ABB ACQ 580 04 R10 User Manual

ABB DRIVES FOR WATER  
ACQ580-04 R10 and R11 drives  
Quick installation guide  
3
O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15  
P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15  
Q. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15  
S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15  
X . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16  
Quick installation guide  
5
Quick installation guide  
Contents of this guide  
This guide tells you briefly how to install the drive module into a 600 mm wide cabinet.  
For installation examples in different cabinets and more detailed instructions,  
document number 3AXD50000048677 [English]).  
Obey the safety instructions  
See figure A on page 13. If you ignore these instructions, injury or death, or damage to  
the equipment can occur.  
WARNING! Handle the drive module carefully. Open the support legs by  
pressing each leg a little down and turning it aside (1, 2).  
Do not tilt the drive module. It is heavy and its center of gravity is high.  
The module will overturn from a sideways tilt of 5 degrees. Do not leave the module  
unattended on a sloping floor.  
To prevent the drive module from falling, attach its top lifting lugs with chains to the  
cabinet frame before you push the module into the cabinet. Work carefully preferably  
with help from another person. Keep a constant pressure with one foot on the base of  
the module to prevent the module from falling on its back.  
WARNING! If you are not a qualified electrician, do not do installation or  
maintenance work. Go through these steps before you begin any installation  
or maintenance work.  
1. Clearly identify the work location.  
2. Disconnect all possible voltage sources.  
Open the main disconnecter of the drive.  
Open the disconnecter of the supply transformer as the main disconnecter of  
the drive does not remove the voltage from the input busbars of the drive.  
Make sure that reconnection is not possible. Lock the disconnecters to open  
position and attach a warning notice to them.  
Disconnect any external power sources from the control circuits before you  
do work on the control cables.  
After you disconnect the drive, always wait for 5 minutes to let the  
intermediate circuit capacitors discharge before you continue.  
3. Protect any other energized parts in the work location against contact.  
4. Take special precautions when close to bare conductors.  
5. Measure that the installation is de-energized.  
Use a multimeter with an impedance of at least 1 Mohm.  
     
6 Quick installation guide  
Make sure that the voltage between the drive module input power terminals  
(L1/U1, L2/V1, L3/W1) and the grounding (PE) busbar is close to 0 V.  
Make sure that the voltage between the drive module UDC+ and UDC-  
terminals and the grounding (PE) busbar is close to 0 V.  
6. Install temporary grounding as required by the local regulations.  
7. Ask for a permit to work from the person in control of the electrical installation work.  
Select the power cables  
Size the power cables according to local regulations to carry the nominal current given  
on the type designation label of your drive.  
Ensure the cooling and fuses (UL)  
See the table below for the losses and cooling air flow through the drive. The allowed  
operating temperature range of the drive without derating is -15 to +40 °C.  
Air flow  
ft3/min  
707  
707  
707  
707  
707  
848  
Heat dissipation  
W
5602  
6409  
8122  
8764  
9862  
10578  
Fuse  
Type  
Drive type  
UL class  
ACQ580-505A-4  
ACQ580-585A-4  
ACQ580-650A-4  
ACQ580-725A-4  
ACQ580-820A-4  
ACQ580-880A-4  
T
L
L
L
L
L
JJS-600  
A4BY800  
A4BY800  
A4BY800  
A4BY900  
A4BY1000  
For more information, see the hardware manual 3AXD5000004867748677 (English).  
Protect the drive and input power cables  
See the table above for the UL class fuses for branch circuit protection per NEC. Check  
that the operating time of the fuse is below 0.1 seconds. Obey local regulations.  
Install the drive module into a cabinet  
See figure B on page 13:  
Install the punched section to the back of the cabinet frame.  
Remove the pedestal guide plate from the bottom of the drive module.  
Install the support rails and pedestal guide plate to the cabinet bottom frame.  
Install the telescopic insertion ramp to the pedestal guide plate.  
For option +B051: See figure C on page 13:  
Remove the sheeting from the clear plastic shrouds from both sides.  
See figure D on page 13:  
Install the mounting bracket to the drive module.  
For option +B051:  
Install the bottom grille to the drive module if there is no bottom plate in the  
cabinet and degree of protection of IP20 is needed for the drive module from  
the bottom side.  
       
