ABB ACS180 Manuals

Manuals and User Guides for ABB ACS180. We have 4 ABB ACS180 manuals available for free PDF download: Firmware Manual, Hardware Manual, Quick Installation And Start-Up Manual

ABB ACS180 Firmware Manual (392 pages)

Machinery control program

Brand: ABB | Category: Controller | Size: 12.07 MB

Table of Contents
5
Introduction to the Manual
11
What this Chapter Contains
11
Applicability
11
Safety Instructions
11
Target Audience
12
Terms and Abbreviations
13
Related Manuals
14
Cybersecurity Disclaimer
14
Control Panel
15
What this Chapter Contains
15
Home View and Message View
16
Options Menu and Main Menu
17
Options Menu
17
Main Menu
17
Start-Up, ID Run and Use
21
What this Chapter Contains
21
Start up the Drive
21
Do the Identification (ID) Run
22
Background Information
22
ID Run Steps
23
Start and Stop the Drive
24
Change the Rotation Direction
24
Set the Speed or Frequency Reference
24
Set the Drive Parameters
25
Open Diagnostics
25
Change the Units
26
Control Macros
27
Contents
27
ABB Standard Macro
27
Default Control Connections for the ABB Standard Macro
28
Hand/Auto Macro
30
Default Control Connections for the Hand/Auto Macro
30
Hand/Pid Macro
32
Default Control Connections for the Hand/Pid Macro
32
Modbus RTU Macro
34
Default Control Connections for the Modbus Macro
34
Alternate Macro
36
Default Control Connections for the Alternate Macro
36
Motor Potentiometer Macro
38
Default Control Connections for the Motor Potentiometer Macro
39
PID Macro
41
Default Control Connections for PID Control Macro
41
Program Features
43
What this Chapter Contains
43
Local and External Control Locations
44
Local Control
44
External Control
44
Operating Modes of the Drive
46
Speed Control Mode
46
Torque Control Mode
47
Frequency Control Mode
47
Special Control Modes
47
Settings and Diagnostics
47
Drive Configuration and Programming
48
Programming Via Parameters
48
Control Interfaces
49
Programmable Analog Inputs
49
Programmable Analog Outputs
49
Programmable Digital Inputs and Outputs
49
Programmable Relay Outputs
49
Fieldbus Control
50
Motor Control
50
Motor Types
50
Motor Identification
50
Scalar Motor Control
51
Vector Control
52
Reference Ramping
52
Constant Speeds/Frequencies
53
Critical Speeds/Frequencies
53
Speed Controller Autotune
54
Rush Control
57
Jogging
58
Autophasing
60
Speed Control Performance Figures
62
Torque Control Performance Figures
62
User Load Curve
63
U/F Ratio
64
Flux Braking
65
DC Magnetization
66
Energy Optimization
68
Switching Frequency
68
Speed Compensated Stop
69
Application Control
70
Control Macros
70
Process PID Control
70
PID Trim Function
73
Mechanical Brake Control
80
DC Voltage Control
85
Overvoltage Control
85
Undervoltage Control (Power Loss Ride-Through)
85
Voltage Control and Trip Limits
86
Settings and Diagnostics
88
Safety and Protections
89
Fixed/Standard Protections
89
Emergency Stop
89
Motor Thermal Protection
90
Automatic Fault Resets
92
Other Programmable Protection Functions
93
Diagnostics
95
Fault and Warning Messages, Data Logging
95
Signal Supervision
95
Energy Saving Calculators
95
Load Analyzer
95
Miscellaneous
97
Backup and Restore
97
User Parameter Sets
97
Data Storage Parameters
98
Parameter Checksum Calculation
98
Motor Potentiometer
99
User Lock
100
Parameters
101
What this Chapter Contains
101
Terms and Abbreviations
102
Fieldbus Addresses
102
Summary of Parameter Groups
103
Short Parameter Listing
104
Long Parameter Listing
108
Actual Values
108
Input References
111
Warnings and Faults
112
Diagnostics
114
Control and Status Words
117
System Info
122
Standard DI, RO
123
Standard DIO, FI, FO
127
Standard AI
131
Standard AO
136
Operation Mode
140
Start/Stop/Direction
142
Start/Stop Mode
152
Speed Reference Selection
160
Speed Reference Ramp
170
Speed Reference Conditioning
175
Speed Control
175
Torque Reference Chain
181
Frequency Reference Chain
185
Limits
197
Fault Functions
205
Supervision
214
Motor Thermal Protection
221
Load Analyzer
227
User Load Curve
230
Process PID Set 1
234
Process PID Set 2
249
Mechanical Brake Control
252
Energy Efficiency
253
Monitoring/Scaling Settings
257
Data Storage
261
Panel Port Communication
262
Embedded Fieldbus
264
External PID1
272
HW Configuration
274
System
276
Motor Control
285
User Motor Parameters
289
Motor Data
291
Differences in the Default Values between 50 Hz and 60 Hz Supply Frequency Settings
297
Parameters Supported by Modbus Backwards Compatibility with 550
298
Additional Parameter Data
301
What this Chapter Contains
301
Terms and Abbreviations
301
Fieldbus Addresses
302
Parameter Groups 1
303
Parameter Groups 10
307
Speed Reference Conditioning
312
Speed Control
312
Torque Reference Chain
312
Frequency Reference Chain
313
Limits
314
Fault Functions
314
Supervision
315
Motor Thermal Protection
316
Load Analyzer
317
User Load Curve
318
Mechanical Brake Control
322
Energy Efficiency
322
Data Storage
324
Panel Port Communication
324
Fault Tracing
331
What this Chapter Contains
331
Safety
331
Indications
332
Warnings and Faults
332
Pure Events
332
Warning/Fault History
332
Event Log
332
Viewing Warning/Fault Information
333
QR Code Generation for Mobile Service Application
333
Warning Messages
334
Fault Messages
342
Fieldbus Control through the Embedded Fieldbus Interface (EFB)
351
What this Chapter Contains
351
System Overview
352
Modbus
352
Embedded Fieldbus and External Control Panel Mode Switch
352
Connecting the Fieldbus to the Drive
352
Setting up the Embedded Fieldbus Interface (Modbus)
353
Setting the Drive Control Parameters
355
Basics of the Embedded Fieldbus Interface
357
Control Word and Status Word
357
References
358
Actual Values
358
Data Input/Outputs
358
Register Addressing
358
About the Control Profiles
359
Control Word
360
Control Word for the DCU Profile
361
Status Word
363
State Transition Diagrams
365
References
367
Actual Values
368
Modbus Holding Register Addresses
369
Modbus Function Codes
370
Exception Codes
371
Coils (0Xxxx Reference Set)
372
Discrete Inputs (1Xxxx Reference Set)
373
Error Code Registers (Holding Registers 400090
374
Control Chain Diagrams
375
What this Chapter Contains
375
Frequency Reference Selection
376
Frequency Reference Modification
377
Speed Reference Source Selection I
378
Speed Reference Source Selection II
379
Speed Reference Ramping and Shaping
380
Speed Error Calculation
381
Speed Controller
382
Torque Reference Source Selection and Modification
383
Reference Selection for Torque Controller
384
Torque Limitation
385
Process PID Setpoint and Feedback Source Selection
386
Process PID Controller
387
External PID Setpoint and Feedback Source Selection
388
External PID Controller
389
Direction Lock
390

