ABB ACS180-04S-03A7-1 Hardware Manual Download Page 25

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Operation principle and
hardware description

Contents of this chapter

This chapter briefly describes the operation principle and construction of the drive.

Operation principle

The ACS180 is a drive for controlling asynchronous AC induction motors and
permanent magnet synchronous motors. The drive is optimized for cabinet
installation.

Operation principle and hardware description 25

Summary of Contents for ACS180-04S-03A7-1

Page 1: ...ABB MACHINERY DRIVES ACS180 drives Hardware manual...

Page 2: ......

Page 3: ...ACS180 drives Hardware manual Table of contents 1 Safety instructions 4 Mechanical installation 6 Electrical installation 3AXD50000467945 Rev D EN Original instructions EFFECTIVE 2024 03 08...

Page 4: ......

Page 5: ...aintenance 20 Safety in operation 2 Introduction to the manual 21 Contents of this chapter 21 Applicability 21 Target audience 21 Categorization by frame size 22 Quick installation and commissioning f...

Page 6: ...ntents of this chapter 43 Limitation of liability 43 North America 43 Selecting the main supply disconnecting device 44 Selecting the main contactor 44 Checking the compatibility of the motor and driv...

Page 7: ...ementing 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 ou...

Page 8: ...ntenance intervals after start up 87 Functional safety components 87 Cleaning the heatsink 88 Replacing the cooling fans 88 To replace the cooling fan for frame size R1 89 To replace the cooling fan f...

Page 9: ...able length 130 Operational functionality and motor cable length 132 EMC compatibility and motor cable length 133 Control connection data 134 Brake resistor connection data 134 Energy efficiency data...

Page 10: ...and brake resistor short circuit situations 157 Protecting the system against thermal overload 158 Mechanical and electrical installation of brake resistor 158 Mechanical installation 159 Electrical...

Page 11: ...n test reports 170 Validation test procedure 172 Use 174 Maintenance 174 Competence 175 Fault tracing 176 Safety data 178 Terms and abbreviations 179 T V certificate 180 Declarations of conformity 13...

Page 12: ...12...

Page 13: ...ou how to prevent the danger Notes draw attention to a particular condition or fact or give information on a subject The manual uses these warning symbols WARNING Electricity warning tells about hazar...

Page 14: ...there is sufficient cooling See the technical data Before you connect voltage to the drive make sure that all covers are in place Do not remove the covers when voltage is connected Before you adjust...

Page 15: ...t immediately after fault reset unless you configure the drive for pulse start See the firmware manual If the drive is in remote control mode you cannot stop or start the drive with the control panel...

Page 16: ...e main disconnecting device of the drive If you have a permanent magnet motor connected to the drive disconnect the motor from the drive with a safety switch or by other means Open the main isolating...

Page 17: ...away from the area near motor drive and the drive power cabling when the drive is in operation There are electromagnetic fields present which can interfere with the function of such devices This can c...

Page 18: ...joining equipment This is necessary for the personnel safety Make sure that the conductivity of the protective earth PE conductors is sufficient and that other requirements are met See the electrical...

Page 19: ...can occur These functions reset the drive automatically and continue operation after a fault or supply break If these functions are activated the installation must be clearly marked as defined in IEC...

Page 20: ...y or through any mechanical connection like belt nip rope etc Do the steps in section Electrical safety precautions page 16 Install temporary grounding to the drive output terminals T1 U T2 V T3 W Con...

Page 21: ...ion and do maintenance work on the drive or create instructions for the end user of the drive concerning the installation and maintenance of the drive Read the manual before you work on the drive You...

Page 22: ...ck page 63 If the drive will be connected to an IT ungrounded system make sure that the internal EMC filter is not connected Installing the drive page 40 Install the drive mechanically Routing the cab...

Page 23: ...and voltage to alternating current and voltage Inverter A pre defined set of default values of parameters in a drive control program Macro In the drive control program user adjustable operation instr...

Page 24: ...24...

Page 25: ...escribes the operation principle and construction of the drive Operation principle The ACS180 is a drive for controlling asynchronous AC induction motors and permanent magnet synchronous motors The dr...

Page 26: ...o the drive The chopper operates when the DC link voltage exceeds a certain maximum limit The voltage rise is typically caused by deceleration braking of a motor The user obtains and installs the brak...

Page 27: ...ion motor 8 Control panel display and status LED 2 Fixed control terminals 9 Motor connection terminal 3 Front cover 10 Cooling fan 4 Model information label 11 Panel and PC tool port RJ45 5 Type desi...

Page 28: ...el display and status LED 2 Fixed control terminals 9 Motor connection terminal 3 Front cover 10 Cooling fan 4 Model information label 11 Panel and PC tool port RJ45 5 Cold configuration connection fo...

