related to such security breaches, any unauthorized access,...
  • Page 7 ACH580-31-027A-4 Construction code MADE IN FINLAND U1 3ph 480 VAC IND CONT EQ. 1PD8 60 Hz U2 3ph 0...U1 FRAME ABB Oy Hiomotie 13 0...500 Hz 00380, Helsinki Finland xxxxxxx Air cooling SCCR: 100 kA IP21 UL type 1 S/N: 1170700001...
  • Page 8 ACH580 Ultra-Low Harmonic Drives Installation, Operation and Maintenance Manual ACH580 Ultra-Low Harmonic Drives Installation Installation Study these installation instructions carefully before proceeding. Failure to observe the warnings and instructions may cause a malfunction or personal hazard. WARNING! Before you begin read Safety instructions on page 3.
  • Page 9 ACH580 Ultra-Low Harmonic Drives Installation, Operation and Maintenance Manual Vertical and horizontal clearances are defined in the following diagrams for each orientation. Allowable mounting orientations 200 mm (8 in.) 300 mm (12 in.) 30 mm (1.5 in.) 200 mm (8 in.) 300 mm (12 in.) 200 mm (8 in.) 30 mm (1.5 in.)
  • Page 10 ACH580 Ultra-Low Harmonic Drives Installation, Operation and Maintenance Manual Vertical installation and deflector plate 200 mm (8 in.) deflector plate 120 mm (5 in.) 250 mm (10 in.) 120 mm (5 in.) 300 mm (12 in.) 2. Prepare for installation Lifting R3, R6 and R8 Use provided lifting points to install drive.
  • Page 11 ACH580 Ultra-Low Harmonic Drives Installation, Operation and Maintenance Manual Unpack the drive 1. Unpack the drive. 2. Check for any damage and notify the shipper immediately if damaged components are found. 3. Check the contents against the order and the shipping label to verify that all parts have been received.
  • Page 12 ACH580 Ultra-Low Harmonic Drives Installation, Operation and Maintenance Manual 3. Insert anchors or plugs into the holes and start the screws or bolts into the anchors or plugs. Drive the screws or bolts long enough into the wall to make them carry the weight of the drive.
  • Page 13 WARNING! Ensure the motor is compatible for use with the ACH580 Ultra-Low Harmonic Drives. The ACH580 Ultra-Low Harmonic Drives must be installed by a competent person. If in doubt, contact your local ABB sales or service office. WARNING! If the drive will be connected on an IT (ungrounded) system, make sure neither the EMC filter nor the ground-to-phase varistor are connected.
  • Page 14 ACH580 Ultra-Low Harmonic Drives Installation, Operation and Maintenance Manual Checking the compatibility of EMC filters with IT (ungrounded), Corner-grounded delta, Midpoint-grounded delta, and TT systems EMC filter A drive with the EMC filter connected can be installed to a symmetrically grounded TN-S system.
  • Page 15 ACH580 Ultra-Low Harmonic Drives Installation, Operation and Maintenance Manual When to disconnect EMC filter or ground-to-phase varistor: TN-S, IT, Corner-grounded delta, and Midpoint-grounded delta systems Frame Symmetrically grounded Corner-grounded and IT systems (ungrounded or size TN-S systems Midpoint-grounded delta high-resistance grounded systems [>30 ohms]) Do not disconnect EMC or...
  • Page 16 • Because the EMC filter screws have been disconnected, ABB does not guarantee the EMC category. • ABB does not guarantee the functioning of the ground leakage detector built inside the drive. • In large systems the residual current device can trip without a real reason.
  • Page 17: Wire Size

    ACH580 Ultra-Low Harmonic Drives Installation, Operation and Maintenance Manual Control cable terminal and lead-through data Control cable entries, wire sizes and tightening torques (T) are given below. Cable entries Control cable entries and terminal sizes +24V, DCOM, DGND, EXT. 24V DI, AI/O, AGND, RO, STO terminals Frame Max cable...
  • Page 18 ACH580 Ultra-Low Harmonic Drives Installation, Operation and Maintenance Manual Heat dissipation and Air flow requirements Heat dissipation Air flow Noise Main circuit Control Control Main and Type Frame at rated circuit circuit control boards ACH580 size at I minimum maximum maximum -31- dB(A)
  • Page 19 ACH580 Ultra-Low Harmonic Drives Installation, Operation and Maintenance Manual Fuses UL class T fuses for branch circuit protection per NEC are listed below. ABB recommends fast acting class T or faster fuses for drives installed in North America. Check on the fuse time-current curve to ensure the operating time of the fuse is below 0.5 seconds for frames R3 and R6 and below 0.1 seconds for frame...
  • Page 20 ACH580 Ultra-Low Harmonic Drives Installation, Operation and Maintenance Manual Layout The layout of the drive is shown below. IP55 (UL Type 12) option +B056, R6 IP21 (UL Type 1) R6 UL Type 12 R6 IP20 (UL Open Type) option +P940, R3 Lifting holes (2 pcs in frame R3, 6 pcs in Front cover frames R6 and R8)
  • Page 21 ACH580 Ultra-Low Harmonic Drives Installation, Operation and Maintenance Manual Auxiliary cooling fan. For frame R3 in 13 Clamps for securing the control cables IP55 (UL Type 12 drives) only. mechanically Clamps for securing the FSO wiring 14 Input power cable entry behind the 360-degree grounding clamps mechanically Power cable connection terminals...