ABB ACS180 Hardware Manual (192 pages)

Brand: ABB | Category: DC Drives | Size: 18.03 MB

Table of Contents
5
1 Safety Instructions

13
2 Introduction to the Manual

21
- Contents of this Chapter
  21
- Applicability
  21
- Target Audience
  21
- Categorization by Frame Size
  21
- Quick Installation and Commissioning Flowchart
  22
- Terms and Abbreviations
  23
- Related Manuals
  23
3 Operation Principle and Hardware Description

25
- Contents of this Chapter
  25
- Operation Principle
  25
  - Simplified Main Circuit Diagram
    26
- Product Variants
  26
- Layout
  27
  - Frame Sizes R0
    27
  - Frame Sizes R2
    28
- Control Connections
  29
  - Standard Variant (ACS180-04S
    29
  - Base Variant (ACS180-04N
    30
- Control Panel Options
  31
- Drive Labels
  31
  - Model Information Label
    31
  - Type Designation Label
    32
- Type Designation Key
  32
- Control Panel
  33
  - Home View
    34
    
    Status Icon
    34
  - Message View
    35
  - Options View
    35
  - Menu
    35
4 Mechanical Installation

37
5 Guidelines for Planning the Electrical Installation

43
6 Electrical Installation

61
7 Installation Checklist

81
- Contents of this Chapter
  81
- Checklist
  81
8 Maintenance

85
9 Technical Data

97
- Contents of this Chapter
  97
- Electrical Ratings
  97
  - IEC Ratings
    97
  - UL (NEC) Ratings
    99
  - Definitions
    100
  - Sizing
    101
- Output Derating
  101
  - Surrounding Air Temperature Derating
    104
  - Altitude Derating
    107
  - Switching Frequency Derating
    107
- Fuses
  109
  - IEC Fuses
    109
    
