ABB ACS180 Quick Installation And Start-up Manual

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Safety instructionsWARNING! Obey these instructions. If you ignore them, injury or death, or damageto the equipment can occur. If you are not a qualified electrical professional, donot do electrical installation or maintenance work.• Do not do work on the drive, motor cable, motor, or control cables when the drive isconnected to the input power. Before you start the work, isolate the drive from alldangerous voltage sources and make sure that it is safe to start the work. Always wait for5 minutes after disconnecting the input power to let the intermediate circuit capacitorsdischarge.• 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 outputterminals.1. Unpack the deliveryKeep the drive in its package until you are ready to install it. After unpacking, protect the drivefrom 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 capacitorsIf the drive has not been powered up for a year or more, you must reform the DC linkcapacitors. The manufacturing date is on the type designation label. Refer toCapacitorreforming 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 EMCperformance. Symmetrical shielded cable also reduces bearing currents, wear, andstress on motor insulation.• Power cable types: In IEC installations, use copper or aluminum cables (ifpermitted). 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 ULinstallations, select a cable rated for at least 75 °C (167 °F).• Size: Refer toFuses and typical power cable sizes for the typical cable sizes and toTerminal data for the power cables for the maximum cable sizes.• Select the control cables. Use double-shielded twisted-pair cable for analog signals. Usedouble-shielded or single-shielded cable for the digital, relay and I/O signals. Do not run24 V and 115/230 V signals in the same cable.• Protect the drive and input power cable with the correct fuses. Refer toFuses and typicalpower cable sizes.4. Examine the installation areaThe drive is intended for cabinet installation and has a degree of protection of IP20 / UL opentype 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.For the minimum free space requirements, refer toFree space requirements.• The ambient conditions meet the requirements. Refer toAmbient conditions.• The installation surface is as close to vertical as possible and strong enough to supportthe weight of the drive. Refer toDimensions and weights.• 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-coreconductors or contactor coils near the drive. A strong magnetic field can causeinterference or inaccuracy in the operation of the drive.5. Install the driveYou 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 fullyhorizontal orientation.• Do not install the drive upside down.• You can install several drives side by side. To install the drive with screws1. Make marks onto the surface for themounting holes. Refer toDimensions andweights.Download the mounting templateonlibrary.abb.com.2. Drill the holes for the mounting screws. Ifnecessary, install suitable plugs or anchorsinto the holes.3. Install the mounting screws into the holes.Leave a gap between the screw head andinstallation 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 R41. 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 resistanceDrive: Do not do voltage tolerance or insulation resistance tests on the drive, because this cancause damage to the drive.Input power cable: Before you connect the input power cable, measure the insulation of theinput 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 thedrive output terminals T1/U, T2/V and T3/W.2. Use a voltage of 1000 V DC to measure theinsulation resistance between each phaseconductor and the protective earth conductor. Theinsulation resistance of an ABB motor must bemore than 100 Mohm (at 25 °C [77 °F]). For theinsulation resistance of other motors, refer to themanufacturer’s documentation.Moisture in the motor decreases the insulationresistance. If you think that there is moisture in themotor, dry the motor and do the measurementagain.7. Make sure that the drive is compatible with thegrounding systemYou can connect all drive types to a symmetrically grounded TN-S system (center-groundedwye). 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 metalEMC screw (disconnect the internal EMC filter) or metal VAR screw (disconnect the varistorcircuit).8. Connect the power cables Connection diagram (shielded cables)1. Disconnecting device.2. Two protective earth (ground) conductors. Drive safety standard IEC/EN61800-5-1requires two PE conductors, if the cross-sectional area of the PE conductor is less than10 mm 2 Cu or 16 mm 2 Al. For example, you can use the cable shield in addition to thefourth 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 forthe PE conductor.4. Use a separate grounding cable for the motor side, if the conductivity of the shield is notsufficient, 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 brakeresistor cable (if used). It is also recommended for the input power cable.6. Brake resistor and resistor cable (optional, for frame R2...R4 only). Connection procedure (shielded cables)For the tightening torques, refer toTerminal data for the power cables.1. Attach the residual voltage warningsticker in the local language to thedrive.2. Strip the motor cable.3. Ground the motor cable shield underthe grounding clamp.4. Twist the motor cable shield into abundle, mark it and connect it to thegrounding terminal.5. Connect the phase conductors of themotor cable to terminals T1/U, T2/Vand T3/W.6. If you use a brake resistor, connect thebrake resistor cable to terminals R- andUDC+. Use a shielded cable and groundthe shield under the grounding clamp.7. Make sure that the R- and UDC+terminal screws are tightened. Do thisstep also if you do not connect cables tothe terminals.8. Strip the input power cable.9. If the input power cable has a shield,ground the shield under the groundingclamp. Then twist the shield into abundle, mark it and connect it to thegrounding