  • Page 22 ACH580 Ultra-Low Harmonic Drives Installation, Operation and Maintenance Manual The main cooling fan is at the top of the drive in frame R3 and at the bottom in frames R6 and R8. The figure below shows the layout of the external control connection terminals of the drive.
  • Page 23 ACH580 Ultra-Low Harmonic Drives Installation, Operation and Maintenance Manual 10…12 Auxiliary voltage output DIGITAL IN 13…18 Digital inputs 34…38 Safe torque off connection FAN2 Internal fan 2 connection FAN1 Internal fan 1 connection Panel port (control panel connection, wired at the factory to the control panel) Reserved to internal use.
  • Page 24 ACH580 Ultra-Low Harmonic Drives Installation, Operation and Maintenance Manual Control cable connection procedure WARNING! Obey the instructions in chapter Safety instructions on page 2. If you ignore them, injury or death, or damage to the equipment can occur. Stop the drive and do the steps in section Precautions before electrical work on page before you start the work.
  • Page 25 ACH580 Ultra-Low Harmonic Drives Installation, Operation and Maintenance Manual 3. Attach the residual voltage warning sticker in the local language. 4. For frames R6 and R8: Remove the shroud on the power cable terminals, 5. For frame R8: For easier installation, you can remove the side plates. 6.
  • Page 26 ACH580 Ultra-Low Harmonic Drives Installation, Operation and Maintenance Manual 7. Attach the cable conduits to the bottom plate holes. Cut an adequate hole into the rubber grommet and slide the grommet onto the cable. Slide the cable through a hole in the bottom plate and attach the grommet to the hole.
  • Page 27 ACH580 Ultra-Low Harmonic Drives Installation, Operation and Maintenance Manual Control terminals Route cables using the Analog and provided tie-downs Digital Inputs Motor leads Grounding terminals Power terminals Power wiring torque table Frame size lb-ft N•m T1/U, T2/V, T3/W L1, L2, L3 R+, R- PE Ground ACH580 Ultra-Low Harmonic Drives Installation...
  • Page 28 ACH580 Ultra-Low Harmonic Drives Installation, Operation and Maintenance Manual Analog and Control terminals Digital Inputs Route cables using the provided tie-downs Motor leads Grounding terminals Power terminals Power wiring torque table Frame size lb-ft N•m T1/U, T2/V, T3/W 22.1 L1, L2, L3 22.1 UDC+ and UDC- 22.1...
  • Page 29 ACH580 Ultra-Low Harmonic Drives Installation, Operation and Maintenance Manual Control terminals Analog and Digital Inputs Route cables using the provided tie-downs Motor leads Power terminals Grounding terminals Power wiring torque table Frame size lb-ft N•m T1/U, T2/V, T3/W 29.6 L1, L2, L3 29.6 UDC+ and UDC- 29.5...
  • Page 30 ACH580 Ultra-Low Harmonic Drives Installation, Operation and Maintenance Manual Wiring Note: These are instructions for conduit wiring. For cable wiring, see the ACH580 Hardware manual, publication number 3AXD50000044839. Note: In US deliveries, options are already installed at the factory. If installing on site, see the appropriate option module manual for specific installation and wiring.
  • Page 31 ACH580 Ultra-Low Harmonic Drives Installation, Operation and Maintenance Manual Default control connections for the HVAC default Reference voltage and analog inputs and outputs Signal cable shield (screen) Output frequency/speed reference: 0…10 V 1…10 kohm AGND Analog input circuit common +10V Reference voltage 10 V DC Actual feedback: 0…10 V AGND...
  • Page 32 ACH580 Ultra-Low Harmonic Drives Installation, Operation and Maintenance Manual Default control connections for the PID control, single motor Reference voltage and analog inputs and outputs Signal cable shield (screen) Output frequency/speed reference: 0…10 V 1…10 kohm AGND Analog input circuit common +10V Reference voltage 10 V DC Actual feedback: 0…20 mA...
  • Page 33 ACH580 Ultra-Low Harmonic Drives Installation, Operation and Maintenance Manual Digital inputs; source and sink wiring You can wire the digital input terminals for internal or external power supply in either a PNP or NPN configuration. Internal +24 V power supply External +24 V power supply PNP connection (source) PNP connection (source)
  • Page 34 ACH580 Ultra-Low Harmonic Drives Installation, Operation and Maintenance Manual Switch Description Position Bias off (default) Switches on the biasing voltages to the bus. One BIAS (and only one) device, preferably at the end of the (BIAS) bus must have the bias on. Bias on BIAS 5.
  • Page 35 ACH580 Ultra-Low Harmonic Drives Installation, Operation and Maintenance Manual 6. Re-install cover(s) After installation, reinstall the covers. UL Type 1 UL Type 12 2 N·m (1.5 lbf·ft) 2 N·m (1.5 lbf·ft) R6, R8 UL Type 1 UL Type 12 2 N·m (1.5 lbf·ft) 2 N·m (1.5 lbf·ft) 7.
