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ACS180-04S-03A7-1
ABB ACS180-04S-03A7-1 User Manual
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ABB
MACHINERY
DRIVES
ACS180
drives
Hardware
manual
2
Table of Contents
Default Chapter
5
Table of Contents
5
1 Safety Instructions
13
Contents of this Chapter
13
Use of Warnings and Notes
13
General Safety in Installation, Start-Up and Maintenance
14
Electrical Safety in Installation, Start-Up and Maintenance
16
Electrical Safety Precautions
16
Additional Instructions and Notes
17
Printed Circuit Boards
17
Grounding
18
General Safety in Operation
19
Additional Instructions for Permanent Magnet Motor Drives
19
Safety in Installation, Start-Up, Maintenance
19
Safety in Operation
20
2 Introduction to the Manual
21
Contents of this Chapter
21
Applicability
21
Target Audience
21
Categorization by Frame Size
21
Quick Installation and Commissioning Flowchart
22
Terms and Abbreviations
23
Related Manuals
23
3 Operation Principle and Hardware Description
25
Contents of this Chapter
25
Operation Principle
25
Simplified Main Circuit Diagram
26
Product Variants
26
Layout
27
Frame Sizes R0
27
Frame Sizes R2
28
Control Connections
29
Standard Variant (ACS180-04S
29
Base Variant (ACS180-04N
30
Control Panel Options
31
Drive Labels
31
Model Information Label
31
Type Designation Label
32
Type Designation Key
32
Control Panel
33
Home View
34
Status Icon
34
Message View
35
Options View
35
Menu
35
4 Mechanical Installation
37
Contents of this Chapter
37
Installation Alternatives
37
Examining the Installation Site
38
Required Tools
38
Unpacking the Delivery
39
Installing the Drive
40
To Install the Drive with Screws
40
To Install the Drive to a DIN Installation Rail for Frame Sizes R0 to R2
41
To Install the Drive to a DIN Installation Rail for Frame Sizes R3 and R4
42
5 Guidelines for Planning the Electrical Installation
43
Contents of this Chapter
43
Limitation of Liability
43
North America
43
Selecting the Main Supply Disconnecting Device
43
Selecting the Main Contactor
44
Checking the Compatibility of the Motor and Drive
44
Selecting the Power Cables
45
General Guidelines
45
Typical Power Cable Sizes
45
Power Cable Types
46
Preferred Power Cable Types
46
Alternate Power Cable Types
47
Not Allowed Power Cable Types
48
Additional Guidelines - North America
48
Metal Conduit
49
Power Cable Shield
49
Grounding Requirements
50
Additional Grounding Requirements - IEC
51
Additional Grounding Requirements - UL (NEC)
52
Selecting the Control Cables
52
Shielding
52
Signals in Separate Cables
52
Signals that Can be Run in the same Cable
52
Relay Cable
53
Control Panel to Drive Cable
53
PC Tool Cable
53
Routing the Cables
53
General Guidelines - IEC
53
General Guidelines - North America
54
Continuous Motor Cable Shield/Conduit and Metal Enclosure for Equipment on the Motor Cable
55
Separate Control Cable Ducts
56
Implementing Short-Circuit and Thermal Overload Protection
56
Protecting the Drive and Input Power Cable in Short-Circuits
56
Protecting the Motor and Motor Cable in Short-Circuits
56
Protecting the Drive, and the Input Power and Motor Cables against Thermal Overload
57
Protecting the Motor against Thermal Overload
57
Protecting the Motor against Overload Without Thermal Model or Temperature Sensors
57
Implementing a Motor Temperature Sensor Connection
58
Protecting the Drive against Ground Faults
58
Residual Current Device Compatibility
58
Implementing the Emergency Stop Function
58
Implementing the Safe Torque off Function
59
Using a Safety Switch between the Drive and the Motor
59
Implementing the Control of a Contactor between Drive and Motor
59
Protecting the Contacts of Relay Outputs
59
6 Electrical Installation
61
Contents of this Chapter
61
Required Tools
61
Measuring the Insulation Resistance
62
Measuring the Insulation Resistance of the Drive
62
Measuring the Insulation Resistance of the Input Power Cable
62
Measuring the Insulation Resistance of the Motor and Motor Cable
62
Measuring the Insulation Resistance of the Brake Resistor Circuit
63
Grounding System Compatibility Check
63
EMC Filter
63
Compatibility of EMC Filter with the Grounding System
64
Disconnecting the EMC Filter
66
Guidelines for Installing the Drive to a TT System
66
Identifying the Grounding System of the Electrical Power Network
67
Connecting the Power Cables
68
Connection Diagram
68
Connection Procedure
69
Connecting the Control Cables
71
Default I/O Connection Diagram (ABB Standard Macro)
72
Control Cable Connection Procedure
73
Additional Information on the Control Connections
75
Embedded EIA-485 Fieldbus Connection
75
PNP Configuration for Digital Inputs
77
NPN Configuration for Digital Inputs
77
Connection Examples of Two-Wire and Three-Wire Sensors
78
Safe Torque off
78
Communication Mode Jumper J2
78
Connecting a PC
79
7 Installation Checklist
81
Contents of this Chapter
81
Checklist
81
8 Maintenance
85
Contents of this Chapter
85
Maintenance Intervals
85
Description of Symbols
85
Recommended Maintenance Intervals after Start-Up
86
Functional Safety Components
87
Cleaning the Heatsink
87
Replacing the Cooling Fans
88
To Replace the Cooling Fan for Frame Size R1
88
To Replace the Cooling Fan for Frame Size R2
89
To Replace the Cooling Fan for Frame Size R3
91
To Replace the Cooling Fan for Frame Size R4
94
Capacitors
95
Reforming the Capacitors
95
9 Technical Data
97
Contents of this Chapter
97
Electrical Ratings
97
IEC Ratings
97
UL (NEC) Ratings
99
Definitions
100
Sizing
101
Output Derating
101
Surrounding Air Temperature Derating
104
Altitude Derating
107
Switching Frequency Derating
107
Fuses
109
IEC Fuses
109
Gg Fuses
109
Gr or Ar -Type Fuses
111
UL (NEC) Fuses
112
Alternate Short-Circuit Protection
114
Miniature Circuit Breakers (IEC)
114
Miniature Circuit Breakers (UL)
116
Manual Self-Protected Combination Motor Controller - Type E USA (UL (NEC))
118
Dimensions and Weights
121
Free Space Requirements
122
Losses, Cooling Data and Noise
122
Typical Power Cable Sizes
123
Terminal Data for the Power Cables
125
Terminal Data for the Control Cables
128
External EMC Filters
128
Electrical Power Network Specification
129
Motor Connection Data
130
Motor Cable Length
130
Operational Functionality and Motor Cable Length
130
EMC Compatibility and Motor Cable Length
132
Control Connection Data
133
Brake Resistor Connection Data
134
Energy Efficiency Data (Ecodesign)
134
Protection Classes
135
Ambient Conditions
135
Storage Conditions
137
Color
137
Materials
137
Drive
137
Drive Package
137
Package Materials for Options, Accessories and Spare Parts
137
Materials of Manuals
137
Disposal
138
Applicable Standards
138
Markings
139
EMC Compliance (IEC/EN 61800-3:2004 + A1:2012)
140
Definitions
140
Category C1
141
Category C2
141
Category C3
142
Category C4
142
UL Checklist
144
Disclaimers
145
Generic Disclaimer
145
Cyber Security Disclaimer
145
10 Dimension Drawings
147
Contents of this Chapter
147
Frame R0
148
Frame R1
149
Frame R2
150
Frame R3
151
Frame R4
152
11 Resistor Braking
153
Contents of this Chapter
153
Safety
153
Operation Principle
153
Selecting the Brake Resistor
153
Reference Brake Resistors
155
Definitions
156
Selecting and Routing the Brake Resistor Cables
156
Minimizing Electromagnetic Interference
156
Maximum Cable Length
156
Selecting the Installation Location for the Brake Resistors
156
Protecting the System in Brake Circuit Fault Situations
157
Protecting the System in Cable and Brake Resistor Short-Circuit Situations
157
Protecting the System against Thermal Overload
157
Mechanical and Electrical Installation of Brake Resistor
158
Mechanical Installation
158
Electrical Installation
159
Measuring the Insulation
159
Connecting Power Cables
159
Connection the Control Cables
159
Start-Up
159
12 The Safe Torque off Function
161
Contents of this Chapter
161
Description
161
Compliance with the European Machinery Directive and the UK Supply of Machinery (Safety) Regulations
162
Wiring
163
Connection Principle
163
Single ACS180 Drive, Internal Power Supply
163
Single ACS180 Drive, External Power Supply
164
Wiring Examples
165
Single ACS180 Drive, Internal Power Supply
165
Single ACS180 Drive, External Power Supply
165
Multiple ACS180 Drives, Internal Power Supply
166
Multiple ACS180 Drives, External Power Supply
167
Activation Switch
167
Cable Types and Lengths
168
Grounding of Protective Shields
168
Operation Principle
169
Start-Up Including Validation Test
170
Competence
170
Validation Test Reports
170
Validation Test Procedure
170
Use
172
Maintenance
174
Competence
174
Fault Tracing
175
Safety Data
176
Terms and Abbreviations
178
TÜV Certificate
179
Declarations of Conformity
180
13 Accessories
185
Contents of this Chapter
185
Warnings
185
BDRK-01 DIN Rail Mounting Kit
186
Dimensions
186
Installation
187
BDRK-02 DIN Rail Mounting Kit
188
Dimensions
188
Installation
189
BMBC-01 Mounting Bracket for CCA-01 Adapter
190
Further Information
191
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ABB ACS180-04S-03A7-1 Specifications
General
Power Rating
0.75 kW
Protection Class
IP20
Weight
1.5 kg
Frame Size
R1
Control Method
V/f Control
Frequency
50/60 Hz
Cooling Method
Fan
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