Converter modules with electrolytic dc capacitors in the dc link (16 pages)
Summary of Contents for ABB ACH580 Series
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ACH580 Installation, Operation and Maintenance Manual (I, O & M) ACH580-01 HVAC Drives (0.75…250 kW, 1…350 HP) ACH580-BCR/BDR/VCR/VDR E-Clipse Bypass Drives (0.75…150 kW, 1…200 HP) ACH580-PCR/PDR Packaged Drives with Disconnect (0.75…150 kW, 1…200 HP)
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ACH580 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 • Frames R5…R9: Lift the drive with a drive and do maintenance on the drive. If you lifting device.
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ACH580 Installation, Operation and Maintenance Manual • Before you connect voltage to the drive, • Frames R1…R5: 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.
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ACH580 Installation, Operation and Maintenance Manual • Make sure that the voltage between the not be installed). Connections with metal drive input power terminals (L1, L2, L3) screws in these systems can cause danger and the grounding terminal (PE) is close or damage.
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ACH580 Installation, Operation and Maintenance Manual Additional instructions for WARNING! Obey these instructions. If you ignore them, injury or death, or permanent magnet motor drives equipment malfunction can occur, and electromagnetic interference can increase. Safety in installation, start-up and • If you are not a qualified electrical maintenance professional, do not do grounding work.
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ABB and its affiliates are not liable for damages and/or losses related to such General safety in operation security breaches, any unauthorized access,...
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ACH580 Installation, Operation and Maintenance Manual Contents This manual is the Installation, Operation and Maintenance Manual for the ACH580 Drives. Complete technical details are available in the ACH580 Hardware manual, publication number 3AXD50000044839. Complete programming information is available in the ACH580 HVAC control program firmware manual, publication number...
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ACH580 Installation, Operation and Maintenance Manual ACH580-01 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 2. 1.
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ACH580 Installation, Operation and Maintenance Manual Vertically side by side c = 0 Vertical installation side by side - Free space Frame Above (a) Below (b) Between (c) size 7.87 7.87 7.87 7.87 7.87 7.87 7.87 7.87 7.87 7.87 7.87 11.81 7.87 11.81...
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ACH580 Installation, Operation and Maintenance Manual Tools required To install the ACH580 you need the following: • Screwdrivers as appropriate for the mounting hardware used, including a T20 Torx driver for drive cover removal • Wire stripper • Tape measure and/or provided mounting template •...
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ACH580 Installation, Operation and Maintenance Manual 3. Install the drive Installing the drive vertically, frames R1…R4 The figures show frame R3 as an example. 1. Mark the hole locations using the mounting template included in the package. Do not leave the mounting template under the drive. The drive dimensions and hole locations are also shown in the drawings in the ACH580 Hardware manual, publication number...
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ACH580 Installation, Operation and Maintenance Manual 8. Install the cable box to the frame. Position the cable box (8a) and tighten the screws (8b). Note: Install the hood to UL (NEMA) Type 12 drives after you have installed the drive electrically and reinstalled covers.
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ACH580 Installation, Operation and Maintenance Manual IP21 (UL (NEMA) Type 1) 4. Remove the front cover: Remove the fastening screws (4a) with a T20 Torx screwdriver and lift the cover from the bottom upwards (4b) and then to the top side (4c). 5.
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ACH580 Installation, Operation and Maintenance Manual Installing the drive vertically, frames R6…R9 1. Mark the hole locations for the six mounting holes using the mounting template included in the package. Do not leave the mounting template under the drive. The drive dimensions and hole locations are also shown in the drawings in the ACH580 Hardware manual, publication number 3AXD50000044839.
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ACH580 Installation, Operation and Maintenance Manual IP21 (UL (NEMA) Type 1) 6. Remove the front cover: Remove the fastening screws (a), with a T20 Torx screwdriver, move the cover to the top side (b) and then up (c). 7. Attach the cable box to the drive frame. 8.
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4. Install wiring WARNING! Ensure the motor is compatible for use with the ACH580. The ACH580 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.
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ACH580 Installation, Operation and Maintenance Manual Checking the compatibility with IT (ungrounded) and corner-grounded TN systems (North America) WARNING! If the drive will be connected on an IT system (ungrounded or high- resistance-grounded [over 30 ohms]), make sure that neither the EMC filter nor the ground-to-phase varistor are connected, that is, the metal screws must not be installed.