  • Page 36 ACH580 Ultra-Low Harmonic Drives Installation, Operation and Maintenance Manual 8. Before Start-up Prepare for start-up by reviewing the following information. The First start assistant walks you through the initial start-up procedure. Motor data The motor data on the ratings plate may differ from the defaults in the ACH580 Ultra-Low Harmonic Drives.
  • Page 37 ACH580 Ultra-Low Harmonic Drives Installation, Operation and Maintenance Manual Operation The ACH580 Ultra-Low Harmonic Drives HVAC control panel features: CONTROL PANEL DISPLAY RIGHT SOFTKEY LEFT SOFTKEY STATUS HELP KEY ARROW KEYS HAND AUTO CONNECTOR Control panel features Left softkey The left softkey ( ) is usually used for exiting and canceling.
  • Page 38 ACH580 Ultra-Low Harmonic Drives Installation, Operation and Maintenance Manual Hand key ( • In local control / Off mode: Starts the drive. The drive will switch to the Hand mode. • In external control: Switches the drive to local control / Hand mode, keeping it running.
  • Page 39 ACH580 Ultra-Low Harmonic Drives Installation, Operation and Maintenance Manual For initial start-up, follow steps 1 through 4 below. WARNING! Do not start up the drive unless you are a qualified electrical professional. Read and obey the instructions in chapter Safety instructions at the beginning of the manual.
  • Page 40 ACH580 Ultra-Low Harmonic Drives Installation, Operation and Maintenance Manual Select the supply voltage with parameter 95.01 Supply Voltage: • In the First start assistant menu, select Exit and press (Next). • In the Home view, press (Menu) to enter the Main menu.
  • Page 41 ACH580 Ultra-Low Harmonic Drives Installation, Operation and Maintenance Manual To select a value in an edit view: to select the value. Press (Save) to accept the new setting, or press (Cancel) to go back to the previous view without making changes. Set the date and time as well as date and time display formats.
  • Page 42 ACH580 Ultra-Low Harmonic Drives Installation, Operation and Maintenance Manual This step is optional, and requires rotating the motor. Do not do this if it could cause any risk, or if the mechanical setup does not allow it. To do the direction test, select Spin the motor and press (Next).
  • Page 43 ACH580 Ultra-Low Harmonic Drives Installation, Operation and Maintenance Manual From the Main menu, select Primary settings. Select Start, stop, reference and How do you control? The default configurations are shown on the panel. For HVAC, press Direct control via I/O. For PID Control, press PID control, single motor.
  • Page 44 ACH580 Ultra-Low Harmonic Drives Installation, Operation and Maintenance Manual Other ways to complete commissioning Run & set reference on the panel Drive is now ready to be run in the Hand mode. Press the Hand key on the panel to Hand start the motor.
  • Page 45 ACH580 Ultra-Low Harmonic Drives Installation, Operation and Maintenance Manual 3. Make additional settings in the Primary settings menu – I/O menu After the additional adjustments, make sure that the actual I/O wiring matches the I/O use in the control program. In the Main menu, select a I/O and press (Select) to enter the I/O menu.
  • Page 46 ACH580 Ultra-Low Harmonic Drives Installation, Operation and Maintenance Manual 4. Check setup with the Diagnostics menu After making the additional adjustments and checking the I/O connections, use the Diagnostics menu to make sure that the setup is functioning correctly. In the Main menu, select Diagnostics and press (Select) Select the diagnostics item you want to view and press (Select).
  • Page 47 ACH580 Ultra-Low Harmonic Drives Installation, Operation and Maintenance Manual How to control the drive through the I/O interface Instructions below are for operating the drive through the digital and analog inputs when: • the motor start-up is performed, and • the default parameter settings of the HVAC default configurations are in use. Preliminary settings If you need to change the direction of rotation, check that limits allow reverse direction.
  • Page 48 ACH580 Ultra-Low Harmonic Drives Installation, Operation and Maintenance Manual Select Motor and press (Select) (or If the control modes is scalar, select Control mode and press (Select) (or ) and continue to the next step. Select Vector control and press (Select) (or Warning message Identification run is shown for a moment.
  • Page 49 ACH580 Ultra-Low Harmonic Drives Installation, Operation and Maintenance Manual Check AI1 scaling, see parameters 12.19 AI1 scaled at AI1 min and 12.20 AI1 scaled at AI1 max. Select the type of ID run you want to do and press (Select) (or Check the motor limits shown on the panel.
  • Page 50 Hardware manual of the drive. If an earth fault is found, fix or change the motor cable and/or motor. If no earth fault can be detected, contact your local ABB representative. ACH580 Ultra-Low Harmonic Drives Installation...
  • Page 51 Check the supply voltage. A3AA DC not charged The voltage of the If the problem persists, contact your intermediate DC circuit local ABB representative. has not yet risen to operating level. A490 Incorrect temperature Temperature cannot be Check the settings of temperature...
  • Page 52 (none) Temperature above Check ambient conditions. warning limit Check air flow and fan operation. Check heatsink fins for dust pick-up. 1 Thermistor broken Contact an ABB service representative for control board replacement. A4A1 IGBT overtemperature Estimated drive IGBT Check ambient conditions.
  • Page 53 STO is lost. parameter 31.22 STO indication run/stop. Check the value of parameter 95.04 Control board supply. A5EA Measurement circuit Problem with internal Contact your local ABB temperature temperature representative. measurement of the drive. A5EB PU board powerfail Power unit power Contact your local ABB supply failure.