Page 29: ...jumper 4 Communication mode jumper1 5 Digital inputs and outputs 6 Analog inputs and outputs 7 EIA 485 Modbus RTU 8 Panel connector external panel or adapter for PC connection 9 Cold configuration con...

Page 30: ...tion jumper 3 Communication mode jumper 4 Digital inputs and outputs 5 Analog inputs and outputs 6 EIA 485 Modbus RTU 7 Panel connector external panel or adapter for PC connection 8 Cold configuration...

Page 31: ...form for cabinet door installation These panel platforms are available Description Type Control panel mounting platform flush mounting and cable DPMP 01 Control panel mounting platform surface mountin...

Page 32: ...nufacture 01 02 03 for week 1 week 2 week 3 R Hardware revision that starts from A XXXX Running item number that starts each week from 0001 Type designation key The type designation shows the specific...

Page 33: ...Options menu Main menu Submenus Control panel By default ACS 180 has an integrated panel If required you can panels such as assistant control panel or a basic panel For more ACX AP x assistant contro...

Page 34: ...nd right arrow keys to highlight a value Use the up and down arrow keys to set a value Push the Back key to cancel a setting or return to the previous view Home view The Home view shows the reading of...

Page 35: ...0467860 English To reset a fault push the OK key with the soft key label Reset Options view To open the Options view push the Back key in the Home view In the Options view you can Set the control loca...

Page 36: ...ction parameter macro Diagnostics view Read the active faults and warnings Parameters view Open and edit the full list of parameters For detailed information on the user interface refer to the ACS180...

Page 37: ...signed for cabinet installation and has a degree of protection of IP20 UL open type as standard Make sure that there is a minimum of 75 mm 3 in of free space at the top and bottom of the drive at the...

Page 38: ...lation surface is as close to vertical as possible and strong enough to support the drive There is sufficient free space around the drive for cooling maintenance and operation See the free space speci...

Page 39: ...ts contents Make sure that all of the items are present and that there are no signs of damage Package contents 1 2 3 1 drive 2 installation accessories cable clamps metal grounding plate screws etc 3...

Page 40: ...hts page 121 2 Drill the holes for the mounting screws R0 R1 M2 M2 M1 M1 R2 R4 M2 M1 Mounting screws M2 M1 Frame size Metric in mm in mm M4 6 46 164 2 36 60 R0 M4 7 09 180 2 36 60 R1 M4 7 5 190 5 4 17...

Page 41: ...To install the drive to a DIN installation rail for frame sizes R0 to R2 Use an optional DIN rail mounting kit Refer to Accessories page 185 Mechanical installation 41...

Page 42: ...ush and hold the locking button down 3 Put the top tabs of the drive onto the top edge of the DIN installation rail 4 Put the drive against the bottom edge of the DIN installation rail 5 Release the l...

Page 43: ...iven by ABB are not followed the drive may experience problems that the warranty does not cover North America Installations must be compliant with NFPA 70 NEC 1 and or Canadian Electrical Code CE alon...

Page 44: ...elect a customer defined main contactor Dimension the contactor according to the nominal voltage and current of the drive Also consider the environmental conditions such as surrounding air temperature...

Page 45: ...rated for at least 75 C 167 F Important For certain product types or option configurations higher temperature rating may be required See the technical data for details Voltage 600 V AC cable is accept...

Page 46: ...e with three phase conductors and con centric PE conductor as shield or armor Yes Yes PE Symmetrical shielded or ar mored cable with three phase conductors and sym metrically constructed PE conductor...

Page 47: ...etween the frames of motor and driven equipment is required Yes Shielded Al Cu shield or ar mor 1 four conductor cable three phase conductors and a PE 1 Armor may act as an EMC shield as long as it pr...

Page 48: ...efer symmetrical shielded VFD cable Electrical metallic tubing Type EMT Use separate conduit run for each motor Rigid metal conduit Type RMC Do not run input power wiring and motor wiring in the same...

Page 49: ...ts with a ground conductor bonded to the conduit on each side of the joint Also bond the conduits to the drive enclosure and motor frame Use separate conduits for input power motor brake resistor and...

Page 50: ...require automatic disconnection of the supply required in 411 3 2 of IEC 60364 4 41 2005 and be capable of withstanding the prospective fault current during the disconnection time of the protective d...

Page 51: ...al grounding requirements IEC ThissectiongivesgroundingrequirementsaccordingtostandardIEC EN61800 5 1 Because the normal touch current of the drive is more than 3 5 mA AC or 10 mA DC the minimum size...

Page 52: ...cting the control cables Shielding Only use shielded control cables Use a double shielded twisted pair cable for analog signals ABB recommends this type of cable also for the pulse encoder signals Use...

Page 53: ...ext to each other Install the motor cable input power cable and control cables on separate trays Avoid long parallel runs of motor cables with other cables Where control cables must cross power cables...

