ABB ACS180 Quick Installation And Start-Up Manual

—
ABB MACHINERY DRIVES
ACS180 drives
Quick installation and start-up guide
Safety instructions
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 electrical installation or maintenance work.
•
Do not do work on the drive, motor cable, motor, or control cables when the drive is
connected to the input power. Before you start the work, isolate the drive from all
dangerous voltage sources and make sure that it is safe to start the work. Always wait for
5 minutes after disconnecting the input power to let the intermediate circuit capacitors
discharge.
•
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
terminals.
1. Unpack the delivery
Keep the drive in its package until you are ready to install it. After unpacking, protect the drive
from dust, debris and moisture.
Make sure that these items are included:
•
drive
•
installation accessories (cable clamps, screws, hardware, etc.)
•
safety instructions
•
multilingual warning sticker sheet (residual voltage warning)
•
user interface guide
•
quick installation and start-up guide.
Make sure that there are no signs of damage to the items.
2. Reform the capacitors
If the drive has not been powered up for a year or more, you must reform the DC link
capacitors. The manufacturing date is on the type designation label. Refer to
reforming instructions (3BFE64059629 [English]).
3. Select the cables and fuse
•
Select the power cables. Obey the local regulations.
•
Input power cable: ABB recommends to use symmetrical shielded cable (VFD cable)
for the best EMC performance.
•
Motor cable: Use symmetrical shielded cable (VFD cable) for the best EMC
performance. Symmetrical shielded cable also reduces bearing currents, wear, and
stress on motor insulation.
•
Power cable types: In IEC installations, use copper or aluminum cables (if
permitted). In UL installations, use only copper cables.
•
Current rating: max. load current.
•
Voltage rating: min. 600 V AC.
•
Temperature rating: In IEC installations, select a cable rated for at least 70 °C
(158 °F) maximum permissible temperature of conductor in continuous use. In UL
installations, select a cable rated for at least 75 °C (167 °F).
•
Fuses and typical power cable sizes
Size: Refer to
Terminal data for the power cables
for the maximum cable sizes.
•
Select the control cables. Use double-shielded twisted-pair cable for analog signals. Use
double-shielded or single-shielded cable for the digital, relay and I/O signals. Do not run
24 V and 115/230 V signals in the same cable.
•
Protect the drive and input power cable with the correct fuses. Refer to
power cable sizes
.
4. Examine the installation area
The drive is intended for cabinet installation and has a degree of protection of IP20 / UL open
type as standard.
Examine the site where you will install the drive. Make sure that:
•
The installation site is sufficiently ventilated and hot air does not recirculate.
•
There is sufficient free space around the drive for cooling, maintenance, and operation.
Free space requirements
For the minimum free space requirements, refer to
•
The ambient conditions meet the requirements. Refer to
•
The installation surface is as close to vertical as possible and strong enough to support
Dimensions and weights
the weight of the drive. Refer to
•
The installation surface, floor and materials near the drive are not flammable.
•
There are no sources of strong magnetic fields such as high-current single-core
conductors or contactor coils near the drive. A strong magnetic field can cause
interference or inaccuracy in the operation of the drive.
5. Install the drive
You can install the drive with screws, or to a DIN rail (top hat type, width × height = 35 mm ×
7.5 mm [1.4 in × 0.3 in]).
•
Install the frame R0 drives upright. The frame R0 drives do not have a fan.
•
You can install the frame R1...R4 drives tilted by up to 90 degrees, from vertical to fully
horizontal orientation.
•
Do not install the drive upside down.
•
You can install several drives side by side.
 To install the drive with screws
R0 R1
M1
M1
1. Make marks onto the surface for the
Dimensions and
mounting holes. Refer to
weights
.Download the mounting template
on library.abb.com .
2. Drill the holes for the mounting screws. If
necessary, install suitable plugs or anchors
into the holes.
3. Install the mounting screws into the holes.
Leave a gap between the screw head and
installation surface.
4. Put the drive onto the mounting screws.
5. Tighten the mounting screws.

To install the drive to a DIN rail for frame sizes R3 and R4
1. Move the locking part to the left. If necessary, use a flat-head screwdriver.
2. Push and hold the locking button down.
3. Put the top tabs of the drive onto the top edge of the DIN rail.
4. Put the drive against the bottom edge of the DIN rail.
5. Release the locking button.
6. Move the locking part to the right.
7. Make sure that the drive is correctly installed.
To remove the drive, open the locking part and lift the drive from the DIN rail.
6. Measure the insulation resistance
Drive: Do not do voltage tolerance or insulation resistance tests on the drive, because this can
cause damage to the drive.
Input power cable: Before you connect the input power cable, measure the insulation of the
input power cable. Obey the local regulations.
Motor and motor cable:
1. Make sure that the motor cable is connected to the motor and disconnected from the
drive output terminals T1/U, T2/V and T3/W.
2. Use a voltage of 1000 V DC to measure the
insulation resistance between each phase
conductor and the protective earth conductor. The
insulation resistance of an ABB motor must be
more than 100 Mohm (at 25 °C [77 °F]). For the
insulation resistance of other motors, refer to the
manufacturer's documentation.
Moisture in the motor decreases the insulation
resistance. If you think that there is moisture in the
motor, dry the motor and do the measurement
again.
7. Make sure that the drive is compatible with the
grounding system
You can connect all drive types to a symmetrically grounded TN-S system (center-grounded
wye). The drive is delivered with the EMC and VAR screws installed. The material of the screws
(plastic or metal) depends on the product variant. The table shows when to remove the metal
EMC screw (disconnect the internal EMC filter) or metal VAR screw (disconnect the varistor
circuit).
Screw Factory default
label screw material
EMC Metal
1)
Plastic
VAR Metal
Plastic
1) Drives sold in North America have a plastic EMC screw.
2) Can install the metal screw (included in the drive delivery) to connect the internal EMC filter.
8. Connect the power cables