  • Page 54 ACH580 Ultra-Low Harmonic Drives Installation, Operation and Maintenance Manual Code Warning / Aux. code Cause What to do (hex) 0001 Slip frequency is too Check the settings of the motor small. configuration parameters in groups 98 and 99. 0002 Synchronous and Check that the drive is sized correctly nominal speeds differ for the motor.
  • Page 55 ACH580 Ultra-Low Harmonic Drives Installation, Operation and Maintenance Manual Code Warning / Aux. code Cause What to do (hex) A6E5 AI parametrization The current/voltage Check the event log for an auxiliary hardware setting of an code. The code identifies the analog analog input does not input whose settings are in conflict.
  • Page 56 ACH580 Ultra-Low Harmonic Drives Installation, Operation and Maintenance Manual Code Warning / Aux. code Cause What to do (hex) 0000 0003 Maximum continuous Check value of 43.09. power not given. A79C BC IGBT excess Brake chopper IGBT Let chopper cool down. temperature temperature has Check for excessive ambient...
  • Page 57 10.27 RO2 source. 0003 Relay output 3 Select a different signal with parameter 10.30 RO3 source. A8B0 ABB Signal supervision 1 Warning generated by Check the source of the warning the signal supervision (parameter 32.07 Supervision 1 (Editable message text) function 1.
  • Page 58 ACH580 Ultra-Low Harmonic Drives Installation, Operation and Maintenance Manual Code Warning / Aux. code Cause What to do (hex) A8B5 ABB Signal supervision 6 Warning generated by Check the source of the warning the signal supervision (parameter 32.57 Supervision 6 (Editable message text) function 6.
  • Page 59 ACH580 Ultra-Low Harmonic Drives Installation, Operation and Maintenance Manual Code Warning / Aux. code Cause What to do (hex) A985 External warning 5 Fault in external device Check the external device. (Editable message text) Check setting of parameter 31.09 External event 5 source. Programmable warning: 31.09 External event 5 source...
  • Page 60 ACH580 Ultra-Low Harmonic Drives Installation, Operation and Maintenance Manual Code Warning / Aux. code Cause What to do (hex) AFEF Start interlock 2 Start interlock 2 is Check the signal source selected for keeping the drive from parameter 20.42 Start interlock 2. starting.
  • Page 61 ID. rating ID of the drive. If the fault reappears, cycle the power to the drive. You may have to be repeat this. If the fault persists, contact your local ABB representative. 2310 Overcurrent Output current has Check motor load.
  • Page 62 ACH580 Ultra-Low Harmonic Drives Installation, Operation and Maintenance Manual Code Fault / Aux. code Cause What to do (hex) 2340 Short circuit Short-circuit in motor Check motor and motor cable for cable(s) or motor cabling errors. Check there are no power factor correction capacitors or surge absorbers in motor cable.
  • Page 63 ACH580 Ultra-Low Harmonic Drives Installation, Operation and Maintenance Manual Code Fault / Aux. code Cause What to do (hex) 4110 Control board temperature Control board Check proper cooling of the drive. temperature is too high. Check the auxiliary cooling fan. Check ambient conditions.
  • Page 64 0001 Auxiliary fan 1 broken. 0002 Auxiliary fan 2 broken. 5090 STO hardware failure STO hardware Contact your local ABB representative diagnostics has for hardware replacement. detected hardware failure. 5091 Safe torque off Safe torque off function Check safety circuit connections.
  • Page 65 Reboot the control unit (using incompatible versions are parameter 96.08 Control board boot) incompatible. or by cycling power. If the problem persists, contact your local ABB representative 6306 FBA A mapping file Fieldbus adapter A Contact your local ABB mapping file read error.
  • Page 66 Internal SSW fault Internal fault. Reboot the control unit (using parameter 96.08 Control board boot) or by cycling power. If the problem persists, contact your local ABB representative. 64B2 User set fault Loading of user Ensure that a valid user parameter set parameter set failed exists.
  • Page 67 EFB protocol protocol. application. 6882 Text 32-bit table overflow Internal fault. Reset the fault. Contact your local ABB representative if the fault persists. 6885 Text file overflow Internal fault. Reset the fault. Contact your local ABB representative if the fault persists.
  • Page 68 Check applicability of torque control. braking torque or Check need for brake chopper and changes in load when resistor(s). using torque reference. 73F0 Overfrequency Maximum allowed Contact your local ABB output representative. frequency exceeded. ACH580 Ultra-Low Harmonic Drives Installation...
  • Page 69 ACH580 Ultra-Low Harmonic Drives Installation, Operation and Maintenance Manual Code Fault / Aux. code Cause What to do (hex) 73B0 Emergency ramp failed Emergency stop did not Check the settings of parameters finish within expected 31.32 Emergency ramp supervision time. and 31.33 Emergency ramp supervision delay.
  • Page 70 ACH580 Ultra-Low Harmonic Drives Installation, Operation and Maintenance Manual Code Fault / Aux. code Cause What to do (hex) 80A0 AI supervision An analog signal is Check signal level at the analog input. outside the limits Programmable fault: Check the auxiliary code. specified for the analog 12.03 AI supervision Check the wiring connected to the...
