106 Electrical Installation: Wiring The Modules

106 Electrical installation
R6…R9
2
7
 Wiring the modules

See the appropriate optional module manual for specific installation and wiring
instructions.
Electrical installation 107
Reinstalling covers
 Reinstalling cover, frames R0…R3
1. Reinstall the cover: Put the tabs on the cover top in their counterparts on the
housing (1a) and the press the cover (1b).
2. Tighten the retaining screw at the bottom with a screwdriver.
1a
1b
 Reinstalling covers, frame R5

1. Install the cover of the cable entry box.
2. Tighten the two retaining screws with a screwdriver.
3. Reinstall the module cover. Put the tabs on the cover top in their counterparts on
the housing and then press the cover.
4. Tighten the two retaining screws with a screwdriver.
1
Electrical installation 109
 Reinstalling side plates and covers, frames R6…R9

1. Reinstall the side plates of the cable entry box. Tighten the retaining screws with a
screwdriver.
2. Slide the cover of the cable entry box on the module from below until the cover
snaps into place.
3. Reinstall the module cover. Tighten the two retaining screws with a screwdriver.
1 2
3
Connecting a PC
To be able to connect a PC to the drive, you need an assistant control panel.
Connect a PC to the drive with a USB data cable (USB Type A <-> USB Type Mini-B)
as follows:
1. Lift the USB connector cover from bottom upwards.
2. Put the USB cable Mini-B plug in the control panel USB connector.
3. Put the USB cable A-plug in the USB connector of the PC (3a). The panel
displays text “USB connected” (3b).
Note: Panel keys cannot be used when a USB data cable is connected to the panel.
2
3a
1 2
For information on using the Drive composer PC tool, see Drive composer PC tool
user's manual (3AUA0000094606 [English]).
Installation checklist 111
7
Installation checklist
Contents of this chapter
This chapter contains an installation checklist which you must complete before you
start up the drive.
Warnings
WARNING! Obey the instructions in chapter Safety instructions on page 11. If

you ignore them, injury or death, or damage to the equipment can occur.
Checklist
Do the steps in section Precautions before electrical work on page 14 before you start
the work. Go through the checklist together with another person.
Check that …
The ambient operating conditions meet the specification in section Ambient conditions
on page 152.
If the drive will be connected to an IT (ungrounded) or corner-grounded TN supply

network: Internal EMC filter has been disconnected. See section Checking the
compatibility with IT (ungrounded) and corner-grounded TN systems on page 71.
If the drive has been stored over one year: The electrolytic DC capacitors in the DC
link of the drive have been reformed. See section Capacitors on page 122.
There is an adequately sized protective earth (ground) conductor between the drive
and the switchboard.
112 Installation checklist
Check that …
There is an adequately sized protective earth (ground) conductor between the motor
and the drive.
All protective earth (ground) conductors have been connected to the appropriate
terminals and the terminals have been tightened (pull conductors to check).
The supply voltage matches the nominal input voltage of the drive. Check the type
designation label.
The input power cable has been connected to appropriate terminals, the phase order
is right, and the terminals have been tightened. (Pull conductors to check.)
Appropriate supply fuses and disconnector have been installed.
The motor cable has been connected to appropriate terminals, the phase order is right,
and the terminals have been tightened. (Pull conductors to check.)
The brake resistor cable (if present) has been connected to appropriate terminals, and
the terminals have been tightened. (Pull conductors to check.)
The motor cable (and brake resistor cable, if present) has been routed away from other
cables.
The control cables (if any) have been connected to the control board.
If a drive bypass connection will be used: The direct-on-line contactor of the motor and
the drive output contactor are either mechanically or electrically interlocked (cannot be
closed simultaneously).
There are no tools, foreign objects or dust from drilling inside the drive.
Drive and motor connection box covers are in place.
The motor and the driven equipment are ready for start-up.
Maintenance and hardware diagnostics 113
8
Maintenance and hardware
diagnostics
The chapter contains preventive maintenance instructions and LED indicator
descriptions.
Maintenance intervals
If installed in an appropriate environment, the drive requires very little maintenance.
Section Preventive maintenance intervals on page 114 lists the routine maintenance
intervals recommended by ABB for customer maintenance tasks.
The 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. Consult
your local ABB Service representative for more details on the maintenance. On the
Internet, go to http://www.abb.com/drives. See the maintenance instructions in this
chapter.
114 Maintenance and hardware diagnostics
 Preventive maintenance intervals

The table below shows the intervals for the preventive maintenance tasks allowed for
the customer. For other maintenance tasks, consult your local ABB Service
representative, or see the complete maintenance schedule on the Internet.
Years from start-up
Maintenance task/object
0 1 2 3 4 5 6 7 8 9 10 11 12 …
Cooling fans
Main cooling fan (R0… R9). See R R
(R) (R)
page 116. (R) (R)
Auxiliary cooling fan for circuit R R R R
boards (R6…R9). See page 121. (R) (R) (R) (R)
Batteries
Control panel battery. See page R
123. (R)
Connections and environment
Quality of supply voltage O O O O O O O O O O O O O
Improvements
I I I I
Based on product notes
(I) (I) (I) (I)
Spare parts
I I I I I I I I I I I I I
Spare part stock
(I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I)
Reforming of DC circuit capacitors
(spare modules and spare O O O O O O O O O O O O O
capacitors). See page 122.
Other useful tasks
Checking tightness of cable and
I I I I I I I I I I I I I
busbar terminals. Tightening if
(I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I)
needed.
Checking ambient conditions I I I I I I I I I I I I I
(dustiness, moisture, temperature) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I) (I)
Cleaning the heatsink. See page O O O O O O O O O O O O O
115. (O) (O) (O) (O) (O) (O) (O) (O) (O) (O) (O) (O) (O)
4FPS10000309652.xlsx B
Symbols
I Inspection, maintenance action if needed
(I) Inspection in harsh conditions*, maintenance action if needed
R Replacement
(R) Replacement in harsh conditions*
O Other work (commissioning, tests, measurements, etc.)
* Ambient temperature constantly over 40 °C, especially dusty or humid ambient conditions,
cyclic heavy load, or continuous nominal (full) load.
To maintain the best possible performance and reliability of the drive, inspect the drive
annually. Contact ABB Service at least once in three years for replacement of aging
components.
Note: Recommended maintenance intervals and component replacements are based on
operation in specified ambient conditions.
Heatsink
The drive heatsink fins pick up dust from the cooling air. The drive runs into
overtemperature warnings and faults if the heatsink is not clean. When necessary,
clean the heatsink as follows.
WARNING! Obey the instructions in chapter Safety instructions on page 11.

Ignoring the instructions can cause physical injury or death, or damage to the
equipment.
WARNING! Use a vacuum cleaner with antistatic hose and nozzle. Using a
normal vacuum cleaner creates static discharges which can damage circuit
boards.
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. See section Precautions before
electrical work on page 14 before you start the work.
2. Remove the cooling fan(s). See section Fans on page 116.
3. Blow clean, dry and oil free compressed air from bottom to top and
simultaneously use a vacuum cleaner at the air outlet to trap the dust.
Note: If there is a risk of dust entering adjoining equipment, perform the cleaning
in another room.
4. Reinstall the cooling fan(s).
Fans
See section Maintenance intervals on page 113 for the fan replacement interval in
average operation conditions. Parameter 05.04 Fan on-time counter indicates the
running time of the cooling fan. Reset the counter after a fan replacement.
In a speed-controlled fan, the speed of the fan matches the cooling needs. This
increases the life span of the fan.
Replacement fans are available from ABB. Do not use other than ABB specified
spare parts.
 Replacing the cooling fan, frames R0…R3

equipment.
2. Lever the fan assembly off the drive frame with for example a screwdriver (2a)
and pull out the fan assembly (2b).
R0 R1…R2 R3
2a 2a
2a
R0 R1…R2 R3
2b
2b 2b
3. Install the fan assembly in reverse order.

 Replacing the cooling fan, frame R5

equipment.
2. Lift the fan assembly upwards from the front edge (2a) and remove the assembly
(2b).
3. Install the new fan assembly in reverse order.
2b
2a
 Replacing the main cooling fan, frames R6…R8

equipment.
2. Undo the two mounting screws of the fan mounting plate at the bottom of the
drive.
3. Pull the fan mounting plate down from the side edge.
4. Unplug the fan power supply wires from the drive.
5. Lift the fan mounting plate off.
6. Remove the fan from the mounting plate.
7. Install the new fan in reverse order.
6
3
2
 Replacing the main cooling fans, frame R9

equipment.
2. Undo the two mounting screws of the fan mounting plate.
3. Turn the mounting plate downwards.
4. Unplug the fan power supply wires from the drive.
5. Remove the fan mounting plate.
6. Remove the fans by undoing the two mounting screws.
7. Install the new fans in reverse order.
4
3
2
6
2 6
 Replacing the auxiliary cooling fan, frames R6…R9

equipment.
2. Remove the front cover (see page 52).
3. Unplug fan power supply wires from the drive.
4. Release the retaining clips.
5. Lift the fan off.
6. Install the new fan in reverse order. Make sure that the arrow on the fan points up.
4
Capacitors
The drive intermediate DC circuit employs several electrolytic capacitors. Their
lifespan depends on the operating time of the drive, loading and ambient
temperature. Capacitor life can be prolonged by lowering the ambient temperature.
Capacitor failure is usually followed by damage to the drive and an input cable fuse
failure, or a fault trip. Contact ABB if capacitor failure is suspected. Replacements are
available from ABB. Do not use other than ABB specified spare parts.
 Reforming the capacitors

The capacitors must be reformed if the drive has been stored for a year or more. See
section Type designation label on page 33 for how to find out the manufacturing date
from the serial number.
For information on reforming the capacitors, see Converter module capacitor
reforming instructions (3BFE64059629 [English]), available on the Internet (go to
http://www.abb.com and enter the code in the Search field).
Control panel
 Cleaning the control panel
Use a soft damp cloth to clean the control panel. Avoid harsh cleaners which could
scratch the display window.
 Replacing the battery in the assistant control panel

A battery is only used in assistant control panels that have the clock function. The
battery keeps the clock operating in memory during power interruptions.
The expected life for the battery is greater than ten years.
Note: The battery is NOT required for any control panel or drive functions, except the
clock.
1. Remove the control panel from the drive. See section Control panel on page 32.
2. To remove the battery, use a coin to rotate the battery cover on the back of the
control panel.
3. Replace the battery with type CR2032. Dispose the old battery according to local
disposal rules or applicable laws.
CR2032
2
LEDs
 Drive LEDs
There is a green POWER and a red FAULT LED on the front of the drive. They are
visible through the panel cover but invisible if a control panel is attached to the drive.
The table below describes the drive LED indications.
Drive LEDs POWER and FAULT, on the front of the drive, under the control panel / panel
cover
If a control panel is attached to the drive, switch to remote control (otherwise a fault will be
generated), and then remove the panel to be able to see the LEDs
LEDs off LED lit and steady LED blinking
No power Green Power supply on the board Green Blinking:
(POWER) OK (POWER) Drive in an alarm state
Blinking for one second:
Drive selected on the
control panel when multiple
drives are connected to the
same panel bus.
Red Active fault in the drive. To Red Active fault in the drive. To
(FAULT) reset the fault, press (FAULT) reset the fault, switch off the
RESET from the control drive power.
panel or switch off the drive
power.
 Assistant panel LEDs

