ABB ACS180 - Hardware Manual

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ABB MACHINERY DRIVES

ACS180 drives

Hardware manual

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Table of Contents5
Safety Instructions13
Contents of this Chapter13
Use of Warnings and Notes13
General Safety in Installation, Start-Up and Maintenance14
Electrical Safety in Installation, Start-Up and Maintenance16
Electrical Safety Precautions16
Additional Instructions and Notes17
Printed Circuit Boards17
Grounding18
General Safety in Operation19
Additional Instructions for Permanent Magnet Motor Drives19
Safety in Installation, Start-Up, Maintenance19
Safety in Operation20
Introduction to the Manual21
Contents of this Chapter21
Applicability21
Target Audience21
Purpose of the Manual21
Categorization by Frame Size21
Quick Installation and Commissioning Flowchart21
Terms and Abbreviations23
Related Manuals24
Manuals on Internet24
Operation Principle and Hardware Description25
Contents of this Chapter25
Operation Principle26
Simplified Main Circuit Diagram26
Product Variants26
Layout27
Frame Sizes R027
Frame Sizes R228
Control Connections29
Standard Variant (ACS180-04S29
Base Variant (ACS180-04N30
Control Panel Options31
Drive Labels31
Model Information Label31
Type Designation Label32
Type Designation Key32
Control Panel33
Home View34
Status Icon34
Message View35
Options View35
Menu35
Mechanical Installation37
Contents of this Chapter37
Installation Alternatives37
Examining the Installation Site38
Required Tools38
Unpacking the Delivery38
Installing the Drive40
To Install the Drive with Screws40
To Install the Drive to a DIN Installation Rail for Frame Sizes R3 and R442
Guidelines for Planning the Electrical Installation43
Contents of this Chapter43
Limitation of Liability43
Selecting the Main Supply Disconnecting Device43
European Union and United Kingdom44
North America44
Other Regions44
Selecting the Main Contactor44
Checking the Compatibility of the Motor and Drive44
Selecting the Power Cables45
General Guidelines45
Typical Power Cable Sizes45
Power Cable Types45
Preferred Power Cable Types45
Alternate Power Cable Types46
Not Allowed Power Cable Types47
Additional Guidelines, North America47
Metal Conduit48
Power Cable Shield48
Selecting the Control Cables49
Shielding49
Signals in Separate Cables49
Signals that Can be Run in the same Cable50
Relay Cable50
Control Panel to Drive Cable50
PC Tool Cable50
Routing the Cables50
General Guidelines - IEC50
General Guidelines - North America51
Continuous Motor Cable Shield/Conduit or Enclosure for Equipment on the Motor Cable52
Separate Control Cable Ducts53
Implementing Short-Circuit and Thermal Overload Protection53
Protecting the Drive and Input Power Cable in Short-Circuits53
Protecting the Motor and Motor Cable in Short-Circuits53
Protecting the Drive, and the Input Power and Motor Cables against Thermal Overload54
Protecting the Motor against Thermal Overload54
Protecting the Motor against Overload Without Thermal Model or Temperature Sensors54
Implementing Motor Temperature Sensor Connection55
Protecting the Drive against Ground Faults55
Residual Current Device Compatibility55
Implementing the Emergency Stop Function56
Implementing the Safe Torque off Function56
Using a Safety Switch between the Drive and the Motor56
Implementing the Control of a Contactor between Drive and Motor56
Protecting the Contacts of Relay Outputs57
Electrical Installation59
Contents of this Chapter59
Warnings59
Required Tools59
Measuring the Insulation60
Measuring the Insulation Resistance of the Drive60
Measuring the Insulation Resistance of the Input Power Cable60
Measuring the Insulation Resistance of the Motor and Motor Cable60
Earthing System Compatibility Check61
EMC Filter61
When to Disconnect the EMC Filter61
Disconnecting the EMC Filter62
Guidelines for Installing the Drive to a TT System63
Identifying the Grounding System of the Electrical Power Network63
Connecting the Power Cables65
Connection Diagram65
