ABB ACS180 User manual

—
ABB MACHINERY DRIVES
ACS180 drives
Hardware manual

ACS180 drives
Hardware manual
Table of contents
1. Safety instructions
4. Mechanical installation
6. Electrical installation
3AXD50000467945 Rev B
EN
Original instructions
EFFECTIVE: 2022-06-28

Table of contents
1 Safety instructions
13Contents of this chapter .........................................................................................
13Use of warnings and notes .....................................................................................
14General safety in installation, start-up and maintenance ................................
16Electrical safety in installation, start-up and maintenance .............................
16Electrical safety precautions ..........................................................................
17Additional instructions and notes .................................................................
17Printed circuit boards ..........................................................................
18Grounding ...........................................................................................................
19General safety in operation ....................................................................................
19Additional instructions for permanent magnet motor drives ........................
19Safety in installation, start-up, maintenance ..............................................
20Safety in operation ...........................................................................................
2 Introduction to the manual
21Contents of this chapter .........................................................................................
21Applicability ...............................................................................................................
21Target audience ........................................................................................................
21Purpose of the manual ............................................................................................
21Categorization by frame size .................................................................................
21Quick installation and commissioning flowchart ..............................................
23Terms and abbreviations ........................................................................................
24Related manuals .......................................................................................................
24Manuals on internet .................................................................................................
3 Operation principle and hardware description
25Contents of this chapter .........................................................................................
26Operation principle ..................................................................................................
26Simplified main circuit diagram .....................................................................
26Product variants .......................................................................................................
27Layout .........................................................................................................................
27Frame sizes R0...R1 ............................................................................................
28Frame sizes R2...R4 ...........................................................................................
29Control connections ................................................................................................
29Standard variant (ACS180-04S-...) .................................................................
30Base variant (ACS180-04N-...) .........................................................................
31Control panel options ..............................................................................................
Table of contents 5

31Drive labels .................................................................................................................
31Model information label ...................................................................................
32Type designation label .....................................................................................
32Type designation key ...............................................................................................
33Control panel .............................................................................................................
34Home view ..........................................................................................................
34Status icon .............................................................................................
35Message view .....................................................................................................
35Options view ......................................................................................................
35Menu ....................................................................................................................
4 Mechanical installation
37Contents of this chapter .........................................................................................
37Installation alternatives ..........................................................................................
38Examining the installation site ..............................................................................
38Required tools ...........................................................................................................
38Unpacking the delivery ............................................................................................
40Installing the drive ....................................................................................................
40To install the drive with screws ......................................................................
42To install the drive to a DIN installation rail for frame sizes R3 and R4 ..
5 Guidelines for planning the electrical installation
43Contents of this chapter .........................................................................................
43Limitation of liability ...............................................................................................
43Selecting the main supply disconnecting device ...............................................
44European Union and United Kingdom ..........................................................
44North America ....................................................................................................
44Other regions .....................................................................................................
44Selecting the main contactor .................................................................................
44Checking the compatibility of the motor and drive ..........................................
45Selecting the power cables ....................................................................................
45General guidelines ............................................................................................
45Typical power cable sizes ................................................................................
45Power cable types .............................................................................................
45Preferred power cable types ..............................................................
46Alternate power cable types ...............................................................
47Not allowed power cable types ..........................................................
47Additional guidelines, North America ...........................................................
48Metal conduit .........................................................................................
48Power cable shield ............................................................................................
49Selecting the control cables ...................................................................................
49Shielding .............................................................................................................
49Signals in separate cables ...............................................................................
50Signals that can be run in the same cable ....................................................
6 Table of contents