The assistant control panel has one LED. The table below describes the control panel
LED indications. For more information see ACS-AP-x assistant control panels user’s
manual (3AUA0000085685 [English]).
Assistant control panel LED, at the left edge of the control panel
LED off LED lit and steady LED blinking/flickering
Panel has Green Drive functioning normally. Green Blinking:
no power. Connection between the Active warning in the drive
drive and control panel may Flickering:
be faulty or lost, or the Data transferred between
panel and drive may be the PC tool and drive
incompatible. Check the through the USB
control panel display. connection of the control
panel
Red Check the display to see Red Active fault in the drive.
where the fault is. To reset the fault, cycle the
• Active fault in the drive. drive power.
Reset the fault.
• Active fault in another
drive in the panel bus.
Switch to the drive in
question and check and
reset the fault.
Technical data 127
9
Technical data
The chapter contains the technical specifications of the drive, for example ratings,
sizes and technical requirements as well as provisions for fulfilling the requirements
for CE, UL and other approval marks.
128 Technical data
Ratings
 IEC ratings
Type Input Max. Output ratings Frame
ACS580 rating current
Nominal use Light- duty use Heavy-duty use size
-01-
I1N Imax IN PN I Ld PLd IHd PHd
A A A kW A kW A kW
3-phase UN = 400 V (380…415 V)
02A6-4 2.6 3.2 2.6 0.75 2.5 0.75 1.8 0.55 R0
03A3-4 3.3 4.7 3.3 1.1 3.1 1.1 2.6 0.75 R0
04A0-4 4.0 5.9 4.0 1.5 3.8 1.5 3.3 1.1 R0
05A6-4 5.6 7.2 5.6 2.2 5.3 2.2 4.0 1.5 R0
07A2-4 7.2 10.1 7.2 3.0 6.8 3.0 5.6 2.2 R1
09A4-4 9.4 13.0 9.4 4.0 8.9 4.0 7.2 3.0 R1
12A6-4 12.6 14.1 12.6 5.5 12.0 5.5 9.4 4.0 R1
017A-4 17.0 22.7 17.0 7.5 16.2 7.5 12.6 5.5 R2
025A-4 25.0 30.6 25.0 11.0 23.8 11.0 17.0 7.5 R2
032A-4 32.0 44.3 32.0 15.0 30.4 15.0 24.6 11.0 R3
038A-4 38.0 56.9 38.0 18.5 36.1 18.5 31.6 15.0 R3
045A-4 45.0 67.9 45.0 22.0 42.8 22.0 37.7 18.5 R3
061A-4 61 76 61 30 58 30 45 22 R5
072A-4 72 104 72 37 68 37 61 30 R5
087A-4 87 122 87 45 83 45 72 37 R5
105A-4 105 148 105 55 100 55 87 45 R6
145A-4 145 178 145 75 138 75 105 55 R6
169A-4 169 247 169 90 161 90 145 75 R7
206A-4 206 287 206 110 196 110 169 90 R7
246A-4 246 350 246 132 234 132 206 110 R8
293A-4 293 418 293 160 278 160 2461) 132 R8
363A-4 363 498 363 200 345 200 293 160 R9
430A-4 430 617 430 250 400 200 3632) 200 R9
3AXD00000586715.xls F
See definitions and notes on page 129.

Technical data 129
 NEMA ratings
Type Input Output ratings Frame
ACS580 rating Nominal use Heavy-duty use size
-01-
I1N I Ld PLd I Hd PHd
A A hp A hp
3-phase UN = 460 V (440…480 V)
02A6-4 2.1 2.1 1.0 1.6 0.75 R0
03A3-4 3.0 3.0 1.5 2.1 1.0 R0
04A0-4 3.4 3.4 2.0 3.0 1.5 R0
05A6-4 4.8 4.8 3.0 3.4 2.0 R0
07A2-4 6.0 6.0 3.0 4.0 3.0 R1
09A4-4 7.6 7.6 5.0 4.8 3.0 R1
12A6-4 11.0 11.0 7.5 7.6 5.0 R1
017A-4 14.0 14.0 10.0 11.0 7.5 R2
025A-4 21.0 21.0 15.0 14.0 10.0 R2
032A-4 27.0 27.0 20.0 21.0 15.0 R3
038A-4 34.0 34.0 25.0 27.0 20.0 R3
045A-4 40.0 40.0 30.0 34.0 25.0 R3
061A-4 52 52 40 40 30 R5
072A-4 65 65 50 52 40 R5
087A-4 77 77 60 65 50 R5
105A-4 96 96 75 77 60 R6
145A-4 124 124 100 96 75 R6
169A-4 156 156 125 124 100 R7
206A-4 180 180 150 156 125 R7
246A-4 240 240 200 180 150 R8
293A-4 260 260 200 2401) 150 R8
363A-4 361 361 300 302 250 R9
430A-4 414 414 350 3612) 300 R9
3AXD00000586715.xls F
 Definitions
UN Nominal supply voltage
I1N Nominal input current. Continuous rms input current (for dimensioning cables
and fuses).
Imax Maximum output current. Available for two seconds at start.
IN Nominal output current. Maximum continuous rms output current allowed (no
overload).
PN Nominal power of the drive. Typical motor power (no overloading). The kilowatt
ratings apply to most IEC 4-pole motors. The horsepower ratings apply to most
NEMA 4-pole motors.
ILd Maximum current with 110% overload, allowed for one minute every ten minutes
PLd Typical motor power in light-duty use (110% overload)
130 Technical data
IHd Maximum current with 150% overload, allowed for one minute every ten minutes
1)
Maximum current with 130% overload, allowed for one minute every ten
minutes
2)
Maximum current with 125% overload, allowed for one minute every ten
minutes
PHd Typical motor power in heavy-duty use (150% overload)
 Sizing
Drive sizing is based on the rated motor current and power. To achieve the rated
motor power given in the table, the rated current of the drive must be higher than or
equal to the rated motor current. Also the rated power of the drive must be higher
than or equal to compared to the rated motor power. The power ratings are the same
regardless of the supply voltage within one voltage range.
Note: For frames R0…R3 the ratings apply at ambient temperature of 50 °C (122 °F)
for IN. For frames R5…R9, the ratings apply at ambient temperature of 40 °C (104 °F)
for IN. Above theses temperatures derating is required.
The DriveSize dimensioning tool available from ABB is recommended for selecting
the drive, motor and gear combination.
Derating
The load capacity (IN, ILd, IHd; note that Imax is not derated) decreases for certain
situations, as defined below. In such situations, where full motor power is required,
oversize the drive so that the derated value provides sufficient capacity.
Note: If several situations are present at a time, the effect of derating for each
situation is cumulative.
Example:
If your application requires continuous 12.0 A of motor current (IN) at 8 kHz switching frequency,
the supply voltage is 400 V and the drive is situated at 1500 m, calculate the appropriate drive
size requirement as follows:
Switching frequency derating (page 134):
The minimum size required is IN = 12.0 A / 0.66 = 18.18 A,
where 0.66 is the derating for 8 kHz switching frequency (frames R0…R3).
Altitude derating (page 134):
The derating factor for 1500 m is 1 - 1/10 000 m · (1500 - 1000) m = 0.95.
The minimum size required becomes then IN = 18.18 A / 0.95 = 19.14 A.
Referring to IN in the ratings tables (starting from page 128), drive type ACS580-01-025A-4
exceeds the IN requirement of 19.24 A.
Technical data 131
 Ambient temperature derating, IP21

Frame size Temperature
range
R0…R3 up to +50 °C No derating
up to +122 °F
R5…R9 up to +40 °C No derating
up to +104 °F
+40…+50 °C Derate 1% for every 1 °C (1.8 °F)
+104…+122 °F
The output current is calculated by multiplying the current given in the rating table by
the derating factor (k, in the diagram below).
k
1.00 R0…R3
0.95
0.90 R5…R9
0.85
0.80
-15 °C … +40 °C +50 °C T
-59 °F +104 °F +122 °F
132 Technical data
 Ambient temperature derating, IP55

IP55 (UL Type 12) drive types, other than the exceptions listed in the following
subheadings
In the temperature range +40…50 °C (+104…122 °F), the rated output current is
derated by 1% for every added 1 °C (1.8 °F). The output current can be calculated by
multiplying the current given in the rating table by the derating factor (k):
k
1.00
0.95
0.90
0.85
0.80
-15 °C … +40 °C +50 °C
T
-59 °F +104 °F +122 °F
 IP55 (UL Type 12) type -045A-4

derated by 1% for every added 1 °C (1.8 °F). In the temperature range +45…50 °C
(+113…122 °F), the rated output current is derated by 1.5% for every added 1 °C (1.8
°F).
k
1.00
0.95
0.90
0.85
0.80
-15 °C … +40 °C +45 °C +50 °C
T
-59 °F +104 °F +113 °F +122 °F
 IP55 (UL Type 12) drive type -293A-4

Technical data 133
°F). The output current can be calculated by multiplying the current given in the rating
table by the derating factor (k):
k
1.00
0.95
0.90
0.85
0.80
0.75
-15 °C … +40 °C +45 °C +50 °C
T
-59 °F +104 °F +113 °F +122 °F
 IP55 (UL Type 12) drive type -363A-4

°F). The output current can be calculated by multiplying the current given in the rating
table by the derating factor (k):
k
1.00
0.95
0.90
0.85
0.80
0.75
-15 °C … +40 °C +45 °C +50 °C
T
-59 °F +104 °F +113 °F +122 °F
 IP55 (UL Type 12) type -430A-4

The maximum ambient temperature is 35 °C (95 °F).
134 Technical data
 Switching frequency derating

