ABB ACS180-04S-03A7-1 Hardware Manual
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ABB ACS180-04S-03A7-1 Hardware Manual

ABB ACS180-04S-03A7-1 Hardware Manual

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ABB MACHINERY DRIVES
ACS180 drives
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Summary of Contents for ABB ACS180-04S-03A7-1

  • Page 1 — ABB MACHINERY DRIVES ACS180 drives Hardware manual...
  • Page 3 ACS180 drives Hardware manual Table of contents 1. Safety instructions 4. Mechanical installation 6. Electrical installation 3AXD50000467945 Rev D Original instructions EFFECTIVE: 2024-03-08...

  • Page 5: Table Of Contents

    Table of contents 5 Table of contents 1 Safety instructions Contents of this chapter ..................Use of warnings and notes ..................General safety in installation, start-up and maintenance ........ Electrical safety in installation, start-up and maintenance ......Electrical safety precautions ................Additional instructions and notes ..............
  • Page 6 6 Table of contents Type designation key ....................Control panel ......................Home view ......................Status icon ..................... Message view ..................... Options view ...................... Menu ........................4 Mechanical installation Contents of this chapter ..................Installation alternatives ..................Examining the installation site ................Required tools ......................
  • Page 7 Guidelines for installing the drive to a TT system ........Identifying the grounding system of the electrical power network ..Connecting the power cables ................Connection diagram ..................Connection procedure ..................Connecting the control cables ................Default I/O connection diagram (ABB standard macro) ......Control cable connection procedure .............
  • Page 8 8 Table of contents Additional information on the control connections ........Embedded EIA-485 fieldbus connection .......... PNP configuration for digital inputs ..........NPN configuration for digital inputs ..........Connection examples of two-wire and three-wire sensors ..Safe torque off ..................Communication mode jumper J2 ............
  • Page 9 Table of contents 9 UL (NEC) fuses ....................Alternate short-circuit protection ................. Miniature circuit breakers (IEC) ..............Miniature circuit breakers (UL) ..............Manual self-protected combination motor controller – Type E USA (UL (NEC)) ......................Dimensions and weights ..................Free space requirements ..................Losses, cooling data and noise ................
  • Page 10 10 Table of contents 10 Dimension drawings Contents of this chapter ..................Frame R0 ........................Frame R1 ........................Frame R2 ........................Frame R3 ........................Frame R4 ........................11 Resistor braking Contents of this chapter ..................Safety .......................... Operation principle ....................Selecting the brake resistor ...................
  • Page 11 Table of contents 11 Multiple ACS180 drives, internal power supply ....... Multiple ACS180 drives, external power supply ......Activation switch ....................Cable types and lengths .................. Grounding of protective shields ..............Operation principle ....................Start-up including validation test ................. Competence ....................... Validation test reports ..................

  • Page 13: Safety Instructions

    Safety instructions 13 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.

  • Page 14: General Safety In Installation, Start-Up And Maintenance

    14 Safety instructions 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. •...
  • Page 15 Safety instructions 15 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.

  • Page 16: Electrical Safety In Installation, Start-Up And Maintenance

    16 Safety instructions 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.

  • Page 17: Additional Instructions And Notes

    Safety instructions 17 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.

  • Page 18: Grounding

    18 Safety instructions ￭ 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.

  • Page 19: General Safety In Operation

    Safety instructions 19 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.

  • Page 20: Safety In Operation

    20 Safety instructions • 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: •...

  • Page 21: Introduction To The Manual

    Introduction to the manual 21 Introduction to the manual Contents of this chapter The chapter describes the applicability, target audience and purpose of the manual. The chapter contains a list of related manuals and a flowchart for installation and commissioning. Applicability This manual is applicable to ACS180 drives.

  • Page 22: Quick Installation And Commissioning Flowchart

    22 Introduction to the manual Quick installation and commissioning flowchart Task Identify the frame size: R0, R1, R2, R3 or R4. Type designation key (page 32) Plan the installation. Guidelines for planning the electrical installation (page 43) Check the ambient conditions, ratings and required cooling air flow.

  • Page 23: Terms And Abbreviations

    Safety integrity level (1…3) (IEC 61508, IEC 62061, IEC 61800-5-2) Safe torque off (IEC/EN 61800-5-2) Related manuals You can find manuals on the Internet. See below for the relevant code/link. For more documentation, go to www.abb.com/drives/documents. ACS180 manuals link list...