Page 54: ...uidelines North America Make sure that the installation is in accordance with national and local codes Obey these general guidelines Use separate conduits for the input power motor brake resistor opti...

Page 55: ...r equipment are installed on the motor cable between the drive and the motor Install the equipment in a metal enclosure Use either a symmetrical shielded cable or install the cabling in a metal condui...

Page 56: ...joining equipment in case of a short circuit inside the drive When located at the distribution board the fuses also protect the input power cable against short circuits See the drive technical data fo...

Page 57: ...temperature indication given by motor temperature sensors The motor thermal protection model supports thermal memory retention and speed sensitivity The user can tune the thermal model further by fee...

Page 58: ...ay must form a double or reinforced insulation between the motor s live parts and the digital input of the drive Make sure that the voltage does not exceed the maximum allowed voltage over the sensor...

Page 59: ...e this operation sequence to open the contactor 1 Give a stop command to the drive 2 Wait until the drive decelerates the motor to zero speed 3 Open the contactor WARNING If vector motor control mode...

Page 60: ...r parts of the system Install the protective component as close to the inductive load as possible Do not install protective components at the relay outputs 230 V AC 230 V AC 24 V DC 1 2 3 4 Relay outp...

Page 61: ...nstall optional modules connect a PC Required tools To do the electrical installation you need the following tools wire stripper screwdriver or wrench with a set of suitable bits For motor cable termi...

Page 62: ...ignore them injury or death or damage to the equipment can occur If you are not a qualified electrical professional do not do installation commissioning or maintenance work 1 Do the steps in section E...

Page 63: ...t the drive end connect the R and R conductors of the resistor cable together Measure the insulation resistance between the conductors and the PE conductor with a measuring voltage of 1000 V DC The in...

Page 64: ...ugh the internal EMC filter capacitors which can cause danger or damage to the drive Compatibility of EMC filter with the grounding system WARNING If you do not obey these instructions injury to perso...

Page 65: ...wye A Remove Remove Do not remove Metal EMC Do not remove Do not remove Do not remove1 Plastic Remove Do not remove Do not remove Metal VAR2 Do not remove Do not remove Do not remove Plastic A B1 B2 A...

Page 66: ...r these conditions 1 There is a residual current device in the supply system 2 The internal EMC filter is disconnected If the EMC filter is not disconnected its leakage current will cause the residual...

Page 67: ...voltage line 1 to ground UL1 G 3 input voltage line 2 to ground UL2 G 4 input voltage line 3 to ground UL3 G The table below shows the line to ground voltages in relation to the line to line voltage f...

Page 68: ...rounding cable or a cable with a separate PE conductor for the line side if the conductivity of the fourth conductor or shield does not meet the requirements for the PE conductor 5 Motor cable Note AB...

Page 69: ...lified electrical professional do not do installation commissioning or maintenance work Refer to Terminal data for the power cables page 125 for the tightening torques 1 Do the steps in section Electr...

Page 70: ...it to the grounding terminal 6 Connect the phase conductors of the motor cable to the T1 U T2 V and T3 W motor terminals 7 For frame sizes R2 R4 if you use a brake resistor connect the brake resistor...

Page 71: ...rds IEC61800 5 and UL 61800 5 11 Connect the phase conductors of the input power cable to the L1 L2 and L3 input terminals 12 Mechanically attach the cables on the outside of the drive Connecting the...

Page 72: ...mmon DCOM Running DO Digital output common DO COM Digital output auxiliary voltage DO SRC Relay output No fault Fault 1 NC COM NO Analog I O Speed reference 0 10V AI1 DI5 AI1 DI5 AGND AI2 AGND AO 10V...

Page 73: ...procedure Do the connections according to the control macro parameter 96 04 used Keep the signal wire pairs twisted as near to the terminals as possible to prevent inductive coupling WARNING Obey the...

Page 74: ...it with screw R0 R1 M3x10 1x R2 M4x20 2x R3 R4 R3 M3x12 2x R4 M4x8 2x 4 Strip a part of the outer shield of the control cable for 360 degree grounding 5 Use a 360 degree grounding clamp to connect the...

Page 75: ...per foot Distributed capacitance between conductors and shield is less than 200 pF per meter 60 pF per foot Foil or braided shields are acceptable Connect the cable to the EIA 485 terminal on the driv...

Page 76: ...J2 4 B A AGND Shield J1 J2 3 B A AGND Shield J1 J2 2 Automation controller Termination ON1 1 Drive J1 Termination OFF J2 Modbus mode2 2 Drive J1 Termination OFF J2 Modbus mode2 3 Drive at the end of t...

Page 77: ...5 24 V DGND DCOM AGND When DI5 is used DI1 DI2 DI3 DI4 24 V DGND DCOM DI5 AGND When DI5 is used NPN configuration for digital inputs Internal and external 24 V power supply connections for NPN sink co...