the derating factor given in the table below.
Note: If you change the minimum switching frequency with parameter 97.02
Minimum switching frequency, derate according to the table below. Changing
parameter 97.01 Switching frequency reference does not require derating.
Frame size Derating factor (k) for the minimum switching frequencies
1 kHz 2 kHz 4kHz 8 kHz 12 kHz
R0 1 1 1 0.67 0.5
R1 1 1 1 0.67 0.5
R2 1 1 1 0.65 0.48
R3 1 1 1 0.65 0.48
R5 1 1 0.92 0.7 0.56
R6 1 0.97 0.83 0.66 0.5
R7 1 0.98 0.88 0.7 0.5
R8 1 0.96 0.81 0.6 N/A
R9 1 0.95 0.78 0.56 N/A
 Altitude derating
In altitudes 1000…4000 m (3300…13120 ft) above sea level, the derating is 1% for
every 100 m (330 ft).
the derating factor k, which for x meters (1000 m <= x <= 4000 m) is:
1 . (x - 1000) m
k=1-
10 000 m
Check the network compatibility restrictions above 2000 m (6562 ft), see Installation
site altitude on page 152. Check also PELV limitation on relay output terminals above
2000 m (6562 ft), see sections Isolation areas, R0…R3 (CCU-11): on page 148 and
Isolation areas, R5…R9 (CCU-12): on page 149.
Technical data 135
Fuses (IEC)
gG as well as uR or aR fuses for protection against short-circuit in the input power
cable or drive are listed below. Either fuse type can be used for frames R0…R3 and
R5…R6 if it operates rapidly enough. The operating time depends on the supply
network impedance and the cross-sectional area and length of the supply cable. For
frames R7…R9 ultrarapid (aR) fuses must be used.
Note 1: See also Implementing thermal overload and short-circuit protection on page
62.
Note 2: Fuses with higher current rating than the recommended ones must not be
used.
Note 3: Fuses from other manufacturers can be used if they meet the ratings and the
melting curve of the fuse does not exceed the melting curve of the fuse mentioned in
the table.
136 Technical data
 gG fuses
Check on the fuse time-current curve to ensure the operating time of the fuse is
below 0.5 seconds. Obey the local regulations.
Type Min. short- Input gG (IEC 60269)
ACS580 circuit current
current1) Nominal VoltageI2 t ABB type IEC 60269
-01- current rating size
A A A A 2s V
3-phase UN = 400 or 460 V (380…415 V, 440…480 V)
02A6-4 32 2.6 4 55 500 OFAF000H4 000
03A3-4 48 3.3 6 110 500 OFAF000H6 000
04A0-4 48 4.0 6 110 500 OFAF000H6 000
05A6-4 80 5.6 10 360 500 OFAF000H10 000
07A2-4 80 7.2 10 360 500 OFAF000H10 000
09A4-4 128 9.4 16 740 500 OFAF000H16 000
12A6-4 128 12.6 16 740 500 OFAF000H16 000
017A-4 200 17.0 25 2500 500 OFAF000H25 000
025A-4 256 25.0 32 4000 500 OFAF000H32 000
032A-4 320 32.0 40 7700 500 OFAF000H40 000
038A-4 400 38.0 50 16000 500 OFAF000H50 000
045A-4 500 45.0 63 20100 500 OFAF000H63 000
061A-4 800 61 80 37500 500 OFAF000H80 000
072A-4 1000 72 100 65000 500 OFAF000H100 000
087A-4 1000 87 100 65000 500 OFAF000H100 000
105A-4 1300 105 125 103000 500 OFAF00H125 1
145A-4 1700 145 160 185000 500 OFAF00H160 1
169A-4 3300 169 250 600000 500 OFAF0H250 1
206A-4 5500 206 315 710000 500 OFAF1H315 1
246A-4 6400 246 355 920000 500 OFAF1H355 2
293A-4 7800 293 425 1300000 500 OFAF2H425 2
363A-4 9400 363 500 2000000 500 OFAF2H500 2
430A-4 10200 430 630 2800000 500 OFAF3H630 2
3AXD00000586715.xls F
1) Minimum short-circuit current of the installation
Technical data 137
 uR and aR fuses
Type Min. short- Input uR or aR
ACS580 circuit current
current1) Nominal I2 t Voltage Bussmann IEC 60269
-01- current rating type size
A A A A 2s V
3-phase UN = 400 or 460 V (380…415 V, 440…480 V)
02A6-4 TBA 2.6 25 130 690 170M1561 000
03A3-4 TBA 3.3 25 130 690 170M1561 000
04A0-4 TBA 4.0 25 130 690 170M1561 000
05A6-4 TBA 5.6 25 130 690 170M1561 000
07A2-4 TBA 7.2 25 130 690 170M1561 000
09A4-4 TBA 9.4 25 130 690 170M1561 000
12A6-4 TBA 12.6 25 130 690 170M1561 000
017A-4 TBA 17.0 40 460 690 170M1563 000
025A-4 TBA 25.0 40 460 690 170M1563 000
032A-4 TBA 32.0 63 1450 690 170M1565 000
038A-4 TBA 38.0 63 1450 690 170M1565 000
045A-4 TBA 45.0 80 2550 690 170M1566 000
061A-4 380 61 100 4650 690 170M1567 1
072A-4 480 72 125 8500 690 170M1568 1
087A-4 480 87 160 16000 690 170M1569 1
105A-4 700 105 200 15000 690 170M3815 1
145A-4 700 145 250 28500 690 170M3816 1
169A-4 1280 169 315 46500 690 170M3817 1
206A-4 1520 206 350 68500 690 170M3818 1
246A-4 2050 246 450 105000 690 170M5809 2
293A-4 2200 293 500 145000 690 170M5810 2
363A-4 3100 363 630 275000 690 170M5812 2
430A-4 3600 430 700 405000 690 170M5813 2
3AXD00000586715.xls F
1)
Minimum short-circuit current of the installation
138 Technical data
Dimensions, weights and free space requirements

Frame Dimensions and weights
size IP21 / UL type 1
H1 H2 H3 H4 W D Weight
mm mm mm mm mm mm kg
R0 -*) -*) 303 330 125 210 4.5
R1 -*) -*) 303 330 125 223 4.6
R2 -*) -*) 394 430 125 227 7.5
R3 -*) -*) 454 490 203 228 14.9
R5 596 598 726 627 203 283 23.0
R6 548 549 726 589 252 369 45.0
R7 600 601 880 641 284 370 55.0
R8 680 677 965 721 300 393 70.0
R9 680 680 955 741 380 418 98.0
3AXD00000586715.xls F
*) Frames with an integrated gland box
Frame Dimensions and weights

size IP55 / UL type 12
H3 H4 W D Weight
mm mm mm mm kg
R0 303 330 125 222 5
R1 303 330 125 233 5
R2 394 430 125 239 7
R3 454 490 203 237 15
R6 726 615 252 380 45
R7 880 641 284 381 55
R8 965 726 300 452 72
R9 955 741 380 477 100
3AXD00000586715.xls F
Technical data 139
W D W D
H1
H2
H4
H3
Symbols
IP21 / UL type 1
H1 Height back without gland box
H2 Height front without gland box
H3 Height front with gland box
H4 Height back with gland box
W Width
D Depth
Frame Free space

size Vertical mounting Vertical mounting Horizontal mounting
stand alone side by side
Above Below Above Below Between Above Below Between
mm mm mm mm mm mm mm mm
R0 200 200 200 200 0 TBA TBA TBA
R1 200 200 200 200 0 TBA TBA TBA
R2 200 200 200 200 0 TBA TBA TBA
R3 200 200 200 200 0 TBA TBA TBA
R5 200 300 200 300 0 TBA TBA TBA
R6 200 300 200 300 0 TBA TBA TBA
R7 200 300 200 300 0 TBA TBA TBA
R8 200 300 200 300 0 TBA TBA TBA
R9 200 300 200 300 0 TBA TBA TBA
3AXD00000586715.xls F
See the figures in section Checking the installation site on page 38.
140 Technical data
Losses, cooling data and noise

The air flow direction is from bottom to top.
The table below specifies the heat dissipation in the main circuit at nominal load and
in the control circuit with minimum load (I/O, options and panel not in use) and
maximum load (all digital inputs and relays in the ON state, and the panel, fieldbus
and fan in use). The total heat dissipation is the sum of the heat dissipation in the
main and control circuits. Use the maximum losses when designing cabinet or
electrical room cooling needs.
Type Heat dissipation Air flow Noise Frame
ACS580 Main circuit Control Control Main and size
-01- at rated circuit circuit control boards
I1N at IN minimum maximum maximum
W W W W m3/h dB(A)
3-phase UN = 400 or 460 V (380…415 V, 440…480 V)
02A6-4 20 3.5 25 45 TBA TBA R0
03A3-4 30 3.5 25 55 TBA TBA R0
04A0-4 41 3.5 25 66 TBA TBA R0
05A6-4 59 3.5 25 84 TBA TBA R0
07A2-4 81 3.5 25 106 TBA TBA R1
09A4-4 108 3.5 25 133 TBA TBA R1
12A6-4 149 3.5 25 174 TBA TBA R1
017A-4 203 3.5 25 228 TBA TBA R2
025A-4 297 3.5 25 322 TBA TBA R2
032A-4 405 3.5 25 430 TBA TBA R3
038A-4 500 3.5 25 525 TBA TBA R3
045A-4 594 3.5 25 619 TBA TBA R3
061A-4 1117 4.1 36 1153 280 62 R5
072A-4 1117 4.1 36 1153 280 62 R5
087A-4 1120 4.1 36 1156 280 62 R5
105A-4 1295 4.1 36 1331 435 67 R6
145A-4 1440 4.1 36 1476 435 67 R6
169A-4 1940 4.1 36 1976 450 67 R7
206A-4 2310 4.1 36 2346 550 67 R7
246A-4 3300 4.1 36 3336 550 65 R8
293A-4 3900 4.1 36 3936 1150 65 R8
363A-4 4800 4.1 36 4836 1150 68 R9
430A-4 6000 4.1 36 6036 1150 68 R9
3AXD00000586715.xls F
Technical data 141
Terminal and lead-through data for the power cables

Input, motor, resistor and DC cable lead-throughs, maximum wire sizes (per phase)
and terminal screw sizes and tightening torques (T) are given below.
Frame Cable lead- L1, L2, L3, T1/U, T2/V, T3/W terminals Grounding
size throughs terminals
Per Ø1) Max wire size T (Wire screw) T (Terminal Max wire T
cable (solid/ nut) size
type stranded)
pcs mm mm2 M… N·m M… N·m mm2 N·m
2)
R0 1 30 6/4 0.5…0.6 N/A N/A TBA TBA
2)
R1 1 30 6/4 0.5…0.6 N/A N/A TBA TBA
2)
R2 1 30 16/16 1.2…1.5 N/A N/A TBA TBA
2)
R3 1 30 35/25 2.5…4.1 N/A N/A TBA TBA
R5 1 32 70 M8 5.6 N/A N/A 35 2.9
R6 1 45 150 M10 30 N/A N/A 185 9.8
R7 1 54 240 M10 40 N/A N/A 185 9.8
R8 2 45 2×150 M10 40 M10 24 2×185 9.8
R9 2 54 2×240 M12 70 M10 24 2×185 9.8
3AXD00000586715.xls F
1) Maximum cable diameter accepted. For the lead-through plate hole diameters, see chapter Dimension
drawings on page 161.
2) See the table below.
Frame Screwdrivers for the terminals of the main circuit

size
R0 Slot 4,5 mm
R1 Slot 4,5 mm
R2 PH1
R3 PH2
3AXD00000586715.xls F
Frame Cable lead- R+, R-, UDC+ and UDC- terminals

size throughs
Per Ø1) Max wire size T (Wire screw) T (Terminal
cable (solid/strand nut)
type ed)
pcs mm mm2 M… N·m M… N·m
2)
R0 1 23 6/4 0.5…0.6 N/A N/A
2)
R1 1 23 6/4 0.5…0.6 N/A N/A
2)
R2 1 23 16/16 1.2…1.5 N/A N/A
2)
R3 1 23 35/25 2.5…4.1 N/A N/A
R5 1 32 70 M8 5.6 N/A N/A
R6 1 45 150 M8 20 N/A N/A
R7 1 54 240 M10 30 N/A N/A
R8 2 45 2×150 M10 40 M10 24
R9 2 54 2×240 M12 70 M10 24
3AXD00000586715.xls F
1)
Maximum cable diameter accepted. For the lead-through plate hole diameters, see
chapter Dimension drawings on page 161.
2)
See the table above.
142 Technical data
Terminal and lead-through data for the control cables

Control cable lead-throughs, wire sizes and tightening torques (T) are given below.
Frame Cable lead- Control cable entries and terminal sizes
size throughs
Holes Max +24V, DCOM, DGND, EXT. 24V DI, AI/O, AGND, RO, STO
cable terminals
size Wire size T Wire size T
pcs mm mm2 N·m mm2 N·m
R0 3 17 0.2…2.5 0.5…0.6 0.14…1.5 0.5…0.6
R1 3 17 0.2…2.5 0.5…0.6 0.14…1.5 0.5…0.6
R2 3 17 0.2…2.5 0.5…0.6 0.14…1.5 0.5…0.6
R3 3 17 0.2…2.5 0.5…0.6 0.14…1.5 0.5…0.6
R5 2 22 0.14…2.5 0.5…0.6 0.14…2.5 0.5…0.6
R6 4 17 0.14…2.5 0.5…0.6 0.14…2.5 0.5…0.6
R7 4 17 0.14…2.5 0.5…0.6 0.14…2.5 0.5…0.6
R8 4 17 0.14…2.5 0.5…0.6 0.14…2.5 0.5…0.6
R9 4 17 0.14…2.5 0.5…0.6 0.14…2.5 0.5…0.6
3AXD00000586715.xls F
Technical data 143
Electrical power network specification