Quick installation guide  
7
Install the top metallic shroud to the drive module.  
Install the back shrouds to the drive module.  
See figure E on page 13:  
Attach the drive module to the cabinet frame with chains.  
Push the drive module into the cabinet along the telescopic insertion ramp.  
Remove the ramp.  
See figure F on page 13:  
Attach the drive module to the pedestal guide plate.  
Attach the drive module from top to the punched section at the cabinet back.  
Note: The mounting bracket grounds the drive module to the cabinet frame.  
Check the insulation of the input and motor cables and the  
motor  
Check the insulation of the input cable according to local regulations before you  
connect it to the drive.  
See figure H on page 14. Ground the motor cable shield at the motor end. For minimal  
interference, make a 360-degree grounding at the cable lead-through, or keep the pig  
tail short.  
Check the insulation of the motor and motor cable when the motor cable is  
disconnected from the drive, see figure I on page 14. Measure the insulation  
resistance between each phase conductor and then between each phase conductor  
and the Protective Earth conductor using a measuring voltage of 1000 V DC. The  
insulation resistance of an ABB motor must exceed 100 Mohm (reference value at  
25 °C or 77 °F). For the insulation resistance of other motors, consult the  
manufacturer’s instructions. Note: Moisture inside the motor casing will reduce the  
insulation resistance. If you suspect moisture, dry the motor and repeat the  
measurement.  
 
8 Quick installation guide  
Connect the power cables (and install the shrouds for option  
+B051)  
See figure G on page 14.  
Step  
Task (motor cables)  
Figure Page  
Install the grounding terminal to the drive module base.  
1
2
Run the motor cables to the cabinet. Ground the cable shields  
360 degrees at the cabinet lead-through.  
Connect the twisted shields of the motor cables to the  
grounding terminal.  
Screw in and tighten the insulators to the drive module by hand.  
Install the T3/W2 connection terminal to the insulators.  
WARNING! Do not use longer screws or  
bigger tightening torque than given in the  
installation drawing. They can damage the  
insulator and cause dangerous voltage to be  
present at the module frame.  
3
4
Connect the phase conductors to the T3/W2 terminal.  
-
-
5
6
Install the T2/V2 connection terminal to the insulators. See the  
warning in step 4.  
Connect the phase conductors to the T2/V2 connection  
terminal.  
Install the T1/U2 connection terminal to the insulators. See the  
warning in step 4.  
7
8
-
-
-
-
-
-
Connect the phase conductors to the T1/U2 terminal.  
9
For option +B051 (if there is no bottom plate in the cabinet and  
degree of protection of IP20 is needed):  
10  
• Step drill carefully sufficiently big holes to the inner clear plastic  
shrouds for the motor cables to the connected. Smooth the hole  
edges. Cut the shroud from the holes to the edge to make it  
possible to put the shroud around the cables.  
• Remove the plastic sheeting from the shrouds from both sides.  
For option +B051: Put the inner clear plastic shrouds of figure O  
around the motor cables.  
For option +B051: Remove the plastic sheeting from the output  
clear plastic shroud from both sides. Install the shroud to the  
drive module.  
11  
12  
For option +B051: Install the lower front cover to the drive  
module.  
13  
Step  
Task (input cables)  
Figure Page  
Ground the input cable shields (if present) 360 degrees at the  
cabinet lead-through.  
Connect the twisted shields of the input cables and separate  
ground cable (if present) to the cabinet grounding busbar.  
1
-
-
-
-
2
 
Quick installation guide  
9
Step  
3
Task (input cables)  
Figure Page  
For option +B051:  
• Step drill carefully sufficiently big holes to the lead-through clear  
plastic shroud for the cables to the connected.  
• Align the holes in the vertical direction according to the  
alignment holes in the shroud. Smooth the hole edges.  
• Remove the plastic sheeting from both sides of the shroud.  
• Attach the cables firmly to the cabinet frame to prevent chafing  
against the hole edges.  
For option +B051: Put the conductors of the input cables  
through the drilled holes in the clear plastic shroud.  
Connect the input power cable conductors to the L1/U1, L2/V1  
and L3/W1 connection busbars.  
For option +B051: Move the lead-through clear plastic shroud  
along input cables to its final position. Install the front clear  
plastic shroud.  
4
5
6
Install the upper front cover.  
7
Remove the cardboard protective covering from the drive  
module air outlet.  
8
For option +B051: Cut the hole for the lead-through clear plastic  
shroud in the side clear plastic shroud. Install the side and top  
clear plastic shrouds to the drive module.  
9
Install the air baffles  
See figure W on page 16 and Guidelines for planning the cabinet installation in the  
hardware manual.  
Connect the control cables  
See figure X on page 16.  
1. Ground the outer shields of all external control cables 360 degrees at the cabinet  
lead-through.  
2. Ground the pair-cable shields of external control cables to a grounding clamp  
below the control unit. Leave the other end of the shields unconnected or ground  
them indirectly via a high-frequency capacitor with a few nanofarads, eg, 3.3 nF /  
630 V.  
3. Connect the conductors to the appropriate terminals of the control unit. See page  
10.  
4. Wire the optional modules if included in the delivery.  
   