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ACH580 Installation, Operation and Maintenance Manual Ground-to-phase varistor The ground-to-phase varistor is not suitable for use on an IT (ungrounded) system. Disconnect the ground-to-phase varistor by removing the metal screw before connecting the drive to the supply network. See the table on page 18. The VAR screw location is labeled on the drive.
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ACH580 Installation, Operation and Maintenance Manual Power cable terminal and lead-through data Input, motor, resistor and DC cable lead-throughs, maximum wire sizes (per phase) and terminal screw sizes. Cable lead- Grounding L1, L2, L3, T1/U, T2/V, T3/W terminals throughs terminals Frame Max cable Min wire size...
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2) Longer motor cables cause a motor voltage decrease which limits the available motor power. The decrease depends on the motor cable length and characteristics. Contact ABB for more information. ACH580-01 Installation...
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ACH580 Installation, Operation and Maintenance Manual Control cable terminal and lead-through data Imperial control cable lead-throughs, wire sizes and tightening torques (T) are given below. Cable Control cable entries and terminal sizes lead-throughs +24V, DCOM, DGND, EXT. 24V DI, AI/O, AGND, RO, STO Frame terminals terminals...
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ACH580 Installation, Operation and Maintenance Manual UL (NEC) ratings at U = 208 V Output Heat Output ratings Frame Ratings dissipation flow Type size /min 3-phase U = 460 V (380…415 V / 440…480 V) Power ratings are valid at nominal voltage, 460V. ACH580-01-04A6-2 ACH580-01-06A6-2 ACH580-01-07A5-2...
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ACH580 Installation, Operation and Maintenance Manual Output Heat Output ratings Frame Ratings dissipation flow Type size /min ACH580-01-124A-4 1476 ACH580-01-156A-4 1976 ACH580-01-180A-4 2346 ACH580-01-240A-4 3336 ACH580-01-302A-4 4836 ACH580-01-361A-4 6036 ACH580-01-414A-4 6036 UL (NEC) ratings at U = 575 V Output Heat Output ratings Frame...
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114A-2 JJS-150 144A-2 JJS-200 169A-2 JJS-250 211A-2 JJS-300 273A-2 JJS-400 1) ABB does not require Bussmann brand fuses. Fuses which meet the appropriate UL class type, current rating, and are rated at 600V, 200 kA may be used. ACH580-01 Installation...
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180A-4 JJS-300 240A-4 JJS-350 302A-4 JJS-500 361A-4 JJS-500 414A-4 JJS-600 1) ABB does not require Bussmann brand fuses. Fuses which meet the appropriate UL class type, current rating, and are rated at 600V, 200 kA may be used. ACH580-01 Installation...
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Class T 242A-6 JJS-400 Class T 271A-6 JJS-400 Class T 1) ABB does not require Bussmann brand fuses. Fuses which meet the appropriate UL class type, current rating, and are rated at 600V, 200 kA may be used. ACH580-01 Installation...
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ACH580 Installation, Operation and Maintenance Manual External control connection terminals, frames R …R5 The layout of the external control connection terminals of the R1 frame is shown below. Layout of the external control connection terminals is identical in frames R1…R5 but the location of the control board with the terminals is different in frames R3…R5.
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ACH580 Installation, Operation and Maintenance Manual External control connection terminals, frames R6…R9 The layout of the external control connection terminals of frames R6…R9 is shown below. R6…R9 Description Analog inputs and outputs Aux. voltage output Digital inputs Safe torque off connection Connection to embedded EIA-485 fieldbus adapter module Relay output 3...
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ACH580 Installation, Operation and Maintenance Manual Wiring R1…R2 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, option slot 1 modules (fieldbus adapter) may be installed by mounting the module on the control board and tightening the mounting screw, which is also the grounding screw.