Voltage (U1) 380 … 480 V AC 3-phase +10%…-15%
Network type Public low voltage networks. TN (grounded), IT
(ungrounded) and corner-grounded TN systems. See
section Checking the compatibility with IT (ungrounded)
and corner-grounded TN systems on page 71.
Rated conditional short-circuit 65 kA when protected by fuses given in the fuse tables
current (IEC 61439-1)
Frequency 47 to 63 Hz
Imbalance Max. ± 3% of nominal phase to phase input voltage
Fundamental power factor 0.98 (at nominal load)
(cos phi1)
Motor connection data
Motor types Asynchronous AC induction motors and permanent
magnet motors
Voltage (U2) 0 to U1, 3-phase symmetrical, Umax at the field weakening
point
Short-circuit protection The motor output is short-circuit proof by IEC/EN 61800-5-
(IEC/EN 61800-5-1, UL 508C) 1 and UL 508C.
Frequency 0.…500 Hz
Frequency resolution 0.01 Hz
Current See section Ratings on page 128.
Switching frequency 2 kHz, 4 kHz, 8 kHz, 12 kHz (depends on the frame and
parameter settings)
144 Technical data
Maximum recommended motor Operational functionality and motor cable length

cable length The drive is designed to operate with optimum performance
with the following maximum motor cable lengths.
Note: Conducted and radiated emissions of these motor
cable lengths do not comply with EMC requirements.
Frame Maximum motor cable length, 4 kHz

size Scalar control Vector control
m ft m ft
Standard drive, without external options
R0 100 330 100 330
R1 100 330 100 330
R2 200 660 200 660
R3 300 990 300 990
R5 300 990 300 990
R6 300 990 300 990
R7 300 990 300 990
R8 300 990 300 990
R9 300 990 300 990
Note: In multimotor systems, the calculated sum of all

motor cable lengths must not exceed the maximum motor
cable length given in the table.
Technical data 145
EMC compatibility and motor cable length

To comply with the European EMC Directive (standard
EN 61800-3), use the following maximum motor cable
lengths at 4 kHz switching frequency.
Frame Maximum motor cable length, 4 kHz

size
m ft
EMC limits for Category C2 1)
Standard drive with an internal EMC filter. See notes 2,
3 and 5.
R0 100 330
R1 100 330
R2 100 330
R3 100 330
R5 100 330
R6 150 492
R7 150 492
R8 150 492
R9 150 492
EMC limits for Category C3 1)
Standard drive with an internal EMC filter. See notes 3
and 4.
R0 100 330
R1 100 330
R2 100 330
R3 100 330
R5 100 330
R6 150 492
R7 150 492
R8 150 492
R9 150 492
3AXD00000586715.xls F
1)
See the terms in section Definitions on page 156.
146 Technical data
Note 2: Radiated emissions are according to C2 with an

internal EMC filter.
Note 3: The internal EMC filter must be connected.
Note 4: Radiated and conducted emissions are according
to category C3 with an internal filter and these cable
lengths.
Note 5: Categories C1 and C2 meet requirements for
connecting equipment to the public low-voltage networks.
Brake resistor connection data

Short-circuit protection The brake resistor output is conditionally short-circuit proof
(IEC/EN 61800-5-1, IEC 60439-1, by IEC/EN 61800-5-1 and UL 508C. For correct fuse
UL 508C) selection, contact your local ABB representative. Rated
conditional short-circuit current as defined in IEC 60439-1.
Control connection data

External power supply Maximum power:
Frames R0…R3: 25 W, 1.04 A at 24 V AC/DC ±10%
with an optional module
Frames R5…R9: 36 W, 1.50 A at 24 V AC/DC ±10% as
standard
Supplied from an external power supply through optional
module CMOD-01 or CMOD-02 with frames R0…R3. With
frames R5…R9 no options are needed.
Terminal size:
Frames R0…R3: 0.2…2.5 mm2
Frames R5…R9: 0.14…2.5 mm2
+24 V DC output Total load capacity of this outputs is 6.0 W (250 mA / 24 V)
(Term. 10) minus the power taken by the option modules installed on
the board.
Terminal size:
Frames R0…R3: 0.2…2.5 mm2
Frames R5…R9: 0.14…2.5 mm2
Digital inputs DI1…DI6 Input type: NPN/PNP
(Term. 13…18) Terminal size:
Frames R0…R3: 0.14…1.5 mm2
Frames R5…R9: 0.14…2.5 mm2
DI1…DI5 (Term.13…17)
12/24 V DC logic levels: “0” < 4 V, “1” > 8 V
Rin: 2,68 kohm
Hardware filtering: 0.04 ms, digital filtering: 2 ms sampling
DI6 (Term.18)
Can be used as a digital or frequency input.
12/24 V DC logic levels: “0” < 3 V, “1” > 8 V
Rin: 6.2 kohm
Max. frequency 16 kHz
Symmetrical signal (duty cycle D = 0.50)
Technical data 147
Relay outputs RO1…RO3 250 V AC / 30 V DC, 2 A

(Term. 19…27) Terminal size:
Frames R0…R3: 0.14…1.5 mm2
Frames R5…R9: 0.14…2.5 mm2
See sections Isolation areas, R0…R3 (CCU-11): on page
148 and Isolation areas, R5…R9 (CCU-12): on page 149.
Analog inputs AI1 and AI2 Current/voltage input mode selected with a dip switch, see
(Term. 2 and 5) page 94.
Current input: 0(4)…20 mA, Rin: 100 ohm
Voltage input: 0(2)…10 V, Rin: > 200 koh
Terminal size:
Frames R0…R3: 0.14…1.5 mm2
Frames R5…R9: 0.14…2.5 mm2
Inaccuracy: typical ±1%, max. ±1.5% of full scale
Analog outputs AO1 and AO2 Current/voltage output mode for AO1 selected with a dip
(Term. 7 and 8) switch, see page 94.
Current output: 0…20 mA, Rload: < 500 ohm
Voltage input: 0…10 V, Rload: > 100 kohm (AO1 only)
Terminal size:
Frames R0…R3: 0.14…1.5 mm2
Frames R5…R9: 0.14…2.5 mm2
Inaccuracy: ±1% of full scale (in voltage and current
modes)
Reference voltage output for Max. 20 mA output
analog inputs +10V DC Inaccuracy: ±1%
(Term. 4)
Safe torque off (STO) inputs IN1 24 V DC logic levels: “0” < 5 V, “1” > 13 V
and IN2 Rin: 2.47 kohm
(Term. 37 and 38) Terminal size:
Frames R0…R3: 0.14…1.5 mm2
Frames R5…R9: 0.14…2.5 mm2
Control panel - drive connection EIA-485, male RJ-45 connector, max. cable length 100 m
Control panel - PC connection USB Type Mini-B, max. cable length 2 m
148 Technical data
Isolation areas, R0…R3 (CCU-11):
Panel port
X1
AI/AO Power unit
connection
X2
24 V
GND
X3
DI
SLOT1
X4 FBA
STO
X8
RO
SLOT3 X7
EFB RO
X6
RO
SLOT2
I/O extension
Symbol Description
Reinforced insulation (IEC/EN 61800-5-1:2007)
Functional insulation (IEC/EN 61800-5-1:2007)
Below altitudes 2000 m (6562 ft): The terminals on the control board fulfil
the Protective Extra Low Voltage (PELV) requirements (EN 50178):
There is adequate insulation between the user terminals which only
accept ELV voltages and terminals that accept higher voltages (relay
outputs).
Between altitudes 2000 m (6562 ft) … 4000 m (13123 ft): If you connect
higher than ELV voltage to one relay output, no relay output meets the
Protective Extra Low Voltage (PELV) requirements (EN 50178), because
there is only functional insulation between the individual relay outputs.
Technical data 149
Isolation areas, R5…R9 (CCU-12):
SLOT1
FBA
X1:1…3
AI1
X1:4…6
AI2
X1:7…8
AO
Power unit
X2 connection
24 V
GND
X3:1…3
DI
X3:4…6
DI SLOT3
EFB
X4
STO
X10
Ext. 24 V
SLOT2
X8
I/O extension
RO1
X7
RO2
Panel port X6
RO3
Symbol Description
Reinforced insulation (IEC/EN 61800-5-1:2007)
The terminals on the control board fulfil the Protective Extra Low Voltage
(PELV) requirements (EN 50178): There is reinforced insulation between
the user terminals which only accept ELV voltages and terminals that
accept higher voltages (relay outputs).
Note: There is reinforced insulation also between the individual relay
outputs.
Note: There is reinforced insulation on the power unit.
150 Technical data
Grounding of frames R0…R3 (CCU-11)
X1 Slot 1 Slot 2
1 SCR
2 AI1
3 AGND
4 +10V
5 AI2
6 AGND
7 AO1
8 AO2
9 AGND
X2 & X3
10 +24V
*) 11 DGND
12 DCOM
13 DI1
14 DI2
15 DI3
16 DI4
17 DI5
18 DI6
X6, X7, X8
19 RO1C
20 RO1A
21 RO1B
22 RO2C
23 RO2A
24 RO2B
25 RO3C
26 RO3A
27 RO3B
X5
29 B+
30 A-
31 DGND
X4
34 OUT1
35 OUT2
36 SGND
37 IN1
38 IN2
Ground
*) Jumper installed at factory

Technical data 151
Grounding of frames R5…R9 (CCU-12)
X1 Slot 1 Slot 2
1 SCR
2 AI1
3 AGND
4 +10V
5 AI2
6 AGND
7 AO1
8 AO2
9 AGND
X2 & X3
10 +24V
*) 11 DGND
12 DCOM
13 DI1
14 DI2
15 DI3
16 DI4
17 DI5
18 DI6
X6, X7, X8
19 RO1C
20 RO1A
21 RO1B
22 RO2C
23 RO2A
24 RO2B
25 RO3C
26 RO3A
27 RO3B
X5
29 B+
30 A-
31 DGND
X4
34 OUT1
35 OUT2
36 SGND
37 IN1
38 IN2
X10
40 24VAC/DC-in
41 24VAC/DC+in
Ground
*) Jumper installed at factory

152 Technical data
Auxiliary circuit power consumption

Maximum external power supply:
Frames R0…R3: 25 W, 1.04 A at 24 V AC/DC (with
optional modules CMOD-01, CMOD-02)
Frames R5…R9: 36 W, 1.50 A at 24 V AC/DC (as
standard, terminals 40…41)
Efficiency
Approximately 98% at nominal power level
Degree of protection
IP21 (UL type 1)
IP55 (UL type 12)
Ambient conditions
Environmental limits for the drive are given below. The drive is to be used in a heated, indoor,
controlled environment. All printed circuit boards are conformal coated.
Operation Storage Transportation
installed for in the protective in the protective
stationary use package package
Installation site altitude • 0 to 4000 m - -
(13123 ft)
above sea level
1)
• 0 to 2000 m
(6561 ft) above
sea level 2)
Above 1000 m
(3281 ft), see
page 134.
Air temperature -15 to +50 °C (5 to -40 to +70 °C (-40 -40 to +70 °C (-40
122 °F). to +158 °F) to +158 °F)
0 to -15 °C (32 to
5 °F): No frost
allowed.
See section
Ratings.
Relative humidity 5 to 95% Max. 95% Max. 95%
No condensation allowed. Maximum allowed relative
humidity is 60% in the presence of corrosive gases.
Contamination levels No conductive dust allowed.
(IEC 60721-3-3, IEC 60721-3-2, Chemical gases: Chemical gases: Chemical gases:
IEC 60721-3-1) Class 3C2 Class 1C2 Class 2C2
Solid particles: Solid particles: Solid particles:
Class 3S2 Class 1S3 Class 2S2
Technical data 153
Atmospheric pressure 70 to 106 kPa 70 to 106 kPa 60 to 106 kPa