  • Page 25: Operation Principle And Hardware Description

    Operation principle and hardware description 25 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.

  • Page 26: Simplified Main Circuit Diagram

    26 Operation principle and hardware description ￭ Simplified main circuit diagram T1/U T2/V T3/W UDC+ UDC- Rectifier. Converts alternating current and voltage to direct current and voltage. DC link. DC circuit between rectifier and inverter. Inverter. Converts direct current and voltage to alternating current and voltage. Brake chopper.

  • Page 27: Layout

    Operation principle and hardware description 27 Layout ￭ Frame sizes R0...R1 Input power connection terminal EMC filter grounding screw Control panel, display and status LED PE connection (motor) Motor connection terminal Fixed control terminals Cooling fan Front cover Panel and PC tool port (RJ45) Model information label Type designation label 1) Drive types ACS180-04N-xxxx-x do not have this EMC screw.

  • Page 28: Frame Sizes R2

    28 Operation principle and hardware description ￭ Frame sizes R2...R4 Input power connection terminal EMC filter grounding screw Control panel, display and status LED PE connection (motor) Motor connection terminal Fixed control terminals Cooling fan Front cover Panel and PC tool port (RJ45) Model information label Type designation label Cold configuration connection for CCA-01...

  • Page 29: Control Connections

    Operation principle and hardware description 29 Control connections ￭ Standard variant (ACS180-04S-...) Connections: 1. Safe torque-off connections 2. Relay output connection 3. Modbus termination jumper 4. Communication mode jumper 5. Digital inputs and outputs 6. Analog inputs and outputs 7. EIA-485 Modbus RTU 8.

  • Page 30: Base Variant (Acs180-04N

    30 Operation principle and hardware description ￭ Base variant (ACS180-04N-...) Connections: 1. Relay output connection 2. Modbus termination 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.

  • Page 31: Control Panel Options

    Operation principle and hardware description 31 Control panel options The drive supports these control panels: • integrated control panel • ACS-AP-I assistant control panel • ACS-AP-S assistant control panel • ACS-AP-W assistant control panel with Bluetooth • ACS-BP-S basic control panel For information on the assistant control panels, refer to ACS-AP-I, -S, -W and ACH-AP-H, -W Assistant control panels user’s manual (3AUA0000085685...

  • Page 32: Type Designation Label

    32 Operation principle and hardware description ￭ Type designation label Code Description Drive type Frame size Nominal ratings Degree of protection Valid markings S/N: Serial number of format MYYWWRXXXX, where M: Manufacturer designation YY: Year of manufacture: 20, 21, 22, … for 2020, 2021, 2022, … WW: Week of manufacture: 01, 02, 03, …...

  • Page 33: Control Panel

    Control panel Operation principle and hardware description 33 Code Description EMC&STO. Contents N=Basic variant (without STO; C4 EMC level); S=Standard variant (integrated STO; C2(1~230V), C3(3~400V) or C4(3~230V) EMC • Control panel level). • Home view and Message view 02A6 Size. See the ratings table in the technical data. •...

  • Page 34: Home View

    34 Operation principle and hardware description Arrow keys (menu navigation and setting values) Stop key (when the drive is locally controlled) Start key (when the drive is locally controlled) Status LED: • Steady green: Normal operation • Blinking green: Active warning •...

  • Page 35: Message View

    Operation principle and hardware description 35 Icon Animation Description None Stopped, start inhibited Blinks Stopped, start commanded but inhibited Rotates Running at reference Rotates Running but not at reference Blinks Running at reference, but reference = 0 Blinks Drive fault None Local reference setting enabled ￭...
  • Page 36 36 Operation principle and hardware description • Motor control view : Set the motor control settings. • Control macros view : Select the connection 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 Firmware manual (3AXD50000467860...

  • Page 37: Mechanical Installation

    Mechanical installation 37 Mechanical installation Contents of this chapter This chapter tells how to examine the installation site, unpack and examine the delivery and install the drive mechanically. Installation alternatives You can install the drive: • with screws on to an assembly plate •...

  • Page 38: Examining The Installation Site

    38 Mechanical installation • Do not install the drive upside down. • Make sure that the hot exhaust air from a drive does not flow into the cooling inlet of other drives or equipment. Examining the installation site Examine the installation site. Make sure that: •...