50Relay cable ..........................................................................................................
50Control panel to drive cable ............................................................................
50PC tool cable ......................................................................................................
50Routing the cables ...................................................................................................
50General guidelines – IEC ...................................................................................
51General guidelines – North America ..............................................................
52
Continuous motor cable shield/conduit or enclosure for equipment on
the motor cable .................................................................................................
53Separate control cable ducts ..........................................................................
53Implementing short-circuit and thermal overload protection ........................
53Protecting the drive and input power cable in short-circuits ..................
53Protecting the motor and motor cable in short-circuits ..........................
54
Protecting the drive, and the input power and motor cables against
thermal overload ...............................................................................................
54Protecting the motor against thermal overload ........................................
54
Protecting the motor against overload without thermal model or
temperature sensors ........................................................................................
55Implementing motor temperature sensor connection .....................................
55Protecting the drive against ground faults .........................................................
55Residual current device compatibility ..........................................................
56Implementing the Emergency stop function ......................................................
56Implementing the Safe torque off function ........................................................
56Using a safety switch between the drive and the motor .................................
56Implementing the control of a contactor between drive and motor .............
57Protecting the contacts of relay outputs ............................................................
6 Electrical installation
59Contents of this chapter .........................................................................................
59Warnings ....................................................................................................................
59Required tools ...........................................................................................................
60Measuring the insulation ........................................................................................
60Measuring the insulation resistance of the drive .......................................
60Measuring the insulation resistance of the input power cable ...............
60Measuring the insulation resistance of the motor and motor cable ......
61Earthing system compatibility check ...................................................................
61EMC filter ............................................................................................................
61When to disconnect the EMC filter ................................................................
62Disconnecting the EMC filter ..........................................................................
63Guidelines for installing the drive to a TT system ......................................
63Identifying the grounding system of the electrical power network .......
65Connecting the power cables ................................................................................
65Connection diagram .........................................................................................
66Connection procedure .....................................................................................
68Connecting the control cables ...............................................................................
69Default I/O connection diagram (ABB standard macro) ..........................
Table of contents 7

70Control cable connection procedure .............................................................
72Additional information on the control connections ..........................................
72Connecting EIA-485 fieldbus cable to the drive ..........................................
73PNP configuration for digital inputs .............................................................
73NPN configuration for digital inputs ............................................................
74Connection examples of two-wire and three-wire sensors .....................
74Safe torque off ..................................................................................................
74Communication mode jumper J2 ...................................................................
75Connecting a PC .......................................................................................................
7 Installation checklist
77Contents of this chapter .........................................................................................
77Checklist .....................................................................................................................
8 Maintenance
79Contents of this chapter .........................................................................................
79Maintenance intervals .............................................................................................
79Description of symbols ....................................................................................
80Recommended maintenance intervals after start-up ...............................
80Cleaning the heatsink ..............................................................................................
81Replacing the cooling fans .....................................................................................
81To replace the cooling fan for frame size R1 ...............................................
83To replace the cooling fan for frame size R2 ...............................................
85To replace the cooling fan for frame size R3 ...............................................
88To replace the cooling fan for frame size R4 ...............................................
89Capacitors ..................................................................................................................
89Reforming the capacitors ................................................................................
9 Technical data
91Contents of this chapter .........................................................................................
91Ratings ........................................................................................................................
91IEC ratings ..........................................................................................................
92UL (NEC) ratings ................................................................................................
94Definitions ..........................................................................................................
94Sizing ...................................................................................................................
94Output derating ........................................................................................................
97Surrounding air temperature derating .........................................................
99Altitude derating ...............................................................................................
99Switching frequency derating ........................................................................
101Fuses ...........................................................................................................................
101gG fuses (IEC) ....................................................................................................
102gR or aR -type fuses (IEC) ................................................................................
103UL fuses (UL(NEC)) ...........................................................................................
8 Table of contents