  • Page 71 ACH580 Ultra-Low Harmonic Drives Installation, Operation and Maintenance Manual Code Fault / Aux. code Cause What to do (hex) 9083 External fault 3 Fault in external device Check the external device. (Editable message text) Check setting of parameter 31.05 External event 3 source. Programmable fault: 31.05 External event 3 source 31.06 External event 3...
  • Page 72 Motor nominal torque, and the torque limits in group 30 Limits. Make sure that the maximum torque limit in force is greater than 100%. 0004 Current measurement Contact your local ABB calibration did not finish representative. within reasonable time 0005…0008 Internal error.
  • Page 73 0012 Motor too large for Check that the motor and drive sizes advanced standstill ID are compatible. run. Contact your local ABB representative. 0013 (Asynchronous motors Check that the motor nominal value only) settings in the drive are the same as in the motor nameplate.
  • Page 74 Maintenance schedule Recommended maintenance intervals and component replacements are based on specified operational and environmental conditions. ABB recommends annual drive inspections to ensure the highest reliability and optimum performance. Note: Long term operation near the maximum specified ratings or environmental conditions may require shorter maintenance intervals for certain components.
  • Page 75 ACH580 Ultra-Low Harmonic Drives Installation, Operation and Maintenance Manual Heatsink 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.
  • Page 76 ACH580 Ultra-Low Harmonic Drives Installation, Operation and Maintenance Manual Replacing the main cooling fan, frame R3 WARNING! Obey the instructions in chapter Safety instructions on page 15. If you ignore them, physical injury or death, or damage to the equipment can occur.
  • Page 77 ACH580 Ultra-Low Harmonic Drives Installation, Operation and Maintenance Manual Replacing the main cooling fan, frame R6 WARNING! Obey the instructions in chapter Safety instructions on page 15. If you ignore them, physical injury or death, or damage to the equipment can occur.
  • Page 78 ACH580 Ultra-Low Harmonic Drives Installation, Operation and Maintenance Manual Replacing the main cooling fan, frame R8 WARNING! Obey the instructions in chapter Safety instructions on page 15. Ignoring the instructions can cause physical injury or death, or damage to the equipment.
  • Page 79 ACH580 Ultra-Low Harmonic Drives Installation, Operation and Maintenance Manual Replacing the auxiliary cooling fan, IP55 (UL Type 12) frame R3 WARNING! Obey the instructions in chapter Safety instructions on page 15. If you ignore them, physical injury or death, or damage to the equipment can occur.
  • Page 80 ACH580 Ultra-Low Harmonic Drives Installation, Operation and Maintenance Manual Replacing the auxiliary cooling fan, frame R6 WARNING! Obey the instructions in chapter Safety instructions on page 15. If you ignore them, physical injury or death, or damage to the equipment can occur.
  • Page 81 ACH580 Ultra-Low Harmonic Drives Installation, Operation and Maintenance Manual Replacing the auxiliary cooling fan, frame R8 WARNING! Obey the instructions in chapter Safety instructions on page 15. If you ignore them, physical injury or death, or damage to the equipment can occur.
  • Page 82 ACH580 Ultra-Low Harmonic Drives Installation, Operation and Maintenance Manual Replacing the second auxiliary cooling fan IP55 (UL Type 12), frame R8 WARNING! Obey the instructions in chapter Safety instructions on page 15. If you ignore them, physical injury or death, or damage to the equipment can occur.
  • Page 83 ACH580 Ultra-Low Harmonic Drives Installation, Operation and Maintenance Manual Fan arrow must point up ACH580 Ultra-Low Harmonic Drives Installation...
  • Page 84 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 document code in the Search field). Control panel Cleaning Use a soft damp cloth to clean the control panel.
  • Page 85 ACH580 Ultra-Low Harmonic Drives Installation, Operation and Maintenance Manual ACH580-3BCR/BDR Installation – drive Follow the Installation instructions for the drive on page 8. Failure to observe the warnings and instructions may cause a malfunction or personal hazard. WARNING! Before you begin read Safety instructions on page 2.
  • Page 86 ACH580 Ultra-Low Harmonic Drives Installation, Operation and Maintenance Manual Installation – bypass WARNING! When the ACH580 with E-Clipse Bypass is connected to the line power, the Motor Terminals T1, T2, and T3 may be live even if the motor is not running. Do not make any connections when the ACH580 with E-Clipse Bypass is connected to the line.
  • Page 87 ACH580 Ultra-Low Harmonic Drives Installation, Operation and Maintenance Manual Connection diagrams – Box E-Clipse Bypass ACH580 Box E-Clipse Bypass units are configured for wiring access from the top (for UL Type 1 and 12). The following figures show the layout and connection points. For drive control wiring see pages 31-32.
  • Page 88 ACH580 Ultra-Low Harmonic Drives Installation, Operation and Maintenance Manual Input ground lug Input terminals E-Clipse bypass Circuit breaker or control board and disconnect terminals Service switch (option) ACH580-31 Drive Motor terminals Drive fuses Motor lug ground ACH580-3BCR R6 20-60 HP Type 1 ACH580-3BCR/BDR...