Page 78: ...Rin 205 ohm AI2 AGND Auxiliary voltage output non isolated 24 V DC max 100 mA 24V DGND Safe torque off For the drive to start both STO connections S to S1 and S to S2 must be closed By default the te...

Page 79: ...01 protocol enable 0 None default When you need to use Modbus RTU communication with the drive set Jumper J2 on the front of the drive Modbus mode Parameter 58 01 protocol enable 1 Modbus RTU Connect...

Page 80: ...information on the Drive Composer PC tool refer to Drive Composer PC tool user s manual 3AUA0000094606 English You can use the CCA 01 cold configuration tool to download software and change drive par...

Page 81: ...ou ignore them injury or death or damage to the equipment can occur If you are not a qualified electrical professional do not do installation commissioning or maintenance work WARNING Stop the drive a...

Page 82: ...is an adequately sized protective earth ground conductor between the motor and the drive The conductor is connected to the correct terminal and the terminal is tightened to the correct torque Groundi...

Page 83: ...Make sure that The motor and the driven equipment are ready for power up Installation checklist 83...

Page 84: ...84...

Page 85: ...done by the end user For ABB Service offering refer to www abb com drivesservices or consult your local ABB Service representative www abb com searchchannels Description of symbols Description Action...

Page 86: ...n 20 years Safety component expiry Mis sion time TM 1 R replacement of component in demanding operating conditions ie if surrounding air temperature in continuous operation is over 40 C 104 F or there...

Page 87: ...the whole circuit is however determined by its oldest component Contact your local ABB service representative for more information Cleaning the heatsink The drive module heatsink fins pick up dust fr...

Page 88: ...death or damage to the equipment can occur If you are not a qualified electrical professional do not do installation commissioning or maintenance work 1 Stop the drive and do the steps in section Ele...

Page 89: ...sition in the drive Make sure that the fan power cable is routed correctly Push the cover to lock into position 8 To replace the cooling fan for frame size R2 WARNING Obey the safety instructions of t...

Page 90: ...lift the fan cover out of the drive Note that the fan cover holds the cooling fan 3 2 2 4 Disconnect the fan power cable 4 5 Free the fan clips and remove the fan from the fan cover 6 Install the new...

Page 91: ...rrectly Push the cover to lock into position 8 To replace the cooling fan for frame size R3 WARNING Obey the safety instructions of the drive If you ignore them injury or death or damage to the equipm...

Page 92: ...ical safety precautions page 16 before you start the work 2 Use a suitable flat screwdriver to open the fan cover 2 3 Carefully lift the fan cover out of the drive The fan cover holds the cooling fan...

Page 93: ...ection The air flows in from the bottom of the drive and out from the top of the drive 5 6 Connect the fan power cable 6 7 Carefully put the fan cover into position in the drive Make sure that the fan...

Page 94: ...professional do not do installation commissioning or maintenance work 1 Stop the drive and do the steps in section Electrical safety precautions page 16 before you start the work 2 Use a suitable flat...

Page 95: ...have an effect on the life of the capacitors Capacitor life can be extended by decreasing the surrounding air temperature Capacitor failure is usually followed by damage to the unit and an input cable...

Page 96: ...96...

Page 97: ...put with choke Input cur rent ACS180 04 Frame size Heavy duty use Light duty use Nominal use Max current PHd IHd PLd ILd Pn In Imax I1 I1 kW A kW A kW A A A A 1 phase Un 208 240 V R0 0 25 1 8 0 37 2 4...

Page 98: ...3 17 5 21 2 17A5 2 R3 4 16 7 5 5 24 2 5 5 25 30 1 25 27 2 25A0 2 R3 5 5 24 2 7 5 30 8 7 5 32 43 6 32 35 033A 2 R4 7 5 30 8 11 46 2 11 48 55 4 48 48 048A 2 R4 11 44 11 50 2 11 55 79 2 55 60 055A 2 3 p...

Page 99: ...3 5 4 3 4 8 6 6 03A7 1 R0 0 75 3 7 1 4 6 6 3 6 2 8 6 04A8 1 R1 1 4 5 1 5 6 6 8 1 9 2 12 1 06A9 1 R1 1 5 6 6 2 7 5 11 9 12 16 5 07A8 1 R1 2 7 5 3 9 8 13 5 17 20 7 09A8 1 R2 3 9 8 3 11 6 16 7 21 1 22 7...

Page 100: ...45 27 33 9 033A 4 R4 20 27 25 34 57 6 34 41 3 038A 4 R4 25 34 30 40 68 4 40 46 9 045A 4 R4 30 42 30 42 81 42 46 9 050A 4 1 15 hp at 208 230 V input 20 hp at 240 V input Definitions The heavy duty rat...