10 Quick installation guide  
Default I/O connections  
Default I/O connections are shown below.  
X1  
1
2
3
4
Reference voltage and analog inputs and outputs  
SCR  
AI1  
Signal cable shield (screen)  
Output frequency/speed reference: 0…10 V  
Analog input circuit common  
Reference voltage 10 V DC  
Not configured  
AGND  
+10V  
AI2  
5
6
7
8
9
AGND  
AO1  
AO2  
Analog input circuit common  
Output frequency: 0…20 mA  
Output current: 0…20 mA  
Analog output circuit common  
AGND  
X2 & X3 Aux. voltage output and programmable digital inputs  
10  
11  
12  
13  
14  
15  
16  
17  
18  
+24V  
DGND  
DCOM  
DI1  
DI2  
DI3  
DI4  
DI5  
DI6  
Aux. voltage output +24 V DC, max. 250 mA  
Aux. voltage output common  
Digital input common for all  
Stop (0) / Start (1)  
Forward (0) / Reverse (1)  
Constant frequency/speed selection  
Constant frequency/speed selection  
Ramp set 1 (0) / Ramp set 2 (1)  
Not configured  
X6, X7, X8 Relay outputs  
19  
20  
21  
22  
23  
24  
25  
26  
27  
X5  
29  
30  
31  
S4  
S5  
X4  
34  
35  
36  
37  
38  
RO1C  
RO1A  
RO1B  
RO2C  
RO2A  
RO2B  
RO3C  
RO3A  
RO3B  
Ready run  
250 V AC / 30 V DC  
2 A  
Running  
250 V AC / 30 V DC  
2 A  
Fault (-1)  
250 V AC / 30 V DC  
2 A  
EIA-485 Modbus RTU  
B+  
Embedded Modbus RTU (EIA-485)  
A-  
DGND  
TERM  
BIAS  
Serial data link termination switch  
Serial data link bias resistors switch  
Safe torque off  
OUT1  
Safe torque off. Factory connection. Both circuits  
must be closed for the drive to start. See chapter  
The Safe torque off function in ACQ580-01 (0.75  
to 250 kW, 1.0 to 350 hp) hardware manual  
(3AXD50000048677[English]).  
OUT2  
SGND  
IN1  
IN2  
Total load capacity of the Auxiliary voltage output +24V (X2:10) is 6.0 W (250 mA / 24 V DC).  
Wire sizes:  
0.2…2.5 mm2 (24…14 AWG): Terminals +24V, DGND, DCOM, B+, A-, DGND, Ext. 24V  
0.14…1.5 mm2 (26…16 AWG): Terminals DI, AI, AO, AGND, RO, STO  
Tightening torques: 0.5…0.6 N·m (0.4 lbf·ft)  
Total load capacity of the Auxiliary voltage output +24V (X2:10) is 6.0 W (250 mA / 24 V  
DC).  
Wire sizes: 0.14…2.5 mm2 (26...16 AWG): All terminals  
Tightening torques: 0.5…0.6 N·m (0.4 lbf·ft)  
 
Quick installation guide 11  
UL checklist  
The drive must be installed in clean air according to enclosure classification.  
Cooling air must be clean, free from corrosive materials and electrically  
conductive dust.  
The maximum ambient air temperature is 40 °C (104 °F) at rated current. The  
current is derated for 40 to 55 °C (104 to 131 °F).  
The drive is suitable for use in a circuit capable of delivering not more than  
100,000 rms symmetrical amperes, 600 V maximum. The ampere rating is based  
on tests done according to UL 61800-5-1.  
The cables located within the motor circuit must be rated for at least 75 °C  
(167 °F) in UL-compliant installations.  
The input cable must be protected with fuses. Circuit breakers must not be used  
without fuses in the USA. Suitable IEC (class aR) fuses and UL (class T) fuses  
are listed in the hardware manual. For suitable circuit breakers, contact your local  
ABB representative.  
For installation in the United States, branch circuit protection must be provided in  
accordance with the National Electrical Code (NEC) and any applicable local  
codes. To fulfill this requirement, use the UL classified fuses.  
For installation in Canada, branch circuit protection must be provided in  
accordance with the Canadian Electrical Code and any applicable provincial  
codes. To fulfill this requirement, use the UL classified fuses.  
The drive provides overload protection in accordance with the National Electrical  
Code (NEC).  
 