    Gg Fuses
    109
    
    Gr or Ar -Type Fuses
    111
- UL (NEC) Fuses
  112
- Alternate Short-Circuit Protection
  114
- Dimensions and Weights
  121
- Free Space Requirements
  122
- Losses, Cooling Data and Noise
  122
- Typical Power Cable Sizes
  123
- Terminal Data for the Power Cables
  125
- Terminal Data for the Control Cables
  128
- External EMC Filters
  128
- Electrical Power Network Specification
  129
- Motor Connection Data
  130
  - Motor Cable Length
    130
    
    Operational Functionality and Motor Cable Length
    130
    
    EMC Compatibility and Motor Cable Length
    132
- Control Connection Data
  133
- Brake Resistor Connection Data
  134
- Energy Efficiency Data (Ecodesign)
  134
- Protection Classes
  135
- Ambient Conditions
  135
- Storage Conditions
  137
- Color
  137
- Materials
  137
  - Drive
    137
  - Drive Package
    137
  - Package Materials for Options, Accessories and Spare Parts
    137
  - Materials of Manuals
    137
- Disposal
  138
- Applicable Standards
  138
- Markings
  139
- EMC Compliance (IEC/EN 61800-3:2004 + A1:2012)
  140
  - Definitions
    140
  - Category C1
    141
  - Category C2
    141
  - Category C3
    142
  - Category C4
    142
- UL Checklist
  144
- Disclaimers
  145
  - Generic Disclaimer
    145
  - Cyber Security Disclaimer
    145
10 Dimension Drawings

147
- Contents of this Chapter
  147
- Frame R0
  148
- Frame R1
  149
- Frame R2
  150
- Frame R3
  151
- Frame R4
  152
11 Resistor Braking

153
- Contents of this Chapter
  153
- Safety
  153
- Operation Principle
  153
- Selecting the Brake Resistor
  153
  - Reference Brake Resistors
    155
    
    Definitions
    156
- Selecting and Routing the Brake Resistor Cables
  156
  - Minimizing Electromagnetic Interference
    156
  - Maximum Cable Length
    156
- Selecting the Installation Location for the Brake Resistors
  156
- Protecting the System in Brake Circuit Fault Situations
  157
  - Protecting the System in Cable and Brake Resistor Short-Circuit Situations
    157
  - Protecting the System against Thermal Overload
    157
- Mechanical and Electrical Installation of Brake Resistor
  158
  - Mechanical Installation
    158
  - Electrical Installation
    159
    
    Measuring the Insulation
    159
    
    Connecting Power Cables
    159
    
    Connection the Control Cables
    159
- Start-Up
  159
12 The Safe Torque off Function

161
- Contents of this Chapter
  161
- Description
  161
  - Compliance with the European Machinery Directive and the UK Supply of Machinery (Safety) Regulations
    162
- Wiring
  163
- Operation Principle
  169
- Start-Up Including Validation Test
  170
  - Competence
    170
  - Validation Test Reports
    170
  - Validation Test Procedure
    170
- Use
  172
- Maintenance
  174
  - Competence
    174
- Fault Tracing
  175
- Safety Data
  176
  - Terms and Abbreviations
    178
  - TÜV Certificate
    179
  - Declarations of Conformity
    180
13 Accessories

185
- Contents of this Chapter
  185
- Warnings
  185
- BDRK-01 DIN Rail Mounting Kit
  186
  - Dimensions
    186
  - Installation
    187
- BDRK-02 DIN Rail Mounting Kit
  188
  - Dimensions
    188
  - Installation
    189
- BMBC-01 Mounting Bracket for CCA-01 Adapter
  190
Further Information

191

ABB ACS180 Hardware Manual (168 pages)