terminal.10. Connect the PE conductor of the inputpower cable to the grounding terminal.If necessary, use a second PEconductor.11. In 3-phase drives, connect the phaseconductors of the input power cable toterminals L1, L2 and L3. In 1-phasedrives, connect the phase and neutralconductors to terminals L and N.12. Mechanically attach the cables on theoutside of the drive.9. Connect the control cables Connection procedureDo the connections according to the defaultcontrol connections of the application macrothat you select. Keep the signal wire pairstwisted as near to the terminals as possibleto prevent inductive coupling.1. Strip a part of the outer shield of thecontrol cable for grounding.2. Use a 360-degree grounding clamp toconnect the outer shield to thegrounding tab.3. Strip the control cable conductors.4. Connect the conductors to the correct control terminals. Insert the conductor into apush-in terminal. To release, pull the conductor with pushing the open/close button allthe 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 standardmacro is shown below.Note: You can select other macros with the control panel. For default IO assignment, see below: Embedded fieldbus connectionConnect 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.1) The devices at the ends of the fieldbus must have termination set to ON. All other devicesmust 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 automationcontroller.10. Start up the driveWARNING! Before you start up the drive, make sure that the installation iscompleted. Make sure also that it is safe to start the motor. Disconnect the motorfrom other machinery, if there is a risk of damage or injury.For information on the user interface, refer to theACS180 User interface guide(3AXD50000606696 [English]).1. Power up the drive.2. Select the units (international or US). In theMotor dataview, set the motor type: AsynM: Asynchronous motorPMSM: Permanent magnet synchronous motor3. Set the motor control mode:Vector: Speed reference. This is suitable for most cases.The drive does an automatic standstill ID run when thedrive is started for the first time.Scalar: Frequency reference. Do not use this mode forpermanent magnet synchronous motors.Use this mode when:• The number of motors can change.• The nominal motor current is less than 20% of thenominal drive current.4. Set the nominal motor values.5. Start the motor and check the direction of rotation. If thedirection 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 automaticstandstill ID run at the first start.6. In theMotor control view, set the start and stop mode.7. Set the acceleration and deceleration times.8. Set the maximum and minimum speeds.9. In theControl macros view, select the applicable macro.10. Tune the drive parameters to the application. You can alsouse the Assistant control panel (ACS-AP-...) or the DriveComposer PC tool.—ABB MACHINERY DRIVESACS180 drivesQuick installation and start-up guideR0 R1M2M1M1 M1M2R2...R4M2ScrewlabelFactory defaultscrew materialGrounding systemsSymmetricallygrounded TN-Ssystems (center-grounded wye)Corner-groundeddelta, midpoint-grounded deltaand TT systemsIT systems(ungrounded orhigh-resistancegrounded)EMC Metal Do not remove Remove RemovePlastic 1)1) Drives sold in North America have a plastic EMC screw.Do not remove 2)2) Can install the metal screw (included in the drive delivery) to connect the internal EMC filter.Do not remove Do not removeVAR Metal Do not remove Do not remove RemovePlastic Do not remove Do not remove Do not removeU1V1W1PEM3~ohmU1-PE, V1-PE, W1-PEPEPEL1 L2 L3 R- R+UDC+ UDC-U1 W1M PE3T1/UT2/VT3/WV1L1 L2 L3(L) (N)2345ACS18016R2...R4Bottom InR0/R1Top InTerminals DescriptionsDigital I/O21 24 V Aux. +24 V DC, max 200 mA22 DGND Aux. voltage output common8 DI1 Stop (0) / Start (1)9 DI2 Forward (0) / Reverse (1)10 DI3 Constant speed selection 111 DI4 Constant speed selection 212 DCOM Digital input common18 DO Running19 DO COM Digital output common20 DO SRC Digital output auxiliary voltageAnalog I/O14 AI1/DI5 Speed reference (0…10V)13 AGND Analog input circuit common15 AI2 Not used16 AGND Analog output circuit common17 AO Output frequency (0...20mA)23 10V Ref. voltage +10 V DC24 SCREEN Signal cable shield (screen)Safe torque off (STO) (only on ACS180-04S)1 S+ Safe torque off (STO). Both circuitsmust be closed for the drive to start.The drawing shows the simplifiedconnection of a safety circuit throughsafety contacts. If STO is not used,leave the factory-installed jumpers inplace. See also sectionSafe torqueoff (STO).2 SGND3 S14 S2Relay output5 NCNo fault [Fault (-1)]6 COM7 NOEIA-485 Modbus RTU25 B+Embedded Modbus RTU (EIA-485)26 A-27 AGND28 SHIELDJumperJ1 Termination Modbus Termination ON-OFFJ2 Comm.Mode Communication Mode SelectionHand/Auto Alternate Motor potentionmeterDI1 Start/Stop (Hand) Start forward Start/StopDI2 Hand(1)/Auto(0) Start reverse Forward/ReverseDI3 Start/Stop (Auto) Const speed selection 1 Speed ref. upDI4 Fault reset Const speed selection 2 Speed ref. downAI1/DI5 Speedref.(Hand)(AI1,0...10V) Fault reset(DI5) Const speed selection1(DI5)AI2 Speed ref.(Auto)(4...20mA) Speed ref.(0...10V) not usedPID Hand/PIDDI1 Start/Stop Start/Stop(Hand)DI2 Internal setpoint sel 1 Hand(1)/PID(0)DI3 Internal setpoint sel 2 Start/Stop(PID)DI4 Constant speed selection 1 Constant speed selection 1AI1/DI5 PID set point(AI1, 0…10V) Hand mode speed ref.(AI1,0...10V)AI2 Process feedback(4...20mA) Process feedback(4...20mA)3-wire ModbusDI1 Start(pulse) Start/Stop(Hand)DI2 Stop(pulse) Forward/Reverse(Hand)DI3 Forward(0)/Reverse(1) Hand(1)/Modbus(0)DI4 Constant speed selection 1 Fault resetAI1/DI5 Constant speed selection 2 (DI5) Constant speed selection 1(DI5)AI2 Speed ref.(0...10V) Speed ref(Hand, 0...10V)All macrosDO RunningRO Fault(-1)AO Output frequency(0...20mA)1...10 kohmMax. 500 ohmG R - +B+A-AGNDShieldB+A-AGNDShieldB+A-AGNDShieldJ1J2J1J2J1J2Termination ON 1)Drive Drive DriveAutomationcontroller2)3)Termination OFFModbus modeTermination OFFModbus modeTermination ON 1)Modbus mode2 3456789

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