12 Quick installation guide  
[Page intentionally left blank]  
13  
AA  
Tapping screw M6x12 Torx T30  
(Hex) 8 Nm  
Rittal 8612.160  
Combi screw  
M4x8 Torx T20  
Rittal 8606.500  
B
D
E
2Nm  
Combi screw  
M8x20 Hex  
20 Nm  
+B051  
Combi screw  
M8x30 Hex  
20 Nm  
1
2
3
Combi screw  
M4x8 Torx T20  
2 Nm  
M6x20 Torx  
T25 8 Nm  
Rittal 4396.500  
+B051  
Tapping screw M6x12 Torx T30 (Hex) 8 Nm  
F
M8 Kalei nut or  
similar (2 pcs)  
C
Combi screw M8x30 Hex 20 Nm  
                       
14  
ohm  
Drive Type  
Air flow  
ft3/min  
Heat  
dissipation  
UL Fuse Information  
UL Class UL Type  
G
I
H
J
U1  
M
3~  
V1  
W1  
W
ohm  
UN = 480 V  
PE  
ACQ580-505A-4  
ACQ580-585A-4  
ACQ580-650A-4  
ACQ580-725A-4  
ACQ580-820A-4  
ACQ580-880A-4  
707  
707  
707  
707  
707  
848  
5602  
6409  
8122  
8764  
9862  
10578  
T
L
L
L
L
L
JJS-600  
A4BY800  
A4BY800  
A4BY800  
A4BY900  
A4BY1000  
M
L
(PE) PE (PE)  
L2 L3  
L1  
L1  
L2 L3  
PE  
Combi screw  
M6x12 Hex  
T25 8 Nm  
K
N
ACQ580-  
L1 L2 L3  
INPU  
UDC- UDC+  
Combi screw  
M12x25 Hex  
(Delta) 70 Nm  
PE  
OUTPU  
T1 T2 T3  
Hex screw M12x35  
full thread 70 Nm  
3
1
2
Washer M12  
or equal  
V1  
W1  
U1  
3 ~  
M
Hex nut M12 70 Nm  
Max 8 Nm  
                               
15  
O
R
P
Q
+B051  
+B051  
+B051  
+B051  
Combi screw M6x20  
Torx T25 2 Nm  
S
T
Hex screw  
M12x35 full thread  
+B051  
Hex nut  
M12  
+B051  
+B051  
Combi screw M4x10  
Torx T20 2 Nm  
Combi screw M6x20  
Torx T25 2 Nm  
                       
16  
+B051  
+B051  
U
V
W
+B051  
Combi screw  
M4x10 Torx  
T20 2 Nm  
+B051  
Combi screw  
M4x10 Torx  
T20 2 Nm  
Combi screw  
M6x20 Torx T25  
2 Nm  
X
3
2
2 × Combi  
screw M4×8  
Torx T20  
1
             
ABB DRIVES FOR WATER  
Quick start-up guide  
Basic ACQ580 program setup  
[Page intentionally left blank]  
Start-up with the First start assistant on a Hand-Off-Auto control panel 19  
Quick start-up guide  
This guide describes how to start-up the drive using the First start  
assistant on the Hand-Off-Auto control panel. For complete information on  
start-up, see ACQ580 firmware manual (3AXD50000035867 [English]).  
Before you start  
Ensure that the drive has been installed as described in  
Start-up with the First start assistant on a Hand-Off-  
Auto control panel  
Safety  
Make sure that the installation work is complete. Make sure that cover of the  
drive and the cable box, if included, are on place.  
Check that the starting of the motor does not cause any danger. De-  
couple the driven machine if there is a risk of damage in case of an  
incorrect direction of rotation.  
Hints on using the assistant control panel  
The two commands at the bottom of the  
display (Options and Menu in the figure on  
the right), show the functions of the two  
softkeys  
and  
located below the  
display. The commands assigned to the  
softkeys vary depending on the context.  
Use keys  
,
,
and  
to move the  
cursor and/or change values depending on  
the active view.  
Key shows a context-sensitive help page.  
?
1 – First start assistant guided settings:  
Language, date and time, and motor nominal values  
Have the motor or pump name plate data at  
hand.  
Power up the drive.  
 