Page 101: ...the motor has a lower nominal current rating than this the drive cannot accurately measure the motor current Output derating The load capacity In ILd IHd decreases in some situations In such situation...

Page 102: ...ting According to the temperature derating table the derating factor of 17A0 4 drive s light duty output current at 131 F surrounding air temperature is 0 95 Multiply the drive output current by all t...

Page 103: ...e derating factor for 5500 ft is Surrounding air temperature derating Derating is not necessary at 95 F surrounding air temperature To see if the derated output current of a drive is sufficient for th...

Page 104: ...IHd R0 0 20 40 60 80 100 10 0 10 20 30 40 50 60 Derating factor Ambient temperature C F 140 122 104 86 68 50 32 14 0 25 50 75 100 Derating factor 10 0 10 20 30 40 50 60 Ambient temperature C F 140 12...

Page 105: ...20 30 40 50 60 70 Ambient temperature C F 158 140 122 104 86 68 50 32 14 Derating factor for In and ILd on ACS180 1 0 20 40 60 80 100 Derating factor 10 0 10 20 30 40 50 60 70 Ambient temperature C F...

Page 106: ...40 60 80 100 10 0 10 20 30 40 50 60 70 Derating factor Ambient temperature 90 C F 158 140 122 104 86 68 50 32 14 Derating factor for In and ILd on ACS180 4 0 20 40 60 80 100 10 0 10 20 30 40 50 60 70...

Page 107: ...rating table with the derating factor k which for x meters 1000 m x 2000 m is Switching frequency derating Derating the drive output current is necessary when using high minimum switching frequencies...

Page 108: ...A9 1 0 7 0 8 1 1 07A8 1 0 7 0 8 1 1 09A8 1 0 7 0 8 1 1 12A2 1 3 phase Un 208 240 V 0 7 0 8 1 1 02A4 2 0 7 0 8 1 1 03A7 2 0 7 0 8 1 1 04A8 2 0 7 0 8 1 1 06A9 2 0 7 0 8 1 1 07A8 2 0 7 0 8 1 1 09A8 2 0 7...

Page 109: ...the input power cable or drive The operating time depends on the supply network impedance and the cross sectional area and length of the supply cable Do not use fuses that have a higher current rating...

Page 110: ...8 139 4 5 03A7 2 C10G16 500 680 16 180 5 7 04A8 2 C10G16 500 680 16 259 7 1 06A9 2 C10G20 500 1200 20 293 8 9 07A8 2 C10G25 500 2300 25 368 12 9 09A8 2 C10G32 400 3000 32 581 19 1 15A6 2 C10G32 400 6...

Page 111: ...ating I2t Nominal current Min short circuit cur rent1 Input current ACS180 04 V A2s A A A 1 phase Un 208 240 V FWP 32G14F 690 679 32 62 5 02A4 1 FWP 32G14F 690 679 32 150 6 9 03A7 1 FWP 40G14F 690 133...

Page 112: ...2 230 12 07A2 4 FWP 32G14F 690 679 32 258 13 09A4 4 FWP 50G14F 690 2200 50 440 17 4 12A6 4 FWP 50G14F 690 2200 50 560 25 2 17A0 4 FWP 80G22F 690 3600 80 400 31 8 25A0 4 FWP 100G22F 690 6650 100 504 40...

Page 113: ...20 300 20 293 9 07A8 2 UL class T JJN 20 300 20 368 10 6 09A8 2 UL class T JJN 30 300 30 581 16 15A6 2 UL class T JJN 35 300 35 656 20 3 17A5 2 UL class T JJN 40 300 40 400 30 5 25A0 2 UL class T JJN...

Page 114: ...ult rating where the Ipeak and I2t of the new fuse is not greater than that of the specified fuse 6 UL listed 248 fast acting time delay or high speed fuses from other manufacturers can be used if the...

Page 115: ...istics ABB does not assume any liability whatsoever for the correct function and protection of the circuit breakers not specified by ABB Furthermore if the specifications given by ABB are not obeyed t...

Page 116: ...50A 4 1 Maximum permitted rated conditional short circuit current IEC 61800 5 1 of the electrical power network Miniature circuit breakers UL ACS180 04 drives are suitable for use on a circuit capable...

Page 117: ...15 SU203M C16 R1 06A9 2 890 15 SU203M C25 R1 07A8 2 890 15 SU203M C25 R1 09A8 2 970 16 SU203M C32 R2 15A6 2 970 16 SU203M C32 R2 17A5 2 1850 30 3 SU203M C50 R3 4 25A0 2 1850 30 3 SU203M C50 R3 4 033A...

Page 118: ...jacent areas on the bottom of the enclosure Manual self protected combination motor controller Type E USA UL NEC You can use the ABB Type E manual motor protectors MMP MS132 S1 M3 25 MS165 xx and MS51...