104Alternate short-circuit protection .........................................................................
104Miniature circuit breakers (IEC) .....................................................................
106
Manual self-protected combination motor controller – Type E USA
(UL (NEC)) ...........................................................................................................
108Dimensions and weights ........................................................................................
109Free space requirements ........................................................................................
109Losses, cooling data and noise .............................................................................
110Terminal data for the power cables ......................................................................
113Typical power cable sizes .......................................................................................
114Terminal data for the control cables ....................................................................
114External EMC filters ..................................................................................................
115Electrical power network specification ...............................................................
116Motor connection data ............................................................................................
116Motor cable length ............................................................................................
116Operational functionality and motor cable length ........................
118EMC compatibility and motor cable length .....................................
119Control connection data .........................................................................................
120Brake resistor connection data .............................................................................
120Energy efficiency data (ecodesign) ......................................................................
120Degrees of protection .............................................................................................
120Ambient conditions .................................................................................................
122Materials .....................................................................................................................
122Disposal ......................................................................................................................
122Applicable standards ...............................................................................................
123Markings .....................................................................................................................
124Compliance with EN 61800-3 .................................................................................
124Definitions ..........................................................................................................
124Category C1 ........................................................................................................
125Category C2 ........................................................................................................
125Category C3 ........................................................................................................
125Category C4 ........................................................................................................
127UL checklist ................................................................................................................
128Compliance with the European Machinery Directive ........................................
128Disclaimers ................................................................................................................
128Generic disclaimer ............................................................................................
128Cybersecurity disclaimer .................................................................................
10 Dimension drawings
129Contents of this chapter .........................................................................................
130Frame R0 ....................................................................................................................
131Frame R1 .....................................................................................................................
132Frame R2 .....................................................................................................................
133Frame R3 .....................................................................................................................
134Frame R4 ....................................................................................................................
Table of contents 9

11 Resistor braking
135Contents of this chapter .........................................................................................
135Safety ..........................................................................................................................
135Operation principle ..................................................................................................
135Selecting the brake resistor ...................................................................................
137Reference brake resistors ...............................................................................
137Definitions ..............................................................................................
138Selecting and routing the brake resistor cables ................................................
138Minimizing electromagnetic interference ....................................................
138Maximum cable length .....................................................................................
138Placing the brake resistors .....................................................................................
139Protecting the system in brake circuit fault situations ....................................
139
Protecting the system in cable and brake resistor short-circuit
situations ............................................................................................................
139Protecting the system against thermal overload .......................................
140Mechanical and electrical installation of brake resistor ...................................
140Mechanical installation ....................................................................................
141Electrical installation ........................................................................................
141Measuring the insulation .....................................................................
141Connecting power cables ....................................................................
141Connection the control cables ...........................................................
141Start-up ......................................................................................................................
12 The Safe torque off function
143Contents of this chapter .........................................................................................
143Description ................................................................................................................
144
Compliance with the European Machinery Directive and the UK Supply
of Machinery (Safety) Regulations ................................................................
145Wiring ..........................................................................................................................
145Connection principle ........................................................................................
145Single ACS180 drive, internal power supply ....................................
146Single ACS180 drive, external power supply ...................................
147Wiring examples ................................................................................................
147Single ACS180 drive, internal power supply ....................................
147Single ACS180 drive, external power supply ...................................
148Multiple ACS180 drives, internal power supply ...............................
149Multiple ACS180 drives, external power supply ..............................
149Activation switch ...............................................................................................
150Cable types and lengths ..................................................................................
150Grounding of protective shields ....................................................................
151Operation principle ..................................................................................................
152Start-up including validation test .........................................................................
152Competence .......................................................................................................
152Validation test reports .....................................................................................
10 Table of contents

152Validation test procedure ...............................................................................
154Use ...............................................................................................................................
156Maintenance ..............................................................................................................
156Competence .......................................................................................................
157Fault tracing ..............................................................................................................
158Safety data .................................................................................................................
160Terms and abbreviations .................................................................................
161TÜV certificate ...................................................................................................
162Declarations of conformity .............................................................................
Further information
Table of contents 11