20 Start-up with the First start assistant on a Hand-Off-Auto control panel  
The First start assistant guides you through  
the first start-up.  
The assistant begins automatically. Wait  
until the control panel enters the view shown  
on the right.  
Select the language you want to use by  
highlighting it (if not already highlighted) and  
pressing  
(OK).  
Note: After you have selected the language,  
it takes a few minutes for the control panel to  
wake up.  
Select Start set-up and press  
(Next).  
Set the date and time as well as date and  
time display formats.  
• Go to the edit view of a selected row by  
pressing  
.
• Scroll the view with  
and  
.
Go to the next view by pressing  
(Next).  
To change a value in an edit view:  
• Use  
and  
to move the cursor left  
and right.  
• Use  
and  
to change the value.  
• Press  
(Save) to accept the new  
setting, or press  
(Cancel) to go  
back to the previous view without making  
changes.  
Start-up with the First start assistant on a Hand-Off-Auto control panel 21  
Change the units shown on the panel if  
needed.  
• Go to the edit view of a selected row by  
pressing  
.
• Scroll the view with  
and  
.
Go to the next view by pressing  
(Next).  
To give the drive a name that will be shown  
at the top, press  
.
If you do not want to change the default  
name (ACQ580), continue by pressing  
(Next).  
For information on editing text, see ACQ580  
firmware manual (3AXD50000035867  
[English]).  
Hint: Name the drive, for example, Pump 1.  
Refer to the motor or pump nameplate for the following nominal value settings of the  
motor. Enter the values exactly as shown on the motor or pump nameplate.  
Example of a nameplate of an induction (asynchronous) motor:  
ABB Motors  
3 ~ motor  
M2AA 200 MLA 4  
IEC 200 M/L 55  
No  
Ins. cl.  
F
IP 55  
V
Hz  
50  
50  
50  
50  
50  
60  
kW  
30  
30  
30  
30  
30  
35  
r/min  
1475  
1475  
1470  
1470  
1475  
1770  
A
cos ijꢀꢀ,$ꢁ,1 tE/S  
690 Y  
400 D  
660 Y  
380 D  
415 D  
440 D  
32.5 0.83  
56  
34  
59  
54  
59  
0.83  
0.83  
0.83  
0.83  
0.83  
3GAA 202 001 - ADA  
Cat. no  
6312/C3  
6210/C3  
180 kg  
IEC 34-1  
22 Start-up with the First start assistant on a Hand-Off-Auto control panel  
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 and  
.
.
Motor nominal cosΦ and nominal torque are  
optional.  
Press  
(Next) to continue.  
Adjust the limits according to your needs.  
• Go to the edit view of a selected row by  
pressing  
.
• Scroll the view with  
and  
.
Go to the next view by pressing  
(Next).  
If you want to make a backup of the settings  
made so far, select Backup and press  
(Next).  
If you do not want to make a backup, select  
Not now and press  
(Next).  
The first start is now complete and the drive  
is ready for use.  
Press  
(Done) to enter the Home view.  
The Home view monitoring the values of the  
selected signals is shown on the panel.  
For changing the signals and their display  
style shown in the Home view, see ACQ-AP-  
x assistant control panels user’s manual  
(3AUA0000085685 [English]).  
Start-up with the First start assistant on a Hand-Off-Auto control panel 23  
2 – Additional settings in the Primary settings menu  
Make any additional adjustments, for  
example, pump protections, starting from  
the Main menu – press  
(Menu) to  
enter the Main menu.  
Select Primary settings and press  
(Select) (or ).  
In the Primary settings menu, select Pump  
protections and press  
(Select) (or  
).  
To get more information on the Primary  
settings menu items, press to open the  
?
help page.  
24 Start-up with the First start assistant on a Hand-Off-Auto control panel  
3 – Hand/Off/Auto operation  
The drive can be in remote control or local  
control, and in local control there are  
additionally two different modes.  
Remote control: Drive is controlled from the  
I/O or the fieldbus.  
Top row of the view shows Auto.  
Local control: Drive is controlled from the  
control panel.  
Top row of the view shows Off, that is, the  
drive is in the Off mode. Drive is stopped.  
Top row of the view shows Hand, that is,  
the drive is in the Hand mode. Drive is  
running. The initial reference in the Hand  
mode is copied from the drive reference.  
Symbol on the top row indicates that  
you can change the reference with  
and  
.
The following diagram shows the state  
transitions when you press the Hand, Off or  
Auto button:  
Off  
Auto  
Hand  
Note: When you restart the drive while fault  
7081 Control panel loss is active, the mode  
changes from Hand or Off to Auto.  
Start-up with the First start assistant on a Hand-Off-Auto control panel 25  
[Page intentionally left blank]  
26 Start-up with the First start assistant on a Hand-Off-Auto control panel  
[Page intentionally left blank]  
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 new.abb.com/service/training.  
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