  • Page 89 ACH580 Ultra-Low Harmonic Drives Installation, Operation and Maintenance Manual Input ground lug E-Clipse bypass control board and terminals Input terminals 150VA Circuit breaker or disconnect ACH580-31 Drive 11/25A 41/60A OT30-100F3 Service switch (option) 115A Motor terminals Drive fuses Motor lug ground ACH580-3BCR R3 5-15 HP Type 12 E-Clipse bypass...
  • Page 90 ACH580 Ultra-Low Harmonic Drives Installation, Operation and Maintenance Manual Power connections – Box E-Clipse Bypass configurations Line input connections Connect the input power to the terminals at the bottom of the disconnect switch or circuit breaker. Connect the equipment grounding conductor to the ground lug near the input power connection point.
  • Page 91 ACH580 Ultra-Low Harmonic Drives Installation, Operation and Maintenance Manual Basic connections The figure on page shows the basic control connections for use with the E-Clipse Bypass HVAC Default macro. BYPASS CONTROL ENTER These connections are described in the ENABLED following paragraphs. HAND SELECTED FAULTED...
  • Page 92 ACH580 Ultra-Low Harmonic Drives Installation, Operation and Maintenance Manual Standard enclosure terminals maximum wire size and terminal torque values Nominal Output Maximum Wire Size and Terminal Torque Ratings Base Drive Package Circuit Disconnect Motor Ground Drive 1, 3 Current Power Breaker Switch Terminals...
  • Page 93 ACH580 Ultra-Low Harmonic Drives Installation, Operation and Maintenance Manual Branch circuit protection Input power is connected to the ACH580 with E-Clipse Bypass through a door interlocked disconnect switch or circuit breaker. Neither of these inputs are fused. The branch circuit that provides power to the ACH580 with E-Clipse Bypass with disconnect switch must include appropriate motor branch circuit protective devices to provide short circuit and ground fault protection for the motor in the bypass mode.
  • Page 94 ACH580 Ultra-Low Harmonic Drives Installation, Operation and Maintenance Manual Basic control connections for E-Clipse HVAC Default ACH580 CONTROL BOARD Terminal for Signal Cable Shield Analog Input 1 Analog Input Common +10V Reference Voltage for Potentiometer Analog Input 2 Analog Input Common Analog Output 1 Analog Output 2 Analog Output Common...
  • Page 95 ACH580 Ultra-Low Harmonic Drives Installation, Operation and Maintenance Manual 2. Check installation – bypass Control panel settings and checks Apply power to the E-Clipse Bypass unit. The ACH580 Control Panel should show the operating status of the drive. If the E-Clipse Bypass Control Panel displays a PHASE SEQ (Phase Sequence) fault, remove power, wait at least 5 minutes and then swap any two input phase wires.
  • Page 96 ACH580 Ultra-Low Harmonic Drives Installation, Operation and Maintenance Manual System check: motor connected to ACH580 with E-Clipse Bypass After performing the control panel checks and setting the ACH580 Drive Start-up Data parameters, check the operation of the ACH580 Drive with E-Clipse Bypass with the motor connected as follows: 1.
  • Page 97 ACH580 Ultra-Low Harmonic Drives Installation, Operation and Maintenance Manual Note: If the ACH580 Control Panel displays an Overcurrent, Short circuit or Earth leakage fault, disconnect and lock out power to the E-Clipse Bypass unit. Wait at least 5 minutes. Disconnect the motor leads from the E-Clipse Bypass unit and Megger each motor lead to ground to determine if the motor is good.
  • Page 98 ACH580 Ultra-Low Harmonic Drives Installation, Operation and Maintenance Manual Parameter Value 58.05 – Parity 2 – 8 EVEN 1 58.25 – Control profile 5 – DCU profile 58.34 – Word order 0 – HI-LO Refer to the ACH580-01 Firmware manual for programming instructions. Note: Primary Settings and E-Clipse Bypass Not to be used to configure parameters above which include: –...
  • Page 99 ACH580 Ultra-Low Harmonic Drives Installation, Operation and Maintenance Manual • OFF key on the bypass control panel causes the bottom line on the E-Clipse Bypass display to indicate “Off Stop”. 7. For Steps 8 through 14, ACH580 Drive Parameter 9904 must be set to “Scalar”. After successful completion of Step 13, Parameter 9904 may be set to “Vector”...
  • Page 100 ACH580 Ultra-Low Harmonic Drives Installation, Operation and Maintenance Manual 3. Check jumpers and switches The settings described in this section are factory set and, for most situations, do not require adjustment. However, it is a good practice to review these settings to confirm that they are appropriate for the configuration installed.
  • Page 101 ACH580 Ultra-Low Harmonic Drives Installation, Operation and Maintenance Manual Operation E-Clipse bypass configurations The ACH580 with E-Clipse Bypass is an ACH580 AC adjustable frequency drive in an integrated UL Type 1 or UL Type 12 package with a bypass motor starter. The ACH580 with E-Clipse Bypass provides: •...
  • Page 102 ACH580 Ultra-Low Harmonic Drives Installation, Operation and Maintenance Manual Operating Handle for Disconnect Switch or Circuit Breaker Drive Control Panel Bx12-31 UL Type 12 E-Clipse Bypass Control Panel WARNING RISK OF FIRE OR ELECTRIC SHOCK- The opening of the branch-circuit protective device may be and indication that a fault current has been interrupted.