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ACH580 Installation, Operation and Maintenance Manual 12. Connect the ground screen pig-tail for Embedded fieldbus, EFB (EIA-485) cables at X5. (Ground only at drive end.) 13. Strip and connect the individual control wires to the drive terminals. Tighten the screws to 0.4 lb-ft (0.5…0.6 N•m). WARNING! To avoid danger or damage to the drive on IT systems and corner grounded TN systems, see section Checking the compatibility with IT (ungrounded)
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ACH580 Installation, Operation and Maintenance Manual Wiring R3 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, option slot 1 modules (fieldbus adapter) may be installed by mounting the module on the control board and tightening the mounting screw, which is also the grounding screw.
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ACH580 Installation, Operation and Maintenance Manual WARNING! To avoid danger or damage to the drive on IT systems and corner grounded TN systems, see section Checking the compatibility with IT (ungrounded) and corner-grounded TN systems (North America) on page 17. Analog Inputs and Outputs Power (Green) and...
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ACH580 Installation, Operation and Maintenance Manual Wiring R4 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, option slot 1 modules (fieldbus adapter) may be installed by mounting the module on the control board and tightening the mounting screw, which is also the grounding screw.
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ACH580 Installation, Operation and Maintenance Manual WARNING! To avoid danger or damage to the drive on IT systems and corner grounded TN systems, see section Checking the compatibility with IT (ungrounded) and corner-grounded TN systems (North America) on page 17. Analog Inputs and Outputs Panel Connector...
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ACH580 Installation, Operation and Maintenance Manual Wiring R5 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, option slot 1 modules (fieldbus adapter) may be installed by mounting the module on the control board and tightening the mounting screw, which is also the grounding screw.
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ACH580 Installation, Operation and Maintenance Manual 12. Strip and connect the individual control wires to the drive terminals. Tighten the screws to 0.4 lb-ft (0.5…0.6 N•m). WARNING! To avoid danger or damage to the drive on IT systems and corner grounded TN systems, see section Checking the compatibility with IT (ungrounded) and corner-grounded TN systems (North America)
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ACH580 Installation, Operation and Maintenance Manual Frame size lb-ft N•m L1, L2, L3 UDC+ and UDC- PE Ground Wiring R6…R9 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.
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ACH580 Installation, Operation and Maintenance Manual WARNING! To avoid danger or damage to the drive on IT systems and corner grounded TN systems, see section Checking the compatibility with IT (ungrounded) and corner-grounded TN systems (North America) on page 17. Analog Inputs and Outputs Panel Connector Power (Green) and...
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ACH580 Installation, Operation and Maintenance Manual Default control connections for the HVAC default Reference voltage and analog inputs and outputs Signal cable shield (screen) 0...10 V DC speed Output frequency/speed reference: 0 to 10 V reference signal AGND Analog input circuit common +10V Reference voltage 10 V DC +10 V...
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ACH580 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) Analog input 1 AGND Analog input circuit common +10V Reference voltage 10 V DC +10 V 4…20 mA temp.
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ACH580 Installation, Operation and Maintenance Manual 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) X2 &...
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ACH580 Installation, Operation and Maintenance Manual 5. Check installation Before applying power, perform the following checks. Check that … The ambient operating conditions meet the specification. If the drive will be connected to a corner-grounded TN system: The internal EMC filter is disconnected.
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ACH580 Installation, Operation and Maintenance Manual 6. Re-install cover(s) Frames R1...R4 1. Reinstall the cover: Put the tabs on the cover top in their counterparts on the housing (1a) and then press the cover (1b) 2. Tighten the retaining screw at the bottom with a screwdriver.
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ACH580 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. The drive provides more precise control and better thermal protection if you enter the rating plate data.
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ACH580 Installation, Operation and Maintenance Manual Operation The ACH580 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. Its function in a given situation is shown by the softkey selection in the bottom left corner of the display.
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ACH580 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.
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ACH580 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.
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ACH580 Installation, Operation and Maintenance Manual Select the localization you want to use and press (Next). Change the units shown on the panel if needed. Go to the edit view of a selected row by pressing Scroll the view with Go to the next view by pressing (Next).
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ACH580 Installation, Operation and Maintenance Manual Check that the motor data is correct. Values are predefined on the basis of the drive size but you should verify that they correspond to the motor. Start with the motor type. Go to the edit view of a selected row by pressing Scroll the view with Motor nominal cos Φ...