0.7 to 1.05 0.7 to 1.05 0.6 to 1.05
atmospheres atmospheres atmospheres
Vibration (IEC 60068-2) Max. 1 mm (0.04 - -
in.)
(5 to 13.2 Hz),
max. 7 m/s2 (23
ft/s2)
(13.2 to 100 Hz)
sinusoidal
Vibration (ISTA) - R0…R5 (ISTA 1A): Displacement,
25 mm peak to peak, 14200 vibratory
impacts
R6…R9 ISTA 3E): Random, overall
Grms level of 0.52
Shock/Drop (ISTA) Not allowed R0…R5 (ISTA 1A): Drop, 6 faces, 3
edges and 1 corner
Weight range mm in
0…10 kg (0…22 lb) 760 29.9
10…19 kg (22…42 lb) 610 24.0
19…28 kg (42…62 lb) 460 18.1
28…41 kg (62…90 lb) 340 13.4
R6…R9 (ISTA 3E): Shock, incline
impact: 1.1 m/s (3.61 ft/s)
Shock, rotational edge drop: 200 mm
(7.9 in)
1)
For neutral-grounded TN and TT systems and non-corner grounded IT systems.
See also section Limiting relay output maximum voltages at high installation altitudes on
page 68.
2) For corner-grounded TN, TT and IT systems
Materials
Drive enclosure • PC/ABS 3 mm, color NCS 1502-Y (RAL 9002 / PMS 1C
Cool Grey) and RAL 9017
• PC+10%GF 3.0mm, Color RAL 9017 (in frames
R0…R3 only)
• hot-dip zinc coated steel sheet 1.5 to 2.5 mm, thickness
of coating 100 micrometers, color NCS 1502-Y
Package Plywood, cardboard and moulded pulp. Foam cushions
PP-E, bands PP.
154 Technical data
Disposal The main parts of the drive can be recycled to preserve

natural resources and energy. Product parts and materials
should be dismantled and separated.
Generally all metals, such as steel, aluminum, copper and
its alloys, and precious metals can be recycled as
material. Plastics, rubber, cardboard and other packaging
material can be used in energy recovery. Printed circuit
boards and DC capacitors (C1-1 to C1-x) need selective
treatment according to IEC 62635 guidelines. To aid
recycling, plastic parts are marked with an appropriate
identification code.
Contact your local ABB distributor for further information
on environmental aspects and recycling instructions for
professional recyclers. End of life treatment must follow
international and local regulations.
Applicable standards
The drive complies with the following standards. The compliance with the European Low
Voltage Directive is verified according to standard EN 61800-5-1.
EN 60204-1:2006 + AC:2010 Safety of machinery. Electrical equipment of machines.
Part 1: General requirements. Provisions for compliance:
The final assembler of the machine is responsible for
installing
- emergency-stop device
- supply disconnecting device.
IEC/EN 60529:1992 + A2: 2013 Degrees of protection provided by enclosures (IP code)
EN 61000-3-12:2011 Electromagnetic compatibility (EMC) - Part 3-12: Limits -
Limits for harmonic currents produced by equipment
connected to public low-voltage systems with input current
IEC/EN 61800-3:2004 + A1:2012 Adjustable speed electrical power drive systems. Part 3:
EMC requirements and specific test methods
IEC/EN 61800-5-1:2007 Adjustable speed electrical power drive systems. Part 5-1:
Safety requirements – electrical, thermal and energy
Technical data 155
CE marking
A CE mark is attached to the drive to verify that the drive follows the provisions of the
European Low Voltage, EMC, RoHS and WEEE Directives.The CE marking also
verifies that the drive, in regard to its safety functions (such as Safe torque off),
conforms with the Machinery Directive as a safety component.
 Compliance with the European Low Voltage Directive

The compliance with the European Low Voltage Directive has been verified according
to standard EN 61800-5-1:2007. Declaration (3AXD10000302784) is available on the
Internet. See section Document library on the Internet on the inside of the back cover.
 Compliance with the European EMC Directive

The EMC Directive defines the requirements for immunity and emissions of electrical
equipment used within the European Union. The EMC product standard (EN 61800-
3:2004 + A1:2012) covers requirements stated for drives. See section Compliance
with the EN 61800-3:2004 + A1:2012 below. The declaration (3AXD10000302784) is
available on the Internet. See section Document library on the Internet on the inside
of the back cover.
 Compliance with the European ROHS Directive 2011/65/EU

The RoHS Directive defines the restriction of the use of certain hazardous
substances in electrical and electronic equipment. The declaration
(3AXD10000302785) is available on the Internet. See section Document library on
the Internet on the inside of the back cover.
 Compliance with the European WEEE Directive 2002/96/EC

The WEEE Directive defines the regulated disposal and recycling of electric and
electrical equipment.
 Compliance with the European Machinery Directive

2006/42/EC 2nd Edition – June 2010
The drive is a machinery component that can be integrated into a wide range of
machinery categories as specified in European Commission’s Guide to application of
the Machinery Directive 2006/42/EC 2nd Edition – June 2010. The declaration
(3AXD10000302783) is available on the Internet. See section Document library on
the Internet on the inside of the back cover.
Validating the operation of the Safe torque off function

See chapter Safe torque off function on page 187.
156 Technical data
Compliance with the EN 61800-3:2004 + A1:2012

 Definitions
EMC stands for Electromagnetic Compatibility. It is the ability of electrical/electronic
equipment to operate without problems within an electromagnetic environment.
Likewise, the equipment must not disturb or interfere with any other product or
system within its locality.
First environment includes establishments connected to a low-voltage network which
supplies buildings used for domestic purposes.
Second environment includes establishments connected to a network not directly
supplying domestic premises.
Drive of category C1: drive of rated voltage less than 1000 V and intended for use in
the first environment.
Drive of category C2: drive of rated voltage less than 1000 V and intended to be
installed and started up only by a professional when used in the first environment.
Note: A professional is a person or organization having necessary skills in installing
and/or starting up power drive systems, including their EMC aspects.
Drive of category C3: drive of rated voltage less than 1000 V, intended for use in the
second environment and not intended for use in the first environment.
 Category C1
The emission limits are complied with the following provisions:
1. The optional EMC filter is selected according to the ABB documentation and
installed as specified in the EMC filter manual.
2. The motor and control cables are selected as specified in this manual.
3. The drive is installed according to the instructions given in this manual.
4. For the maximum motor cable length with 4 kHz switching frequency, see page
144.
WARNING! In a domestic environment, this product may cause radio inference, in

which case supplementary mitigation measures may be required.
Technical data 157
 Category C2
The emission limits are complied with the following provisions:
144.
WARNING! The drive may cause radio interference if used in residential or domestic
environment. The user is required to take measures to prevent interference, in
association to the requirements for the CE compliance listed above, if necessary.
Note: Do not install a drive with the internal EMC filter connected on IT (ungrounded).
The supply network becomes connected to ground potential through the internal
EMC filter capacitors which may cause danger or damage to the drive. For
disconnecting the EMC filter see page 72.
Note: Do not install a drive with internal EMC filter connected on corner-grounded TN
systems; otherwise the drive will be damaged. For disconnecting the internal EMC
filter see page 72.
 Category C3
The drive complies with the standard with the following provisions:
144
WARNING! A drive of category C3 is not intended to be used on a low-voltage public

network which supplies domestic premises. Radio frequency interference is expected
if the drive is used on such a network.
158 Technical data
 Category C4
If the provisions under Category C3 cannot be met, the requirements of the standard
can be met as follows:
1. It is ensured that no excessive emission is propagated to neighboring low-voltage
networks. In some cases, the inherent suppression in transformers and cables is
sufficient. If in doubt, the supply transformer with static screening between the
primary and secondary windings can be used.
Medium voltage network

Supply transformer
Neighboring network
Static screen
Point of measurement
Low voltage Low voltage

Equipment
Drive
(victim)
Equipment Equipment
2. An EMC plan for preventing disturbances is drawn up for the installation. A

template is available from the local ABB representative.
WARNING! A drive of category C4 is not intended to be used on a low-voltage public

network which supplies domestic premises. Radio frequency interference is expected
if the drive is used on such a network.
EAC marking
EAC marking is required in Russia, Belarus and Kazakhstan. The EAC certificate of
conformity (3AXD10000312900) is available on the Internet. See section Document
library on the Internet on the inside of the back cover.
Disclaimer
The manufacturer shall have no obligation with respect to any product which (i) has
been improperly repaired or altered; (ii) has been subjected to misuse, negligence or
Technical data 159
accident; (iii) has been used in a manner contrary to the manufacturer's instructions;
or (iv) has failed as a result of ordinary wear and tear.
160 Technical data
Dimension drawings 161
10
Dimension drawings
This chapter shows the dimension drawings of the ACS580. The dimensions are
given in millimeters and [inches].
162 Dimension drawings
Frame R0, IP21
3AXD10000257110
Frame R0, IP55
3AXD10000341562
Frame R1, IP21
3AXD10000257188
Frame R1, IP55
3AXD10000336766
Frame R2, IP21
3AXD10000257203
Frame R2, IP55
3AXD10000336766
Frame R3, IP21
3AXD10000257219
Frame R3, IP55
3AXD10000335424
Frame R5, IP21
3AXD10000258138
Frame R6, IP21
3AXD10000258705
Frame R6, IP55
3AXD10000330667
Frame R7, IP21
3AXD10000258995
Frame R7, IP55
3AXD10000330932
Frame R8, IP21
3AXD10000287670
Frame R8, IP55
3AXD10000332446
Frame R9, IP21
3AXD10000287428
Frame R9, IP55
3AXD10000334310
Resistor braking 179
11
Resistor braking
The chapter describes how to select the brake resistor and cables, protect the
system, connect the brake resistor and enable resistor braking.
Operation principle and hardware description

The brake chopper handles the energy generated by a decelerating motor. The
chopper connects the brake resistor to the intermediate DC circuit whenever the
voltage in the circuit exceeds the limit defined by the control program. Energy
consumption by the resistor losses lowers the voltage until the resistor can be
disconnected.
For frame R0…R3 internal brake choppers and resistors, see below. For R5…R9
external brake choppers and resistors, see Resistor braking, frames R5…R9 on page
186.
180 Resistor braking
Resistor braking, frames R0…R3

 Planning the braking system
Selecting the brake resistor
Frames R0…R3 have an built-in brake chopper as standard equipment. The brake
resistor is selected using the table and equations presented in this section.
1. Determine the required maximum braking power PRmax for the application. PRmax
must be smaller than PBRmax given in the table on page 181 for the used drive
type.
2. Calculate resistance R with Equation 1.
3. Calculate energy ERpulse with Equation 2.
4. Select the resistor so that the following conditions are met:
• The rated power of the resistor must be greater than or equal to PRmax.
• Resistance R must be between Rmin and Rmax given in the table for the used
drive type.
• The resistor must be able to dissipate energy ERpulse during the braking
cycle T.
Equations for selecting the resistor:
450000 ton
Eq. 1. UN = 400 V: R = PRmax
PRmax
615000 PRave
UN = 460 V: R =
PRmax T
Eq. 2. ERpulse = PRmax · ton
ton
Eq. 3. PRave = PRmax · For conversion, use 1 hp = 746 W.
T
where
R = calculated brake resistor value (ohm). Make sure that: Rmin < R < Rmxx.
PRmax = maximum power during the braking cycle (W)
PRave = average power during the braking cycle (W)
ERpulse = energy conducted into the resistor during a single braking pulse (J)
ton = length of the braking pulse (s)
T = length of the braking cycle (s).
The table shows reference resistor types for the maximum braking power.
Type Rmin Rmax PBRmax Reference resistor types
ACS580-01 ohm ohm kW hp Danotherm
3-phase UN = 400 or 460 V (380…415 V, 440…480 V)
0246-4 54 690 0.6 0.8 CBH 360 C T 406 210R or
CAR 200 D T 406 210R
03A3-4 54 465 0.9 1.2 CBH 360 C T 406 210R or
CAR 200 D T 406 210R
04A0-4 54 313 1.3 1.7 CBH 360 C T 406 210R or
CAR 200 D T 406 210R
05A6-4 54 223 1.9 2.6 CBH 360 C T 406 210R or
CAR 200 D T 406 210R
07A2-4 54 153 2.6 3.5 CBR-V 330 D T 406 78R UL
09A4-4 54 112 3.5 4.7 CBR-V 330 D T 406 78R UL
12A6-4 54 83 4.9 6.6 CBR-V 330 D T 406 78R UL
017A-4 32 60 6.8 9.0 CBR-V 560 D HT 406 39R UL
025A-4 23 42 10 13.6 CBR-V 560 D HT 406 39R UL
032A-4 16 29 14 18.5 CBT-H 560 D HT 406 19R
038A-4 11 21 17 22.8 CBT-H 760 D HT 406 16R
045A-4 11 17 20 27.4 CBT-H 760 D HT 406 16R
3AXD00000586715.xls F
Symbols
Rmin = minimum allowed brake resistor that can be connected to the brake chopper
Rmax = maximum allowed brake resistor that allows PBRmax
PBRmax = maximum braking capacity of the drive, must exceed the desired braking power.
WARNING! Do not use a brake resistor with a resistance below the minimum
value specified for the particular drive. The drive and the internal chopper are
not able to handle the overcurrent caused by the low resistance.
Selecting and routing the brake resistor cables