  • Page 103 ACH580 Ultra-Low Harmonic Drives Installation, Operation and Maintenance Manual The following is a typical power diagram. Drive with E-Clipse Bypass Disconnect Switch Drive Output Bypass or Circuit Breaker Contactor Control 3 Phase ACH580 Motor Drive Input Power Service Switch Bypass (Optional) Contactor Drive Input Fuse...
  • Page 104 ACH580 Ultra-Low Harmonic Drives Installation, Operation and Maintenance Manual Motor Run LED The Motor Run LED is illuminated green when the motor is running in either bypass mode or in drive mode. The Motor Run LED flashes green to indicate the system has been placed in an Override condition.
  • Page 105 ACH580 Ultra-Low Harmonic Drives Installation, Operation and Maintenance Manual Bypass Select Key The Bypass Select Key selects the bypass as the power source for the motor. Off/Reset Key The Off/Reset Key may be used to manually stop the motor if the motor has been running on bypass power.
  • Page 106 ACH580 Ultra-Low Harmonic Drives Installation, Operation and Maintenance Manual Start-up by changing the parameters from the start-up list To change the parameters, follow these steps: The Default Display indicates the DRIVE SELECTED Bypass Control mode. BYPASS IN OFF Press ENTER to enter the Main Menu. *BYPASS STATUS STARTUP PARAMS Select the Startup Params with the...
  • Page 107 ACH580 Ultra-Low Harmonic Drives Installation, Operation and Maintenance Manual Press the Up/Down arrows to change 1601 START/STOP the Parameter Value. 1:DI1 Press ENTER to store the modified *1601 START/STOP value or press ESC to leave the 1602 PERMISSIVE Parameter Edit mode. Press ESC to return to the listing of *16 SYSTEM CTRL Parameter Groups, and again to...
  • Page 108 ACH580 Ultra-Low Harmonic Drives Installation, Operation and Maintenance Manual Diagnostics Fault listing Fault Fault Name In Fault Possible Cause Corrective Action Code Panel 3001 COIL CURR FBK RBCU is sensing Defective component Change RBCU abnormal current on RBCU feedback when neither contactor should be energized 3002...
  • Page 109 ACH580 Ultra-Low Harmonic Drives Installation, Operation and Maintenance Manual Fault Fault Name In Fault Possible Cause Corrective Action Code Panel 3006 UNDERVOLTAGE Fault will be generated Loose J7 connector on Check that J7 only if the drive is RBCU unit (refer to connector is firmly controlling the motor page...
  • Page 110 ACH580 Ultra-Low Harmonic Drives Installation, Operation and Maintenance Manual Fault Fault Name In Fault Possible Cause Corrective Action Code Panel 3012 INP PHASE C Fault will be generated Loose J7 connector Check J7 connector LOSS when the bypass (refer to page (refer to page contactor is requested the J7 connector...
  • Page 111 Bad RBCU values 3027 INVALID SUB ASM Contactor assembly as RBCU unit from a Contact ABB at recorded in the RBCU different size bypass 1-800-HELP-365 unit does not match used to replace a Option 4 drive information defective RBCU.
  • Page 112 Cycle power CORRUPT error Replace RBCU Upgrade firmware 3102 PMAP FILE Parameter file is Cycle Power corrupt Contact ABB with information that preceded fault 3201 T1 OVERLOAD T1 program cycle is Contact ABB with overloaded information that proceeded fault Cycle Power...
  • Page 113 ACH580 Ultra-Low Harmonic Drives Installation, Operation and Maintenance Manual Fault Fault Name In Fault Possible Cause Corrective Action Code Panel 3203 T3 OVERLOAD T3 program cycle is Contact ABB with overloaded information that proceeded fault Cycle Power Replace RBCU 3204 STACK Program cycle is Contact ABB with OVERFLOW...
  • Page 114 ACH580 Ultra-Low Harmonic Drives Installation, Operation and Maintenance Manual Warning listing The following table lists the warnings by code number and describes each. Warning Warning Name In Warning Possible Cause Corrective Action Code Panel 4001 INP PHASE A Warning will occur in Loose J8 connector Check J8 connector LOSS...
  • Page 115 ACH580 Ultra-Low Harmonic Drives Installation, Operation and Maintenance Manual Warning Warning Name In Warning Possible Cause Corrective Action Code Panel 4008 DRIVE SETUP Warning generated Incorrect parameters Check that drive when configuration of settings parameter 95.21, bit 5 drive is such that = “Bypass present”...
  • Page 116 ACH580 Ultra-Low Harmonic Drives Installation, Operation and Maintenance Manual Warning Warning Name In Warning Possible Cause Corrective Action Code Panel 4016 INP VOLTAGE 3-Phase input voltage Loose J7 connector has not reached a Low input voltage. sufficient level to Incoming voltage has enable editing of not reached at least parameters via the...
  • Page 117 ACH580 Ultra-Low Harmonic Drives Installation, Operation and Maintenance Manual Warning Warning Name In Warning Possible Cause Corrective Action Code Panel 4024 Selected by PAR Warning will occur Permissive condition Check 24 Volts on 1624 when start order is is not satisfied. RBCU unit given and the INTERLOCK 4...