Brand: ABB | Category: DC Drives | Size: 11.22 MB

Table of Contents
5
Safety Instructions
13
Contents of this Chapter
13
Use of Warnings and Notes
13
General Safety in Installation, Start-Up and Maintenance
14
Electrical Safety in Installation, Start-Up and Maintenance
16
Electrical Safety Precautions
16
Additional Instructions and Notes
17
Printed Circuit Boards
17
Grounding
18
General Safety in Operation
19
Additional Instructions for Permanent Magnet Motor Drives
19
Safety in Installation, Start-Up, Maintenance
19
Safety in Operation
20
Introduction to the Manual
21
Contents of this Chapter
21
Applicability
21
Target Audience
21
Purpose of the Manual
21
Categorization by Frame Size
21
Quick Installation and Commissioning Flowchart
21
Terms and Abbreviations
23
Related Manuals
24
Manuals on Internet
24
Operation Principle and Hardware Description
25
Contents of this Chapter
25
Operation Principle
26
Simplified Main Circuit Diagram
26
Product Variants
26
Layout
27
Frame Sizes R0
27
Frame Sizes R2
28
Control Connections
29
Standard Variant (ACS180-04S
29
Base Variant (ACS180-04N
30
Control Panel Options
31
Drive Labels
31
Model Information Label
31
Type Designation Label
32
Type Designation Key
32
Control Panel
33
Home View
34
Status Icon
34
Message View
35
Options View
35
Menu
35
Mechanical Installation
37
Contents of this Chapter
37
Installation Alternatives
37
Examining the Installation Site
38
Required Tools
38
Unpacking the Delivery
38
Installing the Drive
40
To Install the Drive with Screws
40
To Install the Drive to a DIN Installation Rail for Frame Sizes R3 and R4
42
Guidelines for Planning the Electrical Installation
43
Contents of this Chapter
43
Limitation of Liability
43
Selecting the Main Supply Disconnecting Device
43
European Union and United Kingdom
44
North America
44
Other Regions
44
Selecting the Main Contactor
44
Checking the Compatibility of the Motor and Drive
44
Selecting the Power Cables
45
General Guidelines
45
Typical Power Cable Sizes
45
Power Cable Types
45
Preferred Power Cable Types
45
Alternate Power Cable Types
46
Not Allowed Power Cable Types
47
Additional Guidelines, North America
47
Metal Conduit
48
Power Cable Shield
48
Selecting the Control Cables
49
Shielding
49
Signals in Separate Cables
49
Signals that Can be Run in the same Cable
50
Relay Cable
50
Control Panel to Drive Cable
50
PC Tool Cable
50
Routing the Cables
50
General Guidelines - IEC
50
General Guidelines - North America
51
Continuous Motor Cable Shield/Conduit or Enclosure for Equipment on the Motor Cable
52
Separate Control Cable Ducts
53
Implementing Short-Circuit and Thermal Overload Protection
53
Protecting the Drive and Input Power Cable in Short-Circuits
53
Protecting the Motor and Motor Cable in Short-Circuits
53
Protecting the Drive, and the Input Power and Motor Cables against Thermal Overload
54
Protecting the Motor against Thermal Overload
54
Protecting the Motor against Overload Without Thermal Model or Temperature Sensors
54
Implementing Motor Temperature Sensor Connection
55
Protecting the Drive against Ground Faults
55
Residual Current Device Compatibility
55
Implementing the Emergency Stop Function
56
Implementing the Safe Torque off Function
56
Using a Safety Switch between the Drive and the Motor
56
Implementing the Control of a Contactor between Drive and Motor
56
Protecting the Contacts of Relay Outputs
57
Electrical Installation
59
Contents of this Chapter
59
Warnings
59
Required Tools
59
Measuring the Insulation
60
Measuring the Insulation Resistance of the Drive
60
Measuring the Insulation Resistance of the Input Power Cable
60
Measuring the Insulation Resistance of the Motor and Motor Cable
60
Earthing System Compatibility Check
61
EMC Filter
61
When to Disconnect the EMC Filter
61
Disconnecting the EMC Filter
62
Guidelines for Installing the Drive to a TT System
63
Identifying the Grounding System of the Electrical Power Network
63
Connecting the Power Cables
65
Connection Diagram
65
Connection Procedure
66
Connecting the Control Cables
68
Default I/O Connection Diagram (ABB Standard Macro)
69
Control Cable Connection Procedure
70
Additional Information on the Control Connections
72
Connecting EIA-485 Fieldbus Cable to the Drive
72
PNP Configuration for Digital Inputs
73
NPN Configuration for Digital Inputs
73
Connection Examples of Two-Wire and Three-Wire Sensors
74
Safe Torque off
74
Communication Mode Jumper J2
74
Connecting a PC
75