12

1
Safety instructions
Contents of this chapter
This chapter contains the safety instructions which you must obey when you install,
start-up, operate and do maintenance work on the drive. If you ignore the safety
instructions, injury, death or damage can occur.
Use of warnings and notes
Warnings tell you about conditions which can cause injury or death, or damage to
the equipment. They also tell you 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 hazards from electricity which can cause injury
or death, or damage to the equipment.
WARNING!
General warning tells about conditions other than those caused by electricity,
which can cause injury or death, or damage to the equipment.
WARNING!
Electrostatic sensitive devices warning tells you about the risk of electrostatic
discharge which can cause damage to the equipment.
Safety instructions 13

General safety in installation, start-up and maintenance
These instructions are for all personnel who do work on the drive.
WARNING!
Obey these instructions. If you ignore them, injury or death, or damage to
the equipment can occur.
• Keep the drive in its package until you install it. After unpacking, protect the
drive from dust, debris and moisture.
• Use the required personal protective equipment: safety shoes with metal toe
cap, safety glasses, protective gloves and long sleeves, etc. Some parts have
sharp edges.
• Beware of hot surfaces. Some parts, such as heatsinks of power
semiconductors, and brake resistors, remain hot for a while after disconnection
of the electrical supply.
• Vacuum clean the area around the drive before the start-up to prevent the
drive cooling fan from drawing dust inside the drive.
• Make sure that debris from drilling, cutting and grinding does not go into the
drive during installation. Electrically conductive debris inside the drive can
cause damage or malfunction.
• Make sure that 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 the drive operation limits, make sure that the motor and all
driven equipment can operate throughout the set operation limits.
• Before you activate the automatic fault reset or automatic restart functions
of the drive control program, make sure that no dangerous situations 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/EN/UL 61800-5-1, subclause 6.5.3,
for example, "THIS MACHINE STARTS AUTOMATICALLY".
• The maximum number of drive power-ups is five in ten minutes. Too frequent
power-ups can damage the charging circuit of the DC capacitors.
• If you have connected safety circuits to the drive (for example, Safe torque off
or emergency stop), validate them at start-up. See separate instructions for
the safety circuits.
• Beware of hot air exiting from the air outlets.
• Do not cover the air inlet or outlet when the drive is running.
14 Safety instructions
3

Note:
• If you select an external source for the start command and it is on, the drive
will start 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.
• Only authorized persons are allowed to repair a malfunctioning drive.
Safety instructions 15

Electrical safety in installation, start-up and maintenance
￭Electrical safety precautions
These electrical safety precautions are for all personnel who do work on the drive,
motor cable or motor.
WARNING!
Obey these instructions. If you ignore them, injury or death, or damage to
the equipment can occur.
If you are not a qualified electrical professional, do not do installation or
maintenance work.
Do these steps before you begin any installation or maintenance work.
1. Clearly identify the work location and equipment.
2. Disconnect all possible voltage sources. Make sure that re-connection is not
possible. Lock out and tag out.
• Open the 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.
• Disconnect all dangerous external voltages from the control circuits.
• After you disconnect power from the drive, always wait 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 quality voltage tester.
Before and after measuring the installation, verify the operation of the
voltage tester on a known voltage source.
•
• Make sure that the voltage between the drive input power terminals (L1,
L2, L3) and the grounding (PE) busbar is zero.
•Make sure that the voltage between the drive output terminals (T1/U, T2/V,
T3/W) and the grounding (PE) busbar is zero.
• Make sure that the voltage between the drive DC terminals (UDC+ and
UDC-) and the grounding (PE) terminal is zero.
Note: If cables are not connected to the drive DC terminals, measuring the
voltage from the DC terminal screws can give incorrect results.
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.
16 Safety instructions
3