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ACH580 Installation, Operation and Maintenance Manual 2. Complete commissioning Default configurations — HVAC and PID Control For more information on Default configurations, see pages 39, and 44. Press the Hand key to start the motor. The Home view is shown on the panel. Select Menu (press on the soft key under “Menu”).
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ACH580 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. Set the reference on the panel.
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ACH580 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.
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ACH580 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).
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ACH580 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.
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ACH580 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.
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ACH580 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. If you need other limits during the ID run you can enter them here.
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See Checking the insulation of the assembly on page 16. 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. ACH580-01 Installation...
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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...
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(none) Temperature above Check ambient conditions. warning limit Check air flow and fan operation. Check heatsink fins for dust pick-up. Thermistor broken Contact an ABB service representative for control board replacement. A4A1 IGBT overtemperature Estimated drive IGBT Check ambient conditions.
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31.22 STO indication run/ stop in the Firmware manual. 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...
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ACH580 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.
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ACH580 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.
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ACH580 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 exceeded internal temperature.
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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.
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ACH580 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.
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ACH580 Installation, Operation and Maintenance Manual Code Warning / Aux. code Cause What to do (hex) A985 External warning 5 Fault in external Check the external device. device 5. (Editable message text) Check setting of parameter 31.09 External event 5 source. Programmable warning: 31.09 External event 5 source...
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ACH580 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. AFF0 Start interlock 3 Start interlock 3 is...
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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.
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ACH580 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.
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ACH580 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. 4210 IGBT overtemperature Estimated drive IGBT...
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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.
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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.
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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.
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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.
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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 frequency representative. exceeded. ACH580-01 Installation...
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ACH580 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.
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ACH580 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 input.
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ACH580 Installation, Operation and Maintenance Manual Code Fault / Aux. code Cause What to do (hex) 9083 External fault 3 Fault in external Check the external device. device 3. (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...
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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.
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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.
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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.
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Main cooling fans are speed-controlled, and the speed of the fan matches the cooling needs. When the drive is stopped, the main fan is kept running at a low speed to cool the control board. Replacement fans are available from ABB. Do not use other than ABB specified spare parts.
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ACH580 Installation, Operation and Maintenance Manual R1...R2 Frame Size R4 To replace the fan: 1. Remove power from drive. 2. Pry the fan assembly off the drive frame with a screwdriver and pull it out. 3. Disconnect the fan cable. 4.
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Auxiliary cooling fan replacement Auxiliary cooling fans are not speed-controlled and run all the time that the control board is powered. Replacement fans are available from ABB. Do not use other than ABB specified spare parts. IP21/UL (NEMA) Type 1 and IP55/UL (NEMA) Type 12 Frame Sizes R5…R9 To replace the fan: 1.
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ACH580 Installation, Operation and Maintenance Manual IP55/UL (NEMA) Type 12 Frame Sizes R1…R2 To replace the fan: WARNING! Obey the Safety instructions on page 2. Ignoring the instructions can cause physical injury or death, or damage to the equipment. 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.
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ACH580 Installation, Operation and Maintenance Manual IP55/UL (NEMA) Type 12 Frame Size R3 To replace the fan: WARNING! Obey the Safety instructions on page 2. Ignoring the instructions can cause physical injury or death, or damage to the equipment. 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.
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ACH580 Installation, Operation and Maintenance Manual IP55/UL (NEMA) Type 12 Frame Size R4 To replace the fan: 1. Remove power from drive. 2. Remove the control panel: Press the retaining clip at the top and pull it forward. 3. Remove the front cover: Loosen the retaining screws at the bottom left and pull the cover outwards from the bottom and then up.
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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.
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ACH580 Installation, Operation and Maintenance Manual ACH580 E-Clipse Bypass 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.
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ACH580 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.
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ACH580 Installation, Operation and Maintenance Manual Connection diagrams – Vertical E-Clipse Bypass ACH580 Vertical E-Clipse Bypass units are configured for wiring access from the bottom only. The following figures show the layout and wiring connection points. For drive control wiring see pages 29-41. Maintain appropriate separation of control and power wires.