Installation Checklist
77
Contents of this Chapter
77
Checklist
77
Maintenance
79
Contents of this Chapter
79
Maintenance Intervals
79
Description of Symbols
79
Recommended Maintenance Intervals after Start-Up
80
Cleaning the Heatsink
80
Replacing the Cooling Fans
81
To Replace the Cooling Fan for Frame Size R1
81
To Replace the Cooling Fan for Frame Size R2
83
To Replace the Cooling Fan for Frame Size R3
85
To Replace the Cooling Fan for Frame Size R4
88
Capacitors
89
Reforming the Capacitors
89
Technical Data
91
Contents of this Chapter
91
Ratings
91
IEC Ratings
91
UL (NEC) Ratings
92
Definitions
94
Sizing
94
Output Derating
94
Surrounding Air Temperature Derating
97
Altitude Derating
99
Switching Frequency Derating
99
Fuses
101
Gg Fuses (IEC)
101
Gr or Ar -Type Fuses (IEC)
102
UL Fuses (UL(NEC))
103
Alternate Short-Circuit Protection
104
Miniature Circuit Breakers (IEC)
104
Manual Self-Protected Combination Motor Controller - Type E USA (UL (NEC))
106
Dimensions and Weights
108
Free Space Requirements
109
Losses, Cooling Data and Noise
109
Terminal Data for the Power Cables
110
Typical Power Cable Sizes
113
Terminal Data for the Control Cables
114
External EMC Filters
114
Electrical Power Network Specification
115
Motor Connection Data
116
Motor Cable Length
116
Operational Functionality and Motor Cable Length
116
EMC Compatibility and Motor Cable Length
118
Control Connection Data
119
Brake Resistor Connection Data
120
Energy Efficiency Data (Ecodesign)
120
Degrees of Protection
120
Ambient Conditions
120
Materials
122
Disposal
122
Applicable Standards
122
Markings
123
Compliance with en 61800-3
124
Definitions
124
Category C1
124
Category C2
125
Category C3
125
Category C4
125
UL Checklist
127
Compliance with the European Machinery Directive
128
Disclaimers
128
Generic Disclaimer
128
Cybersecurity Disclaimer
128
Dimension Drawings
129
Contents of this Chapter
129
Frame R0
130
Frame R1
131
Frame R2
132
Frame R3
133
Frame R4
134
Resistor Braking
135
Contents of this Chapter
135
Safety
135
Operation Principle
135
Selecting the Brake Resistor
135
Reference Brake Resistors
137
Definitions
137
Selecting and Routing the Brake Resistor Cables
138
Minimizing Electromagnetic Interference
138
Maximum Cable Length
138
Placing the Brake Resistors
138
Protecting the System in Brake Circuit Fault Situations
139
Protecting the System in Cable and Brake Resistor Short-Circuit Situations
139
Protecting the System against Thermal Overload
139
Mechanical and Electrical Installation of Brake Resistor
140
Mechanical Installation
140
Electrical Installation
141
Measuring the Insulation
141
Connecting Power Cables
141
Connection the Control Cables
141
Start-Up
141
The Safe Torque off Function
143
Contents of this Chapter
143
Description
143
Compliance with the European Machinery Directive and the UK Supply of Machinery (Safety) Regulations
144
Wiring
145
Connection Principle
145
Single ACS180 Drive, Internal Power Supply
145
Single ACS180 Drive, External Power Supply
146
Wiring Examples
147
Single ACS180 Drive, Internal Power Supply
147
Single ACS180 Drive, External Power Supply
147
Multiple ACS180 Drives, Internal Power Supply
148
Multiple ACS180 Drives, External Power Supply
149
Activation Switch
149
Cable Types and Lengths
150
Grounding of Protective Shields
150
Operation Principle
151
Start-Up Including Validation Test
152
Competence
152
Validation Test Reports
152
Validation Test Procedure
152
Use
154
Maintenance
156
Competence
156
Fault Tracing
157
Safety Data
158
Terms and Abbreviations
160
TÜV Certificate
161
Declarations of Conformity
162

ABB ACS180 Quick Installation And Start-Up Manual (2 pages)

Brand: ABB | Category: DC Drives | Size: 3.58 MB

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ABB ACS180 Manuals

ABB ACS180 Firmware Manual (392 pages)

Table of Contents

ABB ACS180 Hardware Manual (192 pages)

Table of Contents

1 Safety Instructions

2 Introduction to the Manual

3 Operation Principle and Hardware Description

4 Mechanical Installation

5 Guidelines for Planning the Electrical Installation

6 Electrical Installation

7 Installation Checklist

8 Maintenance

9 Technical Data

10 Dimension Drawings

11 Resistor Braking

12 The Safe Torque off Function

13 Accessories

Further Information

ABB ACS180 Hardware Manual (168 pages)

Table of Contents

ABB ACS180 Quick Installation And Start-Up Manual (2 pages)

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