Use a shielded cable with the conductor size specified in section Terminal and lead-
through data for the power cables on page 141.
Minimizing electromagnetic interference

Follow these rules in order to minimize electromagnetic interference caused by the
rapid current changes in the resistor cables:
• Install the cables away from other cable routes.
• Avoid long parallel runs with other cables. The minimum parallel cabling
separation distance should be 0.3 meters.
• Cross the other cables at right angles.
• Keep the cable as short as possible in order to minimize the radiated emissions
and stress on chopper IGBTs. The longer the cable the higher the radiated
emissions, inductive load and voltage peaks over the IGBT semiconductors of the
brake chopper.
Maximum cable length

The maximum length of the resistor cable(s) is 10 m (33 ft).
EMC compliance of the complete installation

Note: ABB has not verified that the EMC requirements are fulfilled with external user-
defined brake resistors and cabling. The EMC compliance of the complete installation
must be considered by the customer.
Placing the brake resistor

Install the resistors outside the drive in a place where they will cool.
Arrange the cooling of the resistor in a way that:
• no danger of overheating is caused to the resistor or nearby materials
• the temperature of the room the resistor is located in does not exceed the allowed
maximum.
Supply the resistor with cooling air/water according to the resistor manufacturer’s
instructions.
WARNING! The materials near the brake resistor must be non-flammable. The
surface temperature of the resistor is high. Air flowing from the resistor is of
hundreds of degrees Celsius. If the exhaust vents are connected to a ventilation
system, ensure that the material withstands high temperatures. Protect the resistor
against physical contact.
Protecting the system in brake circuit fault situations
Protecting the system in cable and brake resistor short-circuit situations
The input fuses will also protect the resistor cable when it is identical with the input
cable.
Protecting the system against thermal overload

Equipping the drive with a main contactor is highly recommended for safety reasons.
Wire the contactor so that it opens in case the resistor overheats. This is essential for
safety since the drive will not otherwise be able to interrupt the main supply if the
chopper remains conductive in a fault situation. An example wiring diagram is shown
below. We recommend that you use resistors equipped with a thermal switch (1)
inside the resistor assembly. The switch indicates overtemperature and overload.
We recommend that you also wire the thermal switch to a digital input of the drive.
L1 L2 L3
OFF
2
1 3 5 13 3
ON
2 4 6 14 4
Θ 1 ACS580
ACS580
L1 L2 L3
10 +24V
x DIx
K1
 Mechanical installation
All brake resistors must be installed outside the drive. Follow the resistor
manufacturer’s instructions.
 Electrical installation
Checking the insulation of the assembly
Follow the instructions given in section Brake resistor assembly on page Brake
resistor assembly.
Connection diagram
See section Connection diagram page 74.
Connection procedure
See section Brake resistor cable (if used) on page 79.
Connect the thermal switch of the brake resistor as described in section Protecting
the system against thermal overload on page 183.
 Start-up
Note: Protective oil on the brake resistors will burn off when the brake resistor is used
for the first time. Make sure that the airflow is sufficient.
Set the following parameters:
1. Disable the overvoltage control of the drive with parameter 30.30 Overvoltage
control.
2. Set the source of parameter 31.01 External event 1 source to point to the digital
input where the thermal switch of the brake resistor is wired.
3. Set parameter 31.02 External event 1 type to Fault.
4. Enable the brake chopper by parameter 43.06 Brake chopper enable. If Enabled
with thermal model is selected, set also the brake resistor overload protection
parameters 43.08 and 43.09 according to the application.
5. Check the resistance value of parameter 43.10 Brake resistance.
With these parameter settings, the drive generates a fault and coasts to a stop on
brake resistor overtemperature.
WARNING! If the drive is equipped with a brake chopper but the chopper is not
enabled by the parameter setting, the internal thermal protection of the drive
against resistor overheating is not in use. In this case, the brake resistor must be
disconnected.
Resistor braking, frames R5…R9

To be added
Safe torque off function 187
12
Safe torque off function
What this chapter contains
This chapter describes the Safe torque off (STO) function of the drive and gives
instructions for its use.
Description
The Safe torque off function can be used, for example, to construct safety or
supervision circuits that stop the drive in case of danger. Another possible application
is a prevention of unexpected start-up switch that enables short-time maintenance
operations like cleaning or work on non-electrical parts of the machinery without
switching off the power supply to the drive.
Note: The Safe torque off function does not disconnect the voltage from the drive,
see the warning on page 194.
When activated, the Safe torque off function disables the control voltage of the power
semiconductors of the drive output stage (A, see diagram on page 190), thus
preventing the drive from generating the torque required to rotate the motor. If the
motor is running when Safe torque off is activated, it coasts to a stop.
The Safe torque off function has a redundant architecture, that is, both channels must
be used in the safety function implementation. The safety data given in this manual is
calculated for redundant use, and does not apply if both channels are not used.
188 Safe torque off function
The Safe torque off function of the drive complies with these standards:
Standard Name
EN 60204-1:2006 + Safety of machinery – Electrical equipment of machines – Part 1:
AC:2010 General requirements
IEC 61326-3-1:2008 Electrical equipment for measurement, control and laboratory use –
EMC requirements – Part 3-1: Immunity requirements for safety-
related systems and for equipment intended to perform safety-
related functions (functional safety) – General industrial
applications
IEC 61508-1:2010 Functional safety of electrical/electronic/programmable electronic
safety-related systems – Part 1: General requirements
IEC 61508-2:2010 Functional safety of electrical/electronic/programmable electronic
safety-related systems – Part 2: Requirements for
electrical/electronic/programmable electronic safety-related
systems
IEC 61511:2003 Functional safety – Safety instrumented systems for the process
industry sector
IEC/EN 61800-5-2:2007 Adjustable speed electrical power drive systems –
Part 5-2: Safety requirements – Functional
IEC/EN 62061:2005 + Safety of machinery – Functional safety of safety-related electrical,
AC:2010 electronic and programmable electronic control systems
EN ISO 13849-1:2008 + Safety of machinery – Safety-related parts of control systems –
AC:2009 Part 1: General principles for design
EN ISO 13849-2:2012 Safety of machinery – Safety-related parts of control systems – Part
2: Validation
The function also corresponds to Prevention of unexpected start-up as specified by

EN 1037:1995 + A1:2008 and Uncontrolled stop (stop category 0) as specified in
EN 60204-1:2006 + AC:2010.
 Compliance with the European Machinery Directive

See section Compliance with the European Machinery Directive 2006/42/EC 2nd
Edition – June 2010 on page 155.
Connection principle
 Connection with internal +24 V DC power supply
Control unit Drive
K STO
OUT1 34
+ 24 V DC
OUT2 35
+ 24 V DC
SGND 36
IN1 37
IN2 38 UDC+
T1/U,
Control logic
A T2/V,
T3/W
UDC-
 Connection with external +24 V DC power supply
24 V DC Drive
- + Control unit
STO
K OUT1 34
+ 24 V DC
OUT2 35
+ 24 V DC
SGND 36
IN1 37
IN2 38 UDC+
T1/U,
Control logic
A T2/V,
T3/W
UDC-
Wiring examples
An example of a Safe torque off wiring with internal +24 V DC power supply is shown
below.
Drive Safe PLC
34 OUT1 OUT
35 OUT2
13 23 31 Y1 Y2
36 SGND
K
Safety relay
14 24 32 A1 A2
37 IN1
38 IN2
GND
An example of a Safe torque off wiring with external +24 V DC power supply is shown
below.
Drive +24 V DC external Safe PLC

power supply
- +
34 OUT1 OUT
35 OUT2
13 23 31 Y1 Y2
36 SGND
K
Safety relay
14 24 32 A1 A2
37 IN1
38 IN2
GND
For information on the specifications of the STO input, see chapter Control
connection data (page 146).
 Activation switch
In the wiring diagram above (page 190), the activation switch has the designation (K).
This represents a component such as a manually operated switch, an emergency
stop push button switch, or the contacts of a safety relay or safety PLC.
• If a manually operated activation switch is used, the switch must be of a type that
can be locked out to the open position.
• Inputs IN1 and IN2 must open/close within 200 ms of each other.
 Cable types and lengths

• Double-shielded twisted-pair cable is recommended.
• Maximum cable length 300 m (984 ft) between activation switch (K) and drive
control unit.
Note: A short-circuit in the wiring between the switch and an STO terminal causes a
dangerous fault and therefore it is recommended to use a safety relay (including
wiring diagnostics), or a wiring method (shield grounding, channel separation) which
reduces or eliminates the risk caused by the short-circuit.
Note: The voltage at the INx terminals of each drive must be at least 13 V DC to be
interpreted as “1”. Pulse tolerance of input channels is 1 ms.
 Grounding of protective shields

• Ground the shield in the cabling between the activation switch and the control
board at the control board.
• Ground the shield in the cabling between two control boards at one control board
only.
Operation principle
1. The Safe torque off activates (the activation switch is opened, or safety relay
contacts open).
2. The STO inputs IN1 and IN2 on the drive control board de-energize.
3. The STO cuts off the control voltage from the drive IGBTs.
4. The control program generates an indication as defined by parameter 31.22 STO
indication run/stop.
The parameter selects which indications are given when one or both Safe torque
off (STO) signals are switched off or lost. The indications also depend on whether
the drive is running or stopped when this occurs.
Note: This parameter does not affect the operation of the STO function itself. The
STO function will operate regardless of the setting of this parameter: a running
drive will stop upon removal of one or both STO signals, and will not start until
both STO signals are restored and all faults reset.
Note: The loss of only one STO signal always generates a fault as it is interpreted
as a malfunction of STO hardware or wiring.
5. Motor coasts to a stop (if running). The drive cannot restart while the activation
switch or safety relay contacts are open. After the contacts close, a new start
command is required to start the drive.
Start-up including acceptance test

To ensure the safe operation of a safety function, validation is required. The final
assembler of the machine must validate the function by performing an acceptance
test. The acceptance test must be performed
• at initial start-up of the safety function
• after any changes related to the safety function (circuit boards, wiring,
components, settings, etc.)
• after any maintenance work related to the safety function.
 Authorized person
The acceptance test of the safety function must be carried out by an authorized
person with expertise and knowledge of the safety function. The test must be
documented and signed by the authorized person.
An authorized person is an individual with authorization from the machine builder or
end user to carry out, report and sign off the safety function validation / acceptance
testing on behalf of the machine builder or end user.
 Acceptance test reports

Signed acceptance test reports must be stored in the logbook of the machine. The
report shall include documentation of start-up activities and test results, references to
failure reports and resolution of failures. Any new acceptance tests performed due to
changes or maintenance shall be logged into the logbook.
 Acceptance test procedure