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ACH580 Installation, Operation and Maintenance Manual Drive Control Panel ACH580 Drive E-Clipse Bypass Control Panel E-Clipse Bypass Control Board Terminals (X2) Disconnect Switch or Circuit Breaker Input Ground Lug Motor Terminals Motor Ground Input Terminals Service Switch (Optional) Fuses V3/V4 (Vx1-3, Vx1-4) ACH580 E-Clipse Bypass...
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ACH580 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 (NEMA) Type 1 and 12) and from the bottom (for UL (NEMA) Type 3R). The following figures show the layout and wiring connection points.
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ACH580 Installation, Operation and Maintenance Manual User Power Cable Guides ACH580 Drive E-Clipse Bypass Control Board Terminals (X2) Disconnect Switch or Circuit Breaker Input Terminals Input Ground Motor Ground Motor Terminals MOV and Line Reactor (Optional) Fuses Service Switch (Optional) (Bx1-2, Bx12-2) ACH580 E-Clipse Bypass...
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ACH580 Installation, Operation and Maintenance Manual Motor Ground Lug Input Ground Lug Motor Terminals Fuses ACH580 Drive Service Switch (Optional) Input Terminals Disconnect Switch or Circuit Breaker E-Clipse Bypass Control Board Terminals X2 600V, 41A - 77A (Bx1-3, Bx12-3*) *Hood and filter kit not shown ACH580 E-Clipse Bypass...
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ACH580 Installation, Operation and Maintenance Manual Motor Ground Lug Input Ground Lug ACH580 Drive Motor Terminals Input Terminals Disconnect Switch or Circuit Breaker E-Clipse Bypass Control Board Terminals X2 Fuses Service Switch (Optional) Units above 77A (Bx1-3, Bx12-3*) *Hood and filter kit not shown ACH580 E-Clipse Bypass...
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ACH580 Installation, Operation and Maintenance Manual RHTR Temperature Heater ON Heater OFF HI/LO Jumper (X1) Temperature Temperature Default Setting 14.4 °C 21.4 °C (X1 jumper in LO 58 °F 70.5 °F position) Alternate Setting 17.8 °C 24.4 °C (X1 jumper in HI 64 °F 76.5 °F E-Clipse Bypass...
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ACH580 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. Also see Connection diagrams – Vertical E-Clipse Bypass page 91.
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ACH580 Installation, Operation and Maintenance Manual Install the control wiring Connect control wiring to terminal block X1 on the ACH580 control board and to terminal block X2 on the E-Clipse Bypass control board. For more information on these connections, refer to the following: •...
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ACH580 Installation, Operation and Maintenance Manual Drive’s power connection terminals The following tables list the maximum power and motor cable terminal sizes for connections to an input circuit breaker or disconnect switch, a motor terminal block and ground lugs. The tables also list that should be applied when tightening the torque terminals.
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ACH580 Installation, Operation and Maintenance Manual Nominal Output Maximum Wire Size and Terminal Torque Ratings Frame Type Code Drive Package Size Circuit Disconnect Motor Ground Current Power Breaker Switch Termination Lugs 575 Volts ACH580-VxR-02A7-6 ACH580-VxR-03A9-6 ACH580-VxR-06A1-6 55 in-lbs 11-13 in-lbs 35 in-lbs ACH580-VxR-09A0-6 ACH580-VxR-011A-6...
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ACH580 Installation, Operation and Maintenance Manual Nominal Output Maximum Wire Size and Terminal Torque Ratings Base Drive Package Circuit Ground Circuit Disconnect Motor Ground Drive Current Power Breaker Disconnect Motor Lugs Type Code Breaker Switch Terminals Lugs Frame Switch Terminals UL (NEMA) UL (NEMA) Size...
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ACH580 Installation, Operation and Maintenance Manual Nominal Output Maximum Wire Size and Terminal Torque Ratings Base Drive Package Circuit Ground Circuit Disconnect Motor Ground Drive Current Power Breaker Disconnect Motor Lugs Type Code Breaker Switch Terminals Lugs Frame Switch Terminals UL (NEMA) UL (NEMA) Size...
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Bypass with the circuit breaker option is suitable for use on a circuit capable of delivering not more than 100,000 RMS symmetrical amperes. When connected to a 600V power source ABB E-Clipse units provided with a circuit breaker, VCR and BCR configurations, are suitable for use on a circuit capable of delivering not more than 10,000 RMS symmetrical amperes.