  • Page 118 ACH580 Ultra-Low Harmonic Drives Installation, Operation and Maintenance Manual Bypass status listing Bypass Status Condition Description (16 Characters) DRIVE/BYPASS? DRIVE SELECTED Displays which one is selected, drive or BYPASS SELECTED bypass SAFETIES? OPEN Displays if safeties (=INTERLOCK 1 and/ CLOSED or INTERLOCK 2) have been applied, or if they are missing RUN PERMISSIVES?
  • Page 119 ACH580 Ultra-Low Harmonic Drives Installation, Operation and Maintenance Manual Error messages Error Message Description CAN’T EDIT Try to save value (=press the ENTER key in Parameter Edit State) of a read-only parameter. E.g. try to change value PAR IS READ ONLY PAR 01.02 INPUT VOLT CAN’T EDIT Try to change value of a parameter, which is allowed to be...
  • Page 120 ACH580 Ultra-Low Harmonic Drives Installation, Operation and Maintenance Manual ACH580-3PCR/3PDR Installation This information is unique to ACH580 input disconnect configurations (3PCR or 3PDR). The ACH580 with input disconnect is an ACH580 AC adjustable frequency drive packaged with an input disconnect switch or circuit breaker. Refer to the Installation instructions on page 8, for all other information.
  • Page 121 ACH580 Ultra-Low Harmonic Drives Installation, Operation and Maintenance Manual Connection diagrams – Box Packaged Drive with input disconnect Type 1 units are configured for bottom entry and bottom exit wiring access, Type 12 units are configured for top entry and bottom exit. The following figures show the layout and wiring connection points.
  • Page 122 ACH580 Ultra-Low Harmonic Drives Installation, Operation and Maintenance Manual Input Ground Input Ground Disconnect or Disconnect or Circuit Breaker Circuit Breaker Switch Switch Input Input Terminals Terminals Fuses Fuses ACH580-31 Drive Motor and ACH580-3PxR motor ground connections R3 5-15 HP Type 12 Px12-31 ACH580-3PxR R6 20-60 HP Type 12...
  • Page 123 ACH580 Ultra-Low Harmonic Drives Installation, Operation and Maintenance Manual Fuses Note: The UL listed drive fuses in the table are provided in the purchased product. • Replacement fuses are required to be of the same class, current rating, and voltage rating. Fuses from other fuse manufacturers can be used if they meet the specifications given in the table.
  • Page 124 ACH580 Ultra-Low Harmonic Drives Installation, Operation and Maintenance Manual Operation This information is unique to ACH580 input disconnect configurations (PCR or PDR). Refer to the Operation instructions on page for all other information. Input disconnect configuration The ACH580-31 with input disconnect is an ACH580-31 AC adjustable frequency drive packaged with an input disconnect switch or circuit breaker, and with a door interlocked, external operating handle.
  • Page 125 Px12-32 Maintenance Maintenance intervals If installed in an appropriate environment, the drive requires very little maintenance. This table lists the routine maintenance intervals recommended by ABB for ACH580 enclosures in addition to the intervals on page and 108. Maintenance Configuration...
  • Page 126 ACH580 Ultra-Low Harmonic Drives Installation, Operation and Maintenance Manual Complete ACH580 Drive Parameter List 4.53 Event word 1 bit 6 code GROUP 12 20.10 Ext2 in3 source GROUP 1 4.55 Event word 1 bit 7 code 20.21 Direction Standard AI Actual values 4.57 Event word 1 bit 8 code...
  • Page 127 ACH580 Ultra-Low Harmonic Drives Installation, Operation and Maintenance Manual 23.15 Deceleration time 2 GROUP 31 34.17 Timer 3 configuration 36.14 PVL DC voltage at peak 23.23 Emergency stop time 34.18 Timer 3 start time 36.15 PVL speed at peak Fault functions 23.28 Variable slope enable 34.19 Timer 3 duration 36.16 PVL reset date...
  • Page 128 ACH580 Ultra-Low Harmonic Drives Installation, Operation and Maintenance Manual 40.40 Set 1 deadband delay 43.07 Brake chopper run permissive 50.07 FBA A actual 1 type 58.12 CRC errors 40.43 Set 1 sleep level 43.08 Brake resistor thermal tc 50.08 FBA A actual 2 type 58.13 Token counter 40.44 Set 1 sleep delay 43.09 Brake resistor Pmax cont...
  • Page 129 ACH580 Ultra-Low Harmonic Drives Installation, Operation and Maintenance Manual 70.69 Override Log 3 Warning 3 73.36 Output min 80.14 Flow feedback multiplier 99.15 Motor polepairs calculated GROUP 71 73.37 Output max 80.15 Maximum flow 99.16 Motor phase order 73.38 Output freeze enable 80.16 Motor cos ɸ...
  • Page 130 52.07 DATA IN 7 03.05 FLT WORD 1 16.41 PASS CNFRM 52.08 DATA IN 8 03.06 FLT WORD 2 16.42 ABB ACCESS 03.07 FLT WORD 3 52.09 DATA IN 9 16.43 FB LOCK 52.10 DATA IN 10 03.08 WRN WORD 1 16.44 DNLD LOCK...
  • Page 131 ABB Inc. 16250 West Glendale Drive New Berlin, WI 53151 Telephone +1 800 752-0696 +1 262 785-0397 Internet www.abb.com/drives...