Page 119: ...S165 20 R1 07A8 2 890 15 MS165 20 R1 09A8 2 970 16 MS165 25 R2 15A6 2 970 16 MS165 32 R2 17A5 2 1850 30 3 MS165 42 R3 6 25A0 2 1850 30 3 MS165 54 R3 6 033A 2 4577 75 MS165 73 R4 048A 2 4577 75 MS165 8...

Page 120: ...nd the voltage from line to line does not exceed the higher of the two ratings e g 480 V AC 3 Manual motor protectors may require adjusting the trip limit from the factory setting at or above the driv...

Page 121: ...3 1 92 7 5 190 5 4 17 106 5 63 143 4 72 120 6 48 164 5 9 06 230 7 95 202 R2 7 28 3 3 7 52 191 5 83 148 6 85 174 6 69 170 6 48 164 5 9 5 241 8 07 205 R3 11 69 5 3 7 52 191 9 21 234 7 03 178 6 10 24 260...

Page 122: ...minal supply voltage default switching frequency and rated output current power Changing these factors may result in increased power losses Frame size Noise Air flow Typical power loss1 ACS180 04 dB A...

Page 123: ...R1 51 21 36 405 118 7 09A4 4 R2 62 77 130 530 155 3 12A6 4 R2 62 77 130 821 240 5 17A0 4 R3 66 75 128 1310 383 9 25A0 4 R3 66 75 128 1829 536 033A 4 R4 69 88 150 1675 490 8 038A 4 R4 69 88 150 1960 5...

Page 124: ...A 2 R4 4 3 25 25 055A 2 3 phase Un 380 480 V R0 16 3 1 5 1 5 01A8 4 R0 16 3 1 5 1 5 02A6 4 R0 16 3 1 5 1 5 03A3 4 R1 16 3 1 5 1 5 04A0 4 R1 16 3 1 5 1 5 05A6 4 R1 14 3 2 5 2 5 07A2 4 R1 14 3 2 5 2 5 0...

Page 125: ...06A9 1 1 2 6 4 4 2 5 0 5 0 6 6 6 0 2 0 2 07A8 1 1 2 6 4 4 2 5 0 5 0 6 6 6 0 2 0 2 09A8 1 1 2 6 4 4 2 5 0 5 0 6 6 6 0 2 0 2 12A2 1 3 phase Un 208 240 V 1 2 6 4 4 2 5 0 5 0 6 6 4 0 2 0 2 02A4 2 1 2 6 4...

Page 126: ...2 6 4 4 2 5 0 5 0 6 6 6 0 2 0 2 12A6 4 1 2 6 4 4 2 5 0 5 0 6 6 6 0 2 0 2 17A0 4 1 2 16 16 0 5 1 2 1 5 10 6 0 5 0 5 25A0 4 1 2 16 16 0 5 1 2 1 5 10 6 0 5 0 5 033A 4 1 2 16 16 0 5 2 5 3 7 25 16 0 5 0 5...

Page 127: ...8 18 17A5 2 10 6 6 20 11 13 8 10 18 25A0 2 10 6 6 20 11 13 8 10 18 033A 2 10 6 6 20 22 32 4 6 18 048A 2 10 6 6 20 22 32 4 6 18 055A 2 3 phase Un 440 480 V 10 6 10 12 5 10 18 01A8 4 10 6 10 12 5 10 18...

Page 128: ...size lbf in N m AWG mm2 n a n a 22 16 0 5 1 5 External EMC filters The table shows the external EMC filters See also EMC compatibility and motor cable length and EMC compliance IEC EN 61800 3 2004 A1...

Page 129: ...t disconnect the internal EMC filter Refer to the electrical installation instructions Electrical power network specification ACS180 04x xxxx 1 drives 1 phase 208 240 V AC 15 10 Voltage U1 ACS180 04x...

Page 130: ...80 drives in the install ation or has voltage imbalance or harmonic distortion that make the input current bigger than the nominal input current ratings You can use one choke for several drives as lon...

Page 131: ...R0 164 50 R1 328 100 R2 328 100 R3 328 100 R4 With external output chokes 164 50 R0 246 75 R1 492 150 R2 492 150 R3 492 150 R4 Note In multimotor systems the calculated sum of all motor cable lengths...

Page 132: ...ss 11 ft m ft m ft m With internal EMC filter 1 phase Un 208 240 V 33 10 16 5 R0 33 10 16 5 R1 33 10 16 5 R2 3 phase Un 380 415 V 33 10 R0 33 10 R1 33 10 R2 98 30 R3 98 30 R4 With optional external EM...

Page 133: ...ves the maximum motor cable lengths are according to the motor cable length table The EMC category for these drives is C4 For ACS180 04S 2 drives the EMC category is C4 In order to achieve higher EMC...