￭Additional instructions and notes
WARNING!
Obey these instructions. If you ignore them, injury or death, or damage to
the equipment can occur.
If you are not a qualified electrical professional, do not do installation or
maintenance work.
• Make sure that the electrical power network, motor/generator, and
environmental conditions agree with the drive data.
• Do not do insulation or voltage withstand tests on the drive.
• If you have a cardiac pacemaker or other electronic medical device, keep 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 cause a health hazard.
Note:
• When the drive is connected to the input power, the motor cable terminals
and the DC bus are at a dangerous voltage.
After disconnecting the drive from the input power, these remain at a
dangerous voltage until the intermediate circuit capacitors have discharged.
• External wiring can supply dangerous voltages to the relay outputs of the
control units of the drive.
• The Safe torque off function does not remove the voltage from the main and
auxiliary circuits. The function is not effective against deliberate sabotage or
misuse.
Printed circuit boards
WARNING!
Use a grounding wristband when you handle printed circuit boards. Do not
touch the boards unnecessarily. The boards contain components sensitive
to electrostatic discharge.
Safety instructions 17

￭Grounding
These instructions are for all personnel who are responsible for the grounding of
the drive.
WARNING!
Obey these instructions. If you ignore them, injury or death, or equipment
malfunction can occur, and electromagnetic interference can increase.
If you are not a qualified electrical professional, do not do grounding work.
•Always ground the drive, the motor and adjoining 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 planning
instructions of the drive. Obey the applicable national and local regulations.
• When using shielded cables, make a 360° grounding of the cable shields at the
cable entries to reduce electromagnetic emission and interference.
• In a multiple-drive installation, connect each drive separately to the protective
earth (PE) busbar of the power supply.
18 Safety instructions
3

General safety in operation
These instructions are for all personnel that operate the drive.
WARNING!
Obey these instructions. If you ignore them, injury or death, or damage to
the equipment can occur.
• If you have a cardiac pacemaker or other electronic medical device, keep 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 cause a health hazard.
• Give a stop command to the drive before you reset a fault. If you have an
external source for the start command and the start is on, the drive will start
immediately after the fault reset, unless you configure the drive for pulse start.
See the firmware manual.
• Before you activate the automatic fault reset or automatic restart functions
of the drive control program, make sure that no dangerous situations 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/EN/UL 61800-5-1, subclause 6.5.3,
for example, "THIS MACHINE STARTS AUTOMATICALLY".
Note:
• The maximum number of drive power-ups is five in ten minutes. Too frequent
power-ups can damage the charging circuit of the DC capacitors. If you need
to start or stop the drive, use the control panel keys or commands through
the I/O terminals of the drive.
• If the drive is in remote control mode, you cannot stop or start the drive with
the control panel.
Additional instructions for permanent magnet motor drives
￭Safety in installation, start-up, maintenance
These are additional warnings concerning permanent magnet motor drives. The
other safety instructions in this chapter are also valid.
WARNING!
Obey these instructions. If you ignore them, injury or death, or damage to
the equipment can occur.
If you are not a qualified electrical professional, do not do installation or
maintenance work.
Safety instructions 19

• Do not do work on the drive when a rotating permanent magnet motor is
connected to it. A rotating permanent magnet motor energizes the drive
including its input and output power terminals.
Before installation, start-up and maintenance work on the drive:
• Stop the drive.
• Disconnect the motor from the drive with a safety switch or by other means.
• If you cannot disconnect the motor, make sure that the motor cannot rotate
during work. Make sure that no other system, like hydraulic crawling drives,
can rotate the motor directly 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).
Connect the output terminals together as well as to the PE.
During the start-up:
• Make sure that the motor cannot run overspeed, for example, driven by the
load. Motor overspeed causes overvoltage that can damage or destroy the
capacitors in the intermediate circuit of the drive.
￭Safety in operation
WARNING!
Make sure that the motor cannot run overspeed, for example, driven by the
load. Motor overspeed causes overvoltage that can damage or destroy the
capacitors in the intermediate circuit of the drive.
20 Safety instructions
3