After wiring the Safe torque off function, validate its operation as follows.
Action
WARNING! Follow the Safety instructions, page 11. Ignoring the

instructions can cause physical injury or death, or damage to the
equipment.
Ensure that the drive can be run and stopped freely during start-up.
Stop the drive (if running), switch the input power off and isolate the drive from the
power line by a disconnector.
Check the Safe torque off circuit connections against the wiring diagram.
Close the disconnector and switch the power on.
Test the operation of the STO function when the motor is stopped.
• Give a stop command for the drive (if running) and wait until the motor shaft is at a
standstill.
Ensure that the drive operates as follows:
• Open the STO circuit. The drive generates an indication if one is defined for the
‘stopped’ state in parameter 31.22 STO indication run/stop. For the description of
the warning, see ACS580 firmware manual (3AXD50000016097 [English]).
• Give a start command to verify that the STO function blocks the drive’s operation.
The drive displays a warning. The motor should not start.
• Close the STO circuit.
• Reset any active faults. Restart the drive and check that the motor runs normally.
Test the operation of the STO function when the motor is running.
• Start the drive and ensure the motor is running.
• Open the STO circuit. The motor should stop. The drive generates an indication if
one is defined for the ‘running’ state in parameter 31.22 STO indication run/stop.
For the description of the warning, see ACS580 firmware manual
(3AXD50000016097 [English]).
• Reset any active faults and try to start the drive.
• Ensure that the motor stays at a standstill and the drive operates as described
above in testing the operation when the motor is stopped.
• Close the STO circuit.
• Reset any active faults. Restart the drive and check that the motor runs normally.
Document and sign the acceptance test report which verifies that the safety function is
safe and accepted for operation.
Use
1. Open the activation switch, or activate the safety functionality that is wired to the
STO connection.
2. STO inputs on the drive control unit de-energize, and the drive control unit cuts off
the control voltage from the drive IGBTs.
3. The control program generates an indication as defined by parameter 31.22 STO
indication run/stop.
4. The motor coasts to a stop (if running). The drive will not restart while the
activation switch or safety relay contacts are open.
5. Deactivate the STO by closing the activation switch, or resetting the safety
functionality that is wired to the STO connection.
6. Reset any faults before restarting.
WARNING! The Safe torque off function does not disconnect the voltage of
the main and auxiliary circuits from the drive. Therefore maintenance work
on electrical parts of the drive or the motor can only be carried out after
isolating the drive from the main supply.
WARNING! (With permanent magnet motors only) In case of a multiple

IGBT power semiconductor failure, the drive system can produce an
alignment torque which maximally rotates the motor shaft by 180/p
degrees regardless of the activation of the Safe torque off function. p
denotes the number of pole pairs.
Notes:
• If a running drive is stopped by using the Safe torque off function, the drive will cut
off the motor supply voltage and the motor will coast to a stop. If this causes
danger or is not otherwise acceptable, stop the drive and machinery using the
appropriate stop mode before activating the Safe torque off function.
• The Safe torque off function overrides all other functions of the drive unit.
• The Safe torque off function is ineffective against deliberate sabotage or misuse.
• The Safe torque off function has been designed to reduce the recognized
hazardous conditions. In spite of this, it is not always possible to eliminate all
potential hazards. The assembler of the machine must inform the final user about
the residual risks.
Maintenance
After the operation of the circuit is validated at start-up, the STO function shall be
maintained by periodic proof testing. In high demand mode of operation, the
maximum proof test interval is 20 years. In low demand mode of operation, the
maximum proof test interval is 2 years. The test procedure is given in section
Acceptance test procedure (page 193).
In addition to proof testing, it is a good practice to check the operation of the function
when other maintenance procedures are carried out on the machinery.
Include the Safe torque off operation test described above in the routine maintenance
program of the machinery that the drive runs.
If any wiring or component change is needed after start up, or the parameters are
restored, follow the test given in section Acceptance test procedure (page 193).
Use only ABB approved spare parts.
Fault tracing
The indications given during the normal operation of the Safe torque off function are
selected by parameter 31.22 STO indication run/stop.
The diagnostics of the Safe torque off function cross-compare the status of the two
STO channels. In case the channels are not in the same state, a fault reaction
function is performed and the drive trips on an “STO hardware failure” fault. An
attempt to use the STO in a non-redundant manner, for example activating only one
channel, will trigger the same reaction.
See the drive firmware manual for the indications generated by the drive, and for
details on directing fault and warning indications to an output on the control unit for
external diagnostics.
Any failures of the Safe torque off function must be reported to ABB.
Safety data
The safety data for the Safe torque off function is given below.
Note: The safety data is calculated for redundant use, and does not apply if both STO
channels are not used.
Frame IEC 61508 and IEC/EN 61800-5-2

size SIL PFHd HFT SFF T1 PFD
(1/h) (%) (a)
R0 3 2.68E-09 1 99.8 20 2.8E-06
R1 3 2.68E-09 1 99.8 20 2.8E-06
R2 3 2.68E-09 1 99.8 20 2.8E-06
R3 3 2.68E-09 1 99.8 20 2.8E-06
R5 3 7.09E-10 1 99.9 20 5.91E-05
R6 3 1.06E-09 1 99.8 20 8.85E-05
R7 3 1.06E-09 1 99.8 20 8.85E-05
R8 3 1.4E-09 1 99.7 20 9.04E-05
R9 3 1.4E-09 1 99.7 20 9.04E-05
Frame EN ISO 13849-1 IEC/EN IEC 61511

size 62061
1 2
PL CCF MTTFd DC Category SILCL SIL
(%) (a) (%)
R0 e 80 2938.483 >90 3 3 3
R1 e 80 2938.483 >90 3 3 3
R2 e 80 2938.192 >90 3 3 3
R3 e 80 2938.192 >90 3 3 3
R5 e 80 16033.9 >90 3 3 3
R6 e 80 10876.08 >90 3 3 3
R7 e 80 10876.08 >90 3 3 3
R8 e 80 2490.467 >90 3 3 3
R9 e 80 2490.467 >90 3 3 3
1
100 years must be used for calculation of a safety loop. 3AXD00000586715.xls F
2 According to standard EN ISO 13849-1 table E.1
• The following temperature profile is used in safety value calculations:

• 670 on/off cycles per year with T = 71.66 °C
• 32 °C board temperature at 2.0% of time
• 60 °C board temperature at 1.5% of time
• 85 °C board temperature at 2.3% of time.
• The STO is a type A safety component as defined in IEC 61508-2.

• Relevant failure modes:
• The STO trips spuriously (safe failure)
• The STO does not activate when requested
A fault exclusion on the failure mode “short circuit on printed circuit board” has
been made (EN 13849-2, table D.5). The analysis is based on an assumption that
one failure occurs at one time. No accumulated failures have been analyzed.
• STO reaction time (shortest detectable break): 1 ms
• STO response time: 2 ms (typical), 5 ms (maximum)
• Fault detection time: Channels in different states for longer than 200 ms
• Fault reaction time: Fault detection time + 10 ms
• STO fault indication (parameter 31.22) delay: < 500 ms
• STO warning indication (parameter 31.22) delay: < 1000 ms
• Maximum cable length 300 m (984 ft) between activation switch (K) and drive
control unit.
• The voltage at the INx terminals of each drive must be at least 13 V DC to be
interpreted as “1”. Pulse tolerance of input channels is 1 ms.
 Abbreviations
Abbr. Reference Description
CCF EN ISO 13849-1 Common cause failure (%)
DC EN ISO 13849-1 Diagnostic coverage
FIT IEC 61508 Failure in time: 1E-9 hours
HFT IEC 61508 Hardware fault tolerance
MTTFd EN ISO 13849-1 Mean time to dangerous failure: (The total number of life
units) / (the number of dangerous, undetected failures)
during a particular measurement interval under stated
conditions
PFD IEC 61508 Probability of failure on demand
PFHD IEC 61508 Probability of dangerous failures per hour
PL EN ISO 13849-1 Performance level. Levels a…e correspond to SIL
SC IEC 61508 Systematic capability
SFF IEC 61508 Safe failure fraction (%)
SIL IEC 61508 Safety integrity level (1…3)
SILCL EN 62061 Maximum SIL (level 1…3) that can be claimed for a safety
function or subsystem
STO IEC/EN 61800-5-2 Safe torque off
T1 IEC 61508 Proof test interval
 Declaration of conformity
Declaration of conformity (3AXD10000302783) is available on the Internet. See
section Document library on the Internet on the inside of the back cover.
 Certificate
TÜV certificate (3AXD10000302787) is available on the Internet. See section
Document library on the Internet on the inside of the back cover.
Optional I/O extension modules 199
13
Optional I/O extension
modules
What this chapter contains
This chapter describes how to install and start up the optional CMOD-01 and
CMOD-01 multifunction extension modules. The chapter also contains diagnostics
and technical data.
CMOD-01 multifunction extension module (external

24 V AC/DC and digital I/O)
 Safety instructions
WARNING! Obey the safety instructions for the drive. If you ignore the safety
instructions, injury or death can occur.
 Hardware description
Product overview
The CMOD-01 multifunction extension module (external 24 V AC/DC and digital I/O)
expands the outputs of the drive control unit. It has two relay outputs and one
transistor output, which can function as a digital or frequency output.
In addition, the extension module has an external power supply interface, which can
be used to power up the drive control unit in case the drive power supply fails. If you
do not need the back-up power supply, you do not have to connect it because the
module is powered from the drive control unit by default.
200 Optional I/O extension modules
Note: In frames R5…R9, you do not need a CMOD-01 module to use external
24 V AC/DC supply. The external supply is connected directly to terminals 40 and 41
on the control unit.
Layout
5
3
6
4 3
Item Description Additional

information
1 Grounding screw Page 200
2 Hole for mounting screw Page 200
3 3-pin terminal blocks for relay outputs Page 201
4 3-pin terminal block for transistor output Page 201
5 2-pin terminal block for external power supply Page 201
6 Diagnostic LED Page 205
Necessary tools and instructions
• Screwdriver and a set of suitable bits.
Unpacking and checking the delivery

1. Open the option package.
2. Make sure that the package contains:
• CMOD-01 multifunction extension module
• mounting screw.
3. Make sure that there are no signs of damage.
Installing the module

See chapter Installing option modules on page 104.
Warnings

you ignore them, injury or death, or damage to the equipment can occur. If you
are not a qualified electrician, do not do electrical work.
Make sure that the drive is disconnected from the input power during
installation. If the drive is already connected to the input power, wait for
5 minutes after disconnecting the input power.