Page 134: ...equency input DI3 and DI4 can be used as digital or frequency inputs FI Refer to The Safe torque off function page 161 STO interface SGND S S1 S2 Brake resistor connection data The brake resistor outp...

Page 135: ...EC 60664 1 l Protective classes IEC EN 61800 5 1 Ambient conditions Environmental limits for the drive are given below The drive must be used in a heated indoor controlled environment Transportation i...

Page 136: ...y rating 10 40 C 14 104 F without derating 40 50 C 104 122 F with derating For frame sizes R1 R2 10 40 C 14 104 F without derating 40 60 C 104 104 F with derating For frame sizes R3 R4 10 50 C 14 122...

Page 137: ...tion 3AXD50000613342 English Drive package Cardboard Molded pulp PE suspension film package plastic bag Package materials for options accessories and spare parts Cardboard Kraft paper PP straps PE fil...

Page 138: ...e drive and to find out where those components are located Contact your local ABB distributor for further information on environmental aspects End of life treatment must follow international and natio...

Page 139: ...complies with the applicable United Kingdom s legislation Statutory In struments Marking is required for products being placed on the market in Great Britain England Wales and Scotland T V Safety App...

Page 140: ...atibility 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 pro...

Page 141: ...ironment supplementary mitigation measures may be required in addition to the requirements listed above for the CE compliance Category C2 This is applicable to drives with an internal EMC C2 filter Th...

Page 142: ...ed to a grounding system that the EMC filter is not compatible with for example an IT system The supply network becomes connected to ground potential through the internal EMC filter capacitors which c...

Page 143: ...d as specified in this manual For the best EMC performance the EMC recommendations are obeyed 4 The drive is installed according to the instructions given in this manual WARNING Do not install a drive...

Page 144: ...hapter The drive is also suitable for use on a circuit capable of delivering not more than 65000 rms symmetrical amperes at these maximum voltages when protected by the specific UL Type E combination...

Page 145: ...onnected to and to communicate information and data via a network interface It is Customer s sole responsibility to provide and continuously ensure a secure connection between the product and Customer...

Page 146: ...146...

Page 147: ...Dimension drawings Contents of this chapter The chapter contains the dimension drawings of the drive The dimensions are in millimeters and inches 10 Dimension drawings 147...

Page 148: ...Frame R0 148 Dimension drawings...

Page 149: ...Frame R1 Dimension drawings 149...

Page 150: ...86 1 3 390 113 4 449 58 2 282 83 5 3 285 75 8 2 984 120 8 4 756 143 5 630 202 7 953 16 7 657 23 1 907 29 4 1 157 97 1 3 823 83 3 268 55 2 165 61 4 2 415 67 7 2 665 74 1 2 915 80 4 3 165 86 8 3 415 6 5...

Page 151: ...Frame R3 Dimension drawings 151...

Page 152: ...Frame R4 152 Dimension drawings...

Page 153: ...gy generated by motor during a quick deceleration The extra energy increases the drive DC link voltage The chopper connects the brake resistor to the DC link whenever the voltage is greater than the l...

Page 154: ...braking cycle T Equations for selecting the resistor Equation 1 When the drive supply voltage is 208 240 V When the drive supply voltage is 380 415 V When the drive supply voltage is 440 480 V Equatio...

Page 155: ...6 19R 6 4 5 3 3 38 16 17A5 2 CBT H 560 D HT 406 21R 8 6 5 4 28 16 25A0 2 CBT H 560 D HT 406 15R 11 8 25 7 5 5 5 17 8 033A 2 CBT V 760 G HT 282 8R 15 11 25 10 7 5 14 3 048A 2 22 16 5 15 11 10 3 055A 2...

Page 156: ...tor cables Shield the brake resistor cable Use shielded cable or a metallic enclosure If you use unshielded single core cables route them inside a cabinet that efficiently suppresses the radiated emis...

Page 157: ...e resistor cable when it is identical with the input power cable Protecting the system against thermal overload The drive has a brake thermal model which protects the brake resistor against overload A...

Page 158: ...witch 4 Digital input Monitors the brake resistor thermal switch 5 Mechanical and electrical installation of brake resistor WARNING Obey the safety instructions of the drive If you ignore them injury...

Page 159: ...r 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 Exte...

Page 160: ...160...

Page 161: ...ng or work on non electrical parts of the machinery without switching off the power supply to the drive When activated the Safe torque off function disables the control voltage for the power semicondu...

Page 162: ...ammable electronic safety related systems Part 2 Requirements for electrical electronic programmableelectronicsafety related systems IEC 61508 2 2010 Functional safety Safety instrumented systems for...

Page 163: ...nection see the technical data of the control unit Connection principle Single ACS180 drive internal power supply S 24 V DC S1 S2 SGND UDC UDC K 1 2 3 4 Drive 1 Control unit 2 Control logic 3 To motor...