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ACH580 Installation, Operation and Maintenance Manual 460 Volt fuses for vertical enclosures Nominal Output Internal Drive External Fuse for Ratings Fuse Rating Disconnect Option Base Drive Type Code Drive Package Frame Current Power Class Current Class Current Size Rating Rating 460 Volts ACH580-VxR-02A1-4 Class CC...
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ACH580 Installation, Operation and Maintenance Manual 208/230 Volt fuses for box enclosures Nominal Output Internal Drive External Fuse for Ratings Fuse Rating Disconnect Option Base Drive Type Code Drive Package Frame Current Power Class Current Class Current Size Rating Rating 208/230 Volts ACH580-BxR-04A6-2 Class CC...
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ACH580 Installation, Operation and Maintenance Manual Nominal Output Internal Drive External Fuse for Ratings Fuse Rating Disconnect Option Base Drive Type Code Drive Package Frame Current Power Size Class Current Class Current Rating Rating ACH580-BxR-065A-4 Class T Class J 100A ACH580-BxR-077A-4 Class T 100A...
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ACH580 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 E-CLIPSE BYPASS CONTROL BOARD...
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ACH580 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.
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ACH580 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.
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ACH580 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.
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ACH580 Installation, Operation and Maintenance Manual Parameter Value 58.01 – Protocol 1 – Modbus RTU 58.04 – Baud rate 6 – 76.8kbits/s 58.05 – Parity 2 – 8 EVEN 1 58.25 – Control profile 5 – DCU profile 58.34 – Word order 0 –...
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ACH580 Installation, Operation and Maintenance Manual • Under normal conditions (motor connected) pressing the Hand key on the bypass control panel causes the bottom line on the E-Clipse Bypass display to indicate “Hand #A Run”. • OFF key on the bypass control panel causes the bottom line on the E-Clipse Bypass display to indicate “Off Stop”.
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ACH580 Installation, Operation and Maintenance Manual If the drive does not operate according to these steps, refer to the ACH580 Hardware manual. 3. Check jumpers and switches The settings described in this section are factory set and, for most situations, do not require adjustment.
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ACH580 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 (NEMA) Type 1, UL (NEMA) Type 12 or UL (NEMA) Type 3R package with a bypass motor starter. The ACH580 with E-Clipse Bypass provides: •...
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ACH580 Installation, Operation and Maintenance Manual The following shows the front view of the ACH580 Vertical E-Clipse Bypass configuration and identifies the major components. Drive Control Panel ACH580 Drive E-Clipse Bypass Control Panel E-Clipse Bypass Operating Handle for Disconnect Switch or Circuit Breaker V1-V4 (Vx1-1, Vx1-2, Vx1-3, Vx1-4)
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ACH580 Installation, Operation and Maintenance Manual E-Clipse Bypass Control Panel (Left) and Drive Control Panel (Right) behind door. Operating Handle for Disconnect Switch or Circuit Breaker B1/B2 (Bx3R-1, Bx3R-2) The following is a typical power diagram. Drive with E-Clipse Bypass Disconnect Switch Drive Output Bypass...
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ACH580 Installation, Operation and Maintenance Manual Bypass control The bypass control panel features: “Ready Indication” LCD Display (Display Illuminated) Down E-CLIPSE BYPASS CONTROL Enter Escape ENTER Enabled LED ENABLED ON/Hand Key Drive and Bypass Selected/Faulted LEDs HAND SELECTED OFF/Reset Key FAULTED DRIVE BYPASS...
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ACH580 Installation, Operation and Maintenance Manual Drive Selected LED The Drive Selected LED is illuminated green when the drive has been selected as the power source for the motor and no drive fault is present. Bypass Selected LED The Bypass Selected LED is illuminated or flashes green when the bypass has been selected as the power source for the motor and no bypass fault is present.
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ACH580 Installation, Operation and Maintenance Manual Auto Key The Auto Key selects the Auto Start contact or serial communications as the means for starting and stopping the motor in the bypass mode. Hand Key The Hand Key can be used to manually start the motor when the bypass has been selected as the power source for the motor.
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ACH580 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 ENTER STARTUP PARAMS...