Connection diagram (shielded cables)
ACS180
L1
PE
3
Capacitor
2
PE L1
(L)
1. Disconnecting device.
2. Two protective earth (ground) conductors. Drive safety standard IEC/EN61800-5-1
requires two PE conductors, if the cross-sectional area of the PE conductor is less than
2
10 mm Cu or 16 mm
fourth conductor.
3. Use a separate grounding 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.
4. Use a separate grounding cable for the motor side, if the conductivity of the shield is not
for the typical cable sizes and to
sufficient, or if there is no symmetrically constructed PE conductor in the cable.
5. 360-degree grounding of the cable shield is required for the motor cable and brake
resistor cable (if used). It is also recommended for the input power cable.
6. Brake resistor and resistor cable (optional, for frame R2...R4 only).
Fuses and typical

Connection procedure (shielded cables)
For the tightening torques, refer to
1. Attach the residual voltage warning
sticker in the local language to the
drive.
2. Strip the motor cable.
3. Ground the motor cable shield under
the grounding clamp.
4. Twist the motor cable shield into a
.
bundle, mark it and connect it to the
Ambient conditions
.
grounding terminal.
5. Connect the phase conductors of the
.
motor cable to terminals T1/U, T2/V
and T3/W.
6. If you use a brake resistor, connect the
brake resistor cable to terminals R- and
UDC+. Use a shielded cable and ground
the shield under the grounding clamp.
7. Make sure that the R- and UDC+
terminal screws are tightened. Do this
step also if you do not connect cables to
the terminals.
8. Strip the input power cable.
9. If the input power cable has a shield,
ground the shield under the grounding
clamp. Then twist the shield into a
bundle, mark it and connect it to the
grounding terminal.
10. Connect the PE conductor of the input
power cable to the grounding terminal.
R2...R4
If necessary, use a second PE
conductor.
11. In 3-phase drives, connect the phase
conductors of the input power cable to
terminals L1, L2 and L3. In 1-phase
drives, connect the phase and neutral
conductors to terminals L and N.
M1
12. Mechanically attach the cables on the
outside of the drive.
9. Connect the control cables

Connection procedure
Do the connections according to the default
control connections of the application macro
that you select. Keep the signal wire pairs
twisted as near to the terminals as possible
to prevent inductive coupling.
1. Strip a part of the outer shield of the
control cable for grounding.
2. Use a 360-degree grounding clamp to
connect the outer shield to the
grounding tab.
ohm
U1-PE, V1-PE, W1-PE
Grounding systems
Symmetrically Corner-grounded
grounded TN-S delta, midpoint- (ungrounded or
systems (center- grounded delta high-resistance
grounded wye) and TT systems
Do not remove Remove
2)
Do not remove Do not remove Do not remove
Do not remove Do not remove
Do not remove Do not remove Do not remove
R+ T1/ T2/ T3/
L2 L3 R- UDC-
UDC+ U V W
5
6
V1
U1 W1
M PE
1
3
L2 L3
(N)
2
Al. For example, you can use the cable shield in addition to the
Terminal data for the power cables .
R2...R4
Bottom In
3. Strip the control cable conductors.
4. Connect the conductors to the correct control terminals. Insert the conductor into a
push-in terminal. To release, pull the conductor with pushing the open/close button all
the way down firmly with a flathead screwdriver.
5. Mechanically attach the control cables on the outside of the drive.

Default I/O connections (ABB standard macro)
The ABB standard macro is the default macro. The connection diagram for the ABB standard
macro is shown below.
Terminals
1...10 kohm
Max. 500 ohm
U1
M
V1
3~
W1
PE
IT systems
Note: You can select other macros with the control panel. For default IO assignment, see below:
grounded)
Hand/Auto
Remove
DI1 Start/Stop (Hand)
DI2 Hand(1)/Auto(0)
Remove
DI3 Start/Stop (Auto)
DI4 Fault reset
Speed
AI1/DI5
ref.(Hand)(AI1,0...10V)
AI2 Speed ref.(Auto)(4...20mA) Speed ref.(0...10V)
PID
DI1 Start/Stop
DI2 Internal setpoint sel 1
DI3 Internal setpoint sel 2
DI4 Constant speed selection 1
AI1/DI5 PID set point(AI1, 0...10V)
AI2 Process feedback(4...20mA)
3-wire
4 DI1 Start(pulse)
DI2 Stop(pulse)
DI3 Forward(0)/Reverse(1)
DI4 Constant speed selection 1
AI1/DI5 Constant speed selection 2 (DI5)
AI2 Speed ref.(0...10V)
DO Running
All macros RO Fault(-1)
AO Output frequency(0...20mA)