• Screwdriver and a set of suitable bits
• Cabling tools
Terminal designations
For more detailed information on the connectors, see section Technical data on
page 205.
Relay outputs
Marking Description
50 RO4C Common, C
51 RO4A Normally closed, NC
52 RO4B Normally open, NO
53 RO5C Common, C
54 RO5A Normally closed, NC
55 RO5B Normally open, NO
Transistor output
Marking Description
42 DO1 SRC Source input
43 DO1 OUT Digital or frequency output
44 DO1 SGND Ground (earth) potential
External power supply6

The external power supply is needed only if you want to connect an external back-up
power supply for the drive control unit
Note: Only frames R0…R3 need CMOD-01 (or CMOD-02) for connecting external
power supply, frames R5…R9 have corresponding terminals 40 and 41 on the control
unit.
Marking Description
40 24V AC/DC + in External 24 V (AC/DC) input
41 24V AC/DC - in External 24 V (AC/DC) input
General cabling instructions

Obey the instructions given in chapter Planning the electrical installation on page 53.
Wiring
Connect the external control cables to the applicable module terminals. Ground the
outer shield of the cables 360 degrees under a grounding clamp on the grounding
shelf of the control cables.
Relay output connection example
RO4C
50
RO4A
24 V DC 51
RO4B
52
CMOD-01
Digital output connection example
42 DO1 SRC
24 V DC
43 DO1 OUT
44 DO1 SGND
CMOD-01
Frequency output connection example
1) 42 DO1 SRC
43 DO1 OUT
44 DO1 SGND
CMOD-01
1) An externally supplied frequency indicator which provides, for example:

• a 40 mA / 12 V DC power supply for the sensor circuit (CMOD frequency output)
• suitable voltage pulse input (10 Hz … 16 kHz).
External power supply connection example
+
1) 40 24V AC/DC - in
- 41 24V AC/DC + in
CMOD-01
1)
External power supply, 24 V AC/DC
 Start-up
Setting the parameters
1. Power up the drive.
2. If no warning is shown,
• make sure that the value of both parameter 15.02 Detected extension module
and parameter 15.01Extension module type is CMOD-01.
If warning A7AB Extension I/O configuration failure is shown,
• make sure that the value of parameter 15.02 Detected extension module is
CMOD-01.
• set parameter 15.01 Extension module type to CMOD-01.
You can now see the parameters of the extension module in parameter group 15
I/O extension module (page 252).
3. Set the parameters of the extension module to applicable values.
Examples are given below.
Parameter setting example for relay output

This example shows how make relay output RO4 of the extension module indicate
the reverse direction of rotation of the motor with a one-second delay.
Parameter Setting
15.07 RO4 source Reverse
15.08 RO4 ON delay 1s
15.09 RO4 OFF delay 1s
Parameter setting example for digital output

This example shows how to make digital output DO1 of the extension module indicate
the reverse direction of rotation of the motor with a one-second delay.
Parameter Setting
15.22 DO1 configuration Digital output
15.23 DO1 source Reverse
15.24 DO1 ON delay 1s
15.25 DO1 OFF delay 1s
Parameter setting example for frequency output

This example shows how to make digital output DO1 of the extension module indicate
the motor speed 0... 1500 rpm with a frequency range of 0...10000 Hz.
Parameter Setting
15.22 DO1 configuration Frequency output
15.33 Freq out 1 source 01.01
15.34 Freq out 1 src min 0
15.35 Freq out 1 src max 1500.00
15.36 Freq out 1 at src min 1000 Hz
15.37 Freq out 1 at src max 10000 Hz
 Diagnostics
Faults and warning messages
Warning A7AB Extension I/O configuration failure, see page 429.
LEDs
The extension module has one diagnostic LED.
Color Description
Green The extension module is powered up.
 Technical data
Dimension drawing:
The dimensions are in millimeters and [inches].
Installation: Into an option slot on the drive control unit

Degree of protection: IP20
Ambient conditions: See the drive technical data.
Package: Cardboard
Isolation areas:
CMOD-01
Plugged to
24 Vin drive SLOT2 RO4
DO1 RO5
Symbol Description
Reinforced insulation (IEC 61800-5-1:2007)
Functional insulation (IEC 61800-5-1:2007)
Relay outputs (50…52, 53…55):

• Wire size max. 1.5 mm2
• Minimum contact rating: 12 V / 10 mA
• Maximum contact rating: 250 V AC / 30 V DC / 2 A
• Maximum breaking capacity: 1500 VA
Transistor output (42…44):
• Type: Transistor output PNP
• Maximum switching voltage: 30 V DC
• Maximum switching current: 100 mA / 30 V DC, short-circuit protected
• Frequency: 10 Hz … 16 kHz
• Resolution: 1 Hz
• Accuracy: 0.2%
External power supply (40…41):

• 24 V AC / V DC ±10% (GND, user potential)
• Maximum current consumption: 25 W, 1.04 A at 24 V DC
CMOD-02 multifunction extension module

(external 24 V AC/DC and isolated PTC interface)
 Safety instructions
WARNING! Obey the safety instructions for the drive. If you ignore the safety
instructions, injury or death can occur.
 Hardware description
Product overview
The CMOD-02 multifunction extension module (external 24 V AC/DC and isolated
PTC interface) has a motor thermistor connection for supervising the motor
temperature and one relay output, which indicates the thermistor status. To trip the
drive, the user must connect this overtemperature indication back to the drive, for
example, to its Safe torque off input.
In addition, the extension module has an external power supply interface, which can
be used to power up the drive control unit in case the drive power supply fails. If you
do not need the back-up power supply, you do not have to connect it because the
module is powered from the drive control unit by default.
There is reinforced insulation between the motor thermistor connection, the relay
output and the drive control unit interface. Thus, you can connect a motor thermistor
to the drive through the extension module.
Note: In frames R5…R9, you do not need a CMOD-01 module to use external
24 V AC/DC supply. The external supply is connected directly to terminals 40 and 41
on the control unit.
Layout
5 4
6 3
Item Description Additional

information
1 Grounding screw Page 209
2 Hole for mounting screw Page 209
3 2-pin terminal block for motor thermistor connection Page 210
4 2-pin terminal block for relay output Page 210
5 2-pin terminal block for external power supply Page 210
6 Diagnostic LED Page 213
Unpacking and checking the delivery

1. Open the option package.
2. Make sure that the package contains:
• CMOD-02 multifunction extension module
• mounting screw
3. Make sure that there are no signs of damage.
Installing the module

See chapter Installing option modules on page 104.
Warnings

you ignore them, injury or death, or damage to the equipment can occur. If you
are not a qualified electrician, do not do electrical work.
Make sure that the drive is disconnected from the input power during
installation. If the drive is already connected to the input power, wait for
5 minutes after disconnecting the input power.

• Cabling tools
Terminal designations
For more detailed information on the connectors, see section Technical data on
page 214.
Motor thermistor connection

Marking Description
60 PTC IN PTC connection
61 PTC IN Ground (earth) potential
Relay output
Marking Description
62 RO PTC C Common, C
63 RO PTC B Normally open, NO
External power supply

The external power supply is needed only if you want to connect an external back-up
power supply for the drive control unit.
Note: Only frames R0…R3 need CMOD-01 (or CMOD-02) for connecting external
power supply, frames R5…R9 have corresponding terminals 40 and 41 on the control
unit.
Marking Description
40 24V AC/DC + in External 24 V (AC/DC) input
41 24V AC/DC - in External 24 V (AC/DC) input
General cabling instructions

Obey the instructions given in chapter Planning the electrical installation on page 53.
Wiring
Connect the external control cables to the applicable module terminals. Ground the
outer shield of the cables 360 degrees under a grounding clamp on the grounding
shelf of the control cables
Motor thermistor connection example
1)
60 PTC IN
61 PTC IN
CMOD-02
1)
One or 3…6 PTC thermistors connected in series.
Relay output connection example
CMOD-02
RO PTC C
62
63
RO
PTC B
X4 CCU
34 OUT1
35 OUT2
36 SGND
37 IN1
38 IN2
Power supply connection example
+
1) 40 24V AC/DC - in
- 41 24V AC/DC + in
CMOD-02
1) External power supply, 24 V AC/DC
 Start-up
Setting the parameters
1. Power up the drive.
2. If no warning is shown,
• make sure that the value of both parameter 15.02 Detected extension module
and parameter 15.01Extension module type is CMOD-02.
If warning A7AB Extension I/O configuration failure is shown,
• make sure that the value of parameter 15.02 Detected extension module is
CMOD-02.
• set parameter 15.01 Extension module type to CMOD-02.
You can now see the parameters of the extension module in parameter group 15
I/O extension module (page 252).
 Diagnostics
Faults and warning messages
Warning A7AB Extension I/O configuration failure, see page 429.
LEDs
The extension module has one diagnostic LED.
Color Description
Green The extension module is powered up.
 Technical data
Dimension drawing:
The dimensions are in millimeters and [inches].
Installation: Into an option slot on the drive control unit

Degree of protection: IP20
Ambient conditions: See the drive technical data.
Package: Cardboard
Isolation areas:
CMOD-02
Plugged to
24 Vin drive SLOT2 RO PTC
PTCin
Symbol Description
Reinforced insulation (IEC 61800-5-1:2007)
Functional insulation (IEC 61800-5-1:2007)
Motor thermistor connection (60…61):

• Supported standards: DIN 44081 and DIN 44082
• Number of PTC thermistor relays: 1 or 3…6 in series
• Triggering threshold: 3.6 kohm
• Recovery threshold: 1.6 kohm
• PTC terminal voltage: < 5.0 V
• PTC terminal current: < 1 mA
• Short-circuit detection: < 50 ohm
Relay output (62…63):
• Maximum contact rating: 250 V AC / 30 V DC / 5 A
• Maximum breaking capacity: 1000 VA
External power supply (40…41):
• 24 V AC / V DC ±10% (GND, user potential)
• Maximum current consumption: 25 W, 1.04 A at 24 V DC
Further information
Product and service inquiries
Address any inquiries about the product to your local ABB representative, quoting
the type designation and serial number of the unit in question. A listing of ABB sales,
support and service contacts can be found by navigating to
www.abb.com/searchchannels.
Product training
For information on ABB product training, navigate to www.abb.com/drives and select
Training courses.
Providing feedback on ABB Drives manuals

Your comments on our manuals are welcome. Go to www.abb.com/drives and select
Document Library – Manuals feedback form (LV AC drives).
Document library on the Internet

You can find manuals and other product documents in PDF format on the Internet.
Go to www.abb.com/drives and select Document Library. You can browse the library
or enter selection criteria, for example a document code, in the search field.
Contact us
www.abb.com/drives
www.abb.com/drivespartners
3AXD50000018826 Rev C (EN) 2014-10-21
3AXD50000018826C

106 Electrical Installation: Wiring The Modules

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106 Electrical installation

 Wiring the modules

 Reinstalling covers, frame R5

 Reinstalling side plates and covers, frames R6…R9

WARNING! Obey the instructions in chapter Safety instructions on page 11. If

If the drive will be connected to an IT (ungrounded) or corner-grounded TN supply

Appropriate supply fuses and disconnector have been installed.

Drive and motor connection box covers are in place.

 Preventive maintenance intervals

WARNING! Obey the instructions in chapter Safety instructions on page 11.

 Replacing the cooling fan, frames R0…R3

WARNING! Obey the instructions in chapter Safety instructions on page 11.

3. Install the fan assembly in reverse order.

 Replacing the cooling fan, frame R5

WARNING! Obey the instructions in chapter Safety instructions on page 11.

 Replacing the main cooling fan, frames R6…R8

WARNING! Obey the instructions in chapter Safety instructions on page 11.

 Replacing the main cooling fans, frame R9

WARNING! Obey the instructions in chapter Safety instructions on page 11.

 Replacing the auxiliary cooling fan, frames R6…R9

WARNING! Obey the instructions in chapter Safety instructions on page 11.

 Reforming the capacitors

 Replacing the battery in the assistant control panel

 Assistant panel LEDs

See definitions and notes on page 129.

 Ambient temperature derating, IP21

 Ambient temperature derating, IP55

 IP55 (UL Type 12) type -045A-4

 IP55 (UL Type 12) drive type -293A-4

 IP55 (UL Type 12) drive type -363A-4

 IP55 (UL Type 12) type -430A-4

 Switching frequency derating

Dimensions, weights and free space requirements

Frame Dimensions and weights

Frame Free space

Losses, cooling data and noise

Terminal and lead-through data for the power cables

Frame Screwdrivers for the terminals of the main circuit

Frame Cable lead- R+, R-, UDC+ and UDC- terminals

Terminal and lead-through data for the control cables

Electrical power network specification

Maximum recommended motor Operational functionality and motor cable length

Frame Maximum motor cable length, 4 kHz

Note: In multimotor systems, the calculated sum of all

EMC compatibility and motor cable length

Frame Maximum motor cable length, 4 kHz

Note 2: Radiated emissions are according to C2 with an

Brake resistor connection data

Control connection data

Relay outputs RO1…RO3 250 V AC / 30 V DC, 2 A

Isolation areas, R0…R3 (CCU-11):

Functional insulation (IEC/EN 61800-5-1:2007)

Isolation areas, R5…R9 (CCU-12):

Grounding of frames R0…R3 (CCU-11)

*) Jumper installed at factory

Grounding of frames R5…R9 (CCU-12)

*) Jumper installed at factory

Auxiliary circuit power consumption

Atmospheric pressure 70 to 106 kPa 70 to 106 kPa 60 to 106 kPa