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ACH580 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 ENTER 1602 PERMISSIVE Parameter Edit mode. Press ESC to return to the listing of *16 SYSTEM CTRL Parameter Groups, and again to return to the Main Menu.
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ACH580 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 on Change RBCU abnormal current RBCU feedback when neither contactor should be energized 3002 BYP CNTACT...
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ACH580 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 connector only if the drive is RBCU unit (refer to is firmly seated in RBCU controlling the motor page...
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ACH580 Installation, Operation and Maintenance Manual Fault Fault Name In Fault Possible Cause Corrective Action Code Panel 3013 DRIVE 1ST START Fault generated if Run bypass unit in drive attempting to close the mode before attempting bypass contactor with bypass mode out running the bypass in drive mode first.
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Bad RBCU greater than allowable values 3027 INVALID SUB ASM Contactor assembly as RBCU unit from a Contact ABB at recorded in the RBCU different size bypass 1-800-752-0696 unit does not match used to replace a option 1 drive information defective RBCU.
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SFLASH CORRUPT Internal checksum error NA Cycle power Replace RBCU Upgrade firmware 3102 PMAP FILE Parameter file is corrupt Cycle Power Contact ABB with information that preceded fault 3201 T1 OVERLOAD T1 program cycle is Contact ABB with overloaded information that...
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ACH580 Installation, Operation and Maintenance Manual Fault Fault Name In Fault Possible Cause Corrective Action Code Panel 3207 UNKNOWN Replace RBCU or load BYPASS most current firmware Contact ABB at 1-800-752-0696 option 1 Replace RBCU or load most current firmware ACH580 E-Clipse Bypass...
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ACH580 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 drive mode.
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ACH580 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” bypass can not properly control the drive.
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ACH580 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 155 VAC within a few...
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ACH580 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 Bad 24v supply...
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ACH580 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/or CLOSED INTERLOCK 2) have been applied, or if they are missing RUN PERMISSIVES? OPEN...
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ACH580 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 changed only when system is not started.
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ACH580 Installation, Operation and Maintenance Manual ACH580-PCR/PDR Installation This information is unique to ACH580 input disconnect configurations (PCR or PDR). 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.
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ACH580 Installation, Operation and Maintenance Manual Connection diagrams – Vertical Packaged Drive with input disconnect ACH580 Vertical Packaged Drive units are configured for wiring access from the bottom only. The following figures show the layout and wiring connection points. For drive control wiring see pages 29-41.
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ACH580 Installation, Operation and Maintenance Manual ACH580 Drive Motor Terminals Motor Ground Lug Fuses Disconnect Switch or Circuit Breaker Input Terminals Input Ground Lug P3/P4 (Px1-3, Px12-3, Px1-4, Px12-4) ACH580-PCR/PDR...
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ACH580 Installation, Operation and Maintenance Manual Connection diagrams – Box Packaged Drive with input disconnect ACH580 Vertical Packaged Drive units are configured for wiring access from the top (for UL (NEMA) Type 1 and 12) and from the bottom (for UL (NEMA) Type 3R). The following figures show the layout and wiring connection points.
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ACH580 Installation, Operation and Maintenance Manual User Power Cable Guides ACH580 Drive Disconnect Switch or Circuit Breaker Motor Input Terminals Ground Lug Motor Input Ground Lug Terminals MOV and Line Reactor (Optional) Fuses (PxB1-2, PxB12-2) ACH580-PCR/PDR...
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ACH580 Installation, Operation and Maintenance Manual Motor Ground Lug Input ACH580 Drive Ground Lug User Power Cable Guide Input Terminals Disconnect Switch or Motor Circuit Terminals Breaker User Power Cable Fuses Guide Motor Ground Lug (PxB1-3, PxB12-3) ACH580-PCR/PDR...
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ACH580 Installation, Operation and Maintenance Manual RHTR Temperature Heater ON Heater OFF HI/LO Jumber (X1) Temperature Temperature Default Setting 14.4 °C 21.4 °C (X1 jumper in LO 58 °F 70.5 °F position) Alternate Setting 17.8 °C 24.4 °C (X1 jumper in HI 64 °F 76.5 °F position)
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ACH580 Installation, Operation and Maintenance Manual Power connection terminals The following tables show maximum wire size and required tightening torque for incoming power, grounding and motor terminals. 1)“PxR” represents both PCR and PDR. Output 208/230 Volt Maximum Power Wiring Data Ratings Base Circuit...