Page 164: ...Single ACS180 drive external power supply S S1 S2 SGND 24 V DC UDC UDC 24 V DC K 2 1 3 4 Drive 1 Control unit 2 Control logic 3 To motor 4 Activation switch K 164 The Safe torque off function...

Page 165: ...23 13 Y1 A2 Y2 A1 31 32 OUT GND S1 S S2 SGND K 1 2 Drive 1 Safety PLC 2 Safety relay K Single ACS180 drive external power supply 24 14 23 13 Y1 A2 Y2 A1 31 32 OUT GND S1 S S2 SGND K 1 2 24 V DC Drive...

Page 166: ...Multiple ACS180 drives internal power supply 24 V S SGND S1 S2 S SGND S1 S2 S SGND S1 S2 K 1 1 1 2 2 2 Drive 1 Control unit 2 Activation switch K 166 The Safe torque off function...

Page 167: ...Drive 1 Control unit 2 Activation switch K Activation switch In the wiring diagrams the activation switch has the designation K This represents a component such as a manually operated switch an emerg...

Page 168: ...in the wiring between the switch and an STO terminal causes a dangerous fault Therefore it is recommended to use a safety relay including wiring diagnostics or a wiring method shield grounding channe...

Page 169: ...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 remova...

Page 170: ...6 The test procedures and report must be documented and signed by this person Validation test reports Signed validation test reports must be stored in the logbook of the machine The report shall inclu...

Page 171: ...e STO circuit Reset any active faults Restart the drive and check that the motor runs normally Test the operation of the failure detection of the drive The motor can be stopped or running Open the 1st...

Page 172: ...ny changes in the STO circuitry when the drive control unit is not powered or when the main power to the drive is off If both STO circuits are closed and a level type start signal is active when the p...

Page 173: ...he 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 m...

Page 174: ...rity requirement for the safety function is SIL 2 HFT 1 or PL d cat 3 the proof test for the function must be performed at least every 12 months The STO function of the drive does not contain any elec...

Page 175: ...on function is performed and the drive trips on an FA81 or FA82 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...

Page 176: ...ty data The safety data for the Safe torque off function is given below Note The safety data is calculated for redundant use and applies only if both STO channels are used 176 The Safe torque off func...

Page 177: ...50E 10 90 e 3 3 R0 4 39E 08 6 59E 08 4 39E 08 20 80 1 3 90 6461 3 12E 06 1 27E 06 1 41E 10 90 e 3 3 R1 4 39E 08 6 59E 08 4 39E 08 20 80 1 3 90 6461 3 12E 06 1 27E 06 1 41E 10 90 e 3 3 R2 4 39E 08 6 59...

Page 178: ...er 31 22 delay 1000 ms Terms and abbreviations Description Reference Term or abbreviation Classification of the safety related parts of a control system in respect of their resistance to faults and th...

Page 179: ...ty level 1 3 IEC 61508 SIL Safe torque off IEC EN 61800 5 2 STO Proof test interval T1 is a parameter used to define the probabilistic failure rate PFH or PFD for the safety function or subsystem Perf...

Page 180: ...Declarations of conformity 180 The Safe torque off function...

Page 181: ...The Safe torque off function 181...

Page 182: ...182 The Safe torque off function...

Page 183: ...The Safe torque off function 183...

Page 184: ...184...

Page 185: ...cessories that you can use with ACS180 Warnings WARNING Obey the safety instructions of the drive If you ignore them injury or death or damage to the equipment can occur If you are not a qualified ele...

Page 186: ...DRK 01 DIN rail mounting kit BDRK 01 is applicable to ACS180 frame size R0 and R1 drives Dimensions 1 039 7 5 295 35 1 378 198 4 7 811 150 3 5 917 17 1 673 70 2 756 190 7 480 Unit mm in 186 Accessorie...

Page 187: ...Installation 1 2 N m M4x16 2x 3 3 3 2 2 2 2 Accessories 187...

Page 188: ...BDRK 02 DIN rail mounting kit BDRK 02 is applicable to ACS180 frame size R2 drive Dimensions 1 039 7 5 295 35 1 378 120 4 724 17 1 673 162 2 6 386 202 7 953 210 4 8 283 Unit mm in 188 Accessories...

Page 189: ...Installation 3 3 2 2 2 3 2 2 N m M4x16 4x 1 Accessories 189...

Page 190: ...CCA 01 adapter to ACS180 frame size R1 with BMBC 01 mounting bracket and configure the drive with ABB software tools shown in the figure below For more information refer to CCA 01 quick installation...

Page 191: ...by navigating to www abb com contact centers Product training For information on ABB product training navigate to new abb com service training Providing feedback on ABB manuals Your comments on our ma...

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Summary of Contents for ACS180-04S-03A7-1

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Summary of Contents for ACS180-04S-03A7-1

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