Embedded fieldbus connection
Connect the fieldbus to the EIA-485 Modbus RTU terminal which is on the front of the drive.
To configure Modbus RTU communication with the embedded fieldbus:
1. Connect the fieldbus cables and the necessary I/O signals.
2. Use the jumpers to set the termination and bias settings.
3. Power up the drive and set the necessary parameters.
A connection example is shown below.
3)
G R - +
1)
Termination ON
Termination OFF
J1
Modbus mode
J2
Automation
Drive
controller
1) The devices at the ends of the fieldbus must have termination set to ON. All other devices
must have termination set to OFF.
2) Attach the cable shields together at each drive, but do not connect them to the drive.
Connect the shields only to the grounding terminal in the automation controller.
3) Connect the AGND conductor to the signal ground reference terminal in the automation
controller.
10. Start up the drive
WARNING! Before you start up the drive, make sure that the installation is
completed. Make sure also that it is safe to start the motor. Disconnect the motor
from other machinery, if there is a risk of damage or injury.
R0/R1
Top In For information on the user interface, refer to the
(3AXD50000606696 [English]).
1. Power up the drive.
2. Select the units (international or US). In the
view, set the motor type: 
AsynM: Asynchronous motor
PMSM: Permanent magnet synchronous motor
3. Set the motor control mode:
Vector: Speed reference. This is suitable for most cases.
The drive does an automatic standstill ID run when the
drive is started for the first time.
Scalar: Frequency reference. Do not use this mode for
permanent magnet synchronous motors.
Use this mode when:
•
The number of motors can change.
•
The nominal motor current is less than 20% of the
nominal drive current.
4. Set the nominal motor values.
5. Start the motor and check the direction of rotation. If the
direction is incorrect, you can:
•
change the Phase order setting, or
•
change the phase order of the motor cable.
Note: In vector control mode the drive does an automatic
standstill ID run at the first start.
6. In the Motor control view, set the start and stop mode.
7. Set the acceleration and deceleration times.
8. Set the maximum and minimum speeds.
9. In the Control macros view, select the applicable macro.
10. Tune the drive parameters to the application. You can also
use the Assistant control panel (ACS-AP-...) or the Drive
Composer PC tool.
Descriptions
Digital I/O
21 24 V Aux. +24 V DC, max 200 mA
22 DGND Aux. voltage output common
8 DI1 Stop (0) / Start (1)
9 DI2 Forward (0) / Reverse (1)
10 DI3 Constant speed selection 1
11 DI4 Constant speed selection 2
12 DCOM Digital input common
18 DO Running
19 DO COM Digital output common
20 DO SRC Digital output auxiliary voltage
Analog I/O
14 AI1/DI5 Speed reference (0...10V)
13 AGND Analog input circuit common
15 AI2 Not used
16 AGND Analog output circuit common
17 AO Output frequency (0...20mA)
23 10V Ref. voltage +10 V DC
24 SCREEN Signal cable shield (screen)
Safe torque off (STO) (only on ACS180-04S)
1 S+ Safe torque off (STO). Both circuits
must be closed for the drive to start.
2 SGND
The drawing shows the simplified
3 S1
connection of a safety circuit through
safety contacts. If STO is not used,
4 S2
leave the factory-installed jumpers in
Safe torque
place. See also section
off (STO) .
Relay output
5 NC
No fault [Fault (-1)]
6 COM
7 NO
EIA-485 Modbus RTU
25 B+
26 A-
Embedded Modbus RTU (EIA-485)
27 AGND
28 SHIELD
Jumper
J1 Termination Modbus Termination ON-OFF
J2 Comm.Mode Communication Mode Selection
Alternate Motor potentionmeter
Start forward Start/Stop
Start reverse Forward/Reverse
Const speed selection 1 Speed ref. up
Const speed selection 2 Speed ref. down
Const speed selection
Fault reset(DI5)
1(DI5)
not used
Hand/PID
Start/Stop(Hand)
Hand(1)/PID(0)
Start/Stop(PID)
Constant speed selection 1
Hand mode speed ref.(AI1,0...10V)
Process feedback(4...20mA)
Modbus
Start/Stop(Hand)
Forward/Reverse(Hand)
Hand(1)/Modbus(0)
Fault reset
Constant speed selection 1(DI5)
Speed ref(Hand, 0...10V)
2)
1)
Termination OFF Termination ON
J1 J1
Modbus mode Modbus mode
J2
J2
Drive
Drive
ACS180 User interface guide
2 3
Motor data
4
5
6
7
8
9