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ACH580 Installation, Operation and Maintenance Manual 1) “PxR” represents both PCR and PDR. Output 460 Volt Maximum Power Wiring Data Ratings Base Circuit Ground Circuit Disconnect Ground Drive Breaker Disconnec Lugs Breaker Switch Lugs Frame t Switch Motor Type Code Size UL (NEMA) Terminals...
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ACH580 Installation, Operation and Maintenance Manual 575 Volt Output Range Maximum Power Wiring Data Base Circuit Ground Drive Breaker Circuit Disconnect Disconnect Ground ACH580 Lugs Frame Breaker UL Switch UL Switch Lugs 1, 2 Type Code Motor UL (NEMA) Size (NEMA) (NEMA) (NEMA) Type...
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ACH580 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 the specified external fuses to provide short circuit and ground fault protection for the motor in the bypass mode.
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ACH580 Installation, Operation and Maintenance Manual 460 Volt fuses for packaged drive Nominal Output 480 Volt Range Internal Drive External Fuse for Base Fuse Rating Disconnect Option Drive Package Drive Current Power Frame Type Code Size Current Max Current Class Class Rating Rating...
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ACH580 Installation, Operation and Maintenance Manual Nominal Output 575 Volt Range Internal Drive External Fuse for Base Fuse Rating Disconnect Option Drive Package Drive Current Power Frame 1, 2 Type Code Size Current Max Current Class Class Rating Rating ACH580-PxR-052A-6 Class T ACH580-PxR-062A-6 Class T...
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ACH580 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 with Input Disconnect is an ACH580 AC adjustable frequency drive packaged with an input disconnect switch or circuit breaker, and with a door interlocked, external operating handle.
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ACH580 Installation, Operation and Maintenance Manual The following shows the front view of the ACH580 Box Packaged Drive configurations and identifies the major components. Drive Control Panel Operating Handle for Disconnect Switch or Circuit Breaker PB1/PB2 (PxB1-1, PxB12-1, PxB1-2, PxB12-2) (PxB12-3)* *Hood and filter kit not shown Drive Control...
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ACH580 Installation, Operation and Maintenance Manual 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 81. Maintenance Configuration...
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ACH580 Installation, Operation and Maintenance Manual Complete ACH580 Drive Parameter List GROUP 1 GROUP 5 12.27 AI2 min 21.04 Emergency stop mode 12.28 AI2 max 21.05 Emergency stop source Actual values Diagnostics 12.29 AI2 scaled at AI2 min 21.06 Zero speed limit 1.01 Motor speed used 5.01...
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ACH580 Installation, Operation and Maintenance Manual GROUP 25 31.20 Earth fault 34.38 Timer 10 configuration 36.45 AL2 50 to 60% 31.21 Supply phase loss 34.39 Timer 10 start time 36.46 AL2 60 to 70% Speed control 31.22 STO indication run/stop 34.40 Timer 10 duration 36.47 AL2 70 to 80% 25.01 Torque reference speed...
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ACH580 Installation, Operation and Maintenance Manual 40.73 Set 1 compensated output 1 45.10 Total saved CO2 GROUP 51 58.30 EFB status word transparent 40.74 Set 1 compensation input 2 45.11 Energy optimizer FBA A settings source 40.75 Set 1 compensated output 2 45.12 Energy tariff 1 51.01 FBA A type 58.31 EFB act1 transparent source...
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ACH580 Installation, Operation and Maintenance Manual 71.34 Derivation time 74.22 Internal setpoint 2 96.11 User set save/load 71.35 Derivation filter time 74.23 Internal setpoint 3 96.12 User set I/O mode in1 71.36 Output min 74.26 Setpoint min 96.13 User set I/O mode in2 71.37 Output max 74.27 Setpoint max 96.16 Unit selection...
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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...
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ABB Inc. 16250 West Glendale Drive New Berlin, WI 53151 Telephone +1 800 752-0696 +1 262 785-0397 Internet www.abb.com/drives...