Connection Procedure66
Connecting the Control Cables68
Default I/O Connection Diagram (ABB Standard Macro)69
Control Cable Connection Procedure70
Additional Information on the Control Connections72
Connecting EIA-485 Fieldbus Cable to the Drive72
PNP Configuration for Digital Inputs73
NPN Configuration for Digital Inputs73
Connection Examples of Two-Wire and Three-Wire Sensors74
Safe Torque off74
Communication Mode Jumper J274
Connecting a PC75
Installation Checklist77
Contents of this Chapter77
Checklist77
Maintenance79
Contents of this Chapter79
Maintenance Intervals79
Description of Symbols79
Recommended Maintenance Intervals after Start-Up80
Cleaning the Heatsink80
Replacing the Cooling Fans81
To Replace the Cooling Fan for Frame Size R181
To Replace the Cooling Fan for Frame Size R283
To Replace the Cooling Fan for Frame Size R385
To Replace the Cooling Fan for Frame Size R488
Capacitors89
Reforming the Capacitors89
Technical Data91
Contents of this Chapter91
Ratings91
IEC Ratings91
UL (NEC) Ratings92
Definitions94
Sizing94
Output Derating94
Surrounding Air Temperature Derating97
Altitude Derating99
Switching Frequency Derating99
Fuses101
Gg Fuses (IEC)101
Gr or Ar -Type Fuses (IEC)102
UL Fuses (UL(NEC))103
Alternate Short-Circuit Protection104
Miniature Circuit Breakers (IEC)104
Manual Self-Protected Combination Motor Controller - Type E USA (UL (NEC))106
Dimensions and Weights108
Free Space Requirements109
Losses, Cooling Data and Noise109
Terminal Data for the Power Cables110
Typical Power Cable Sizes113
Terminal Data for the Control Cables114
External EMC Filters114
Electrical Power Network Specification115
Motor Connection Data116
Motor Cable Length116
Operational Functionality and Motor Cable Length116
EMC Compatibility and Motor Cable Length118
Control Connection Data119
Brake Resistor Connection Data120
Energy Efficiency Data (Ecodesign)120
Degrees of Protection120
Ambient Conditions120
Materials122
Disposal122
Applicable Standards122
Markings123
Compliance with en 61800-3124
Definitions124
Category C1124
Category C2125
Category C3125
Category C4125
UL Checklist127
Compliance with the European Machinery Directive128
Disclaimers128
Generic Disclaimer128
Cybersecurity Disclaimer128
Dimension Drawings129
Contents of this Chapter129
Frame R0130
Frame R1131
Frame R2132
Frame R3133
Frame R4134
Resistor Braking135
Contents of this Chapter135
Safety135
Operation Principle135
Selecting the Brake Resistor135
Reference Brake Resistors137
Definitions137
Selecting and Routing the Brake Resistor Cables138
Minimizing Electromagnetic Interference138
Maximum Cable Length138
Placing the Brake Resistors138
Protecting the System in Brake Circuit Fault Situations139
Protecting the System in Cable and Brake Resistor Short-Circuit Situations139
Protecting the System against Thermal Overload139
Mechanical and Electrical Installation of Brake Resistor140
Mechanical Installation140
Electrical Installation141
Measuring the Insulation141
Connecting Power Cables141
Connection the Control Cables141
Start-Up141
The Safe Torque off Function143
Contents of this Chapter143
Description143
Compliance with the European Machinery Directive and the UK Supply of Machinery (Safety) Regulations144
Wiring145
Connection Principle145
Single ACS180 Drive, Internal Power Supply145
Single ACS180 Drive, External Power Supply146
Wiring Examples147
Single ACS180 Drive, Internal Power Supply147
Single ACS180 Drive, External Power Supply147
Multiple ACS180 Drives, Internal Power Supply148
Multiple ACS180 Drives, External Power Supply149
Activation Switch149
Cable Types and Lengths150
Grounding of Protective Shields150
Operation Principle151
Start-Up Including Validation Test152
Competence152
Validation Test Reports152
Validation Test Procedure152
Use154
Maintenance156
Competence156
Fault Tracing157
Safety Data158
Terms and Abbreviations160
TÜV Certificate161
Declarations of Conformity162

ABB ACS180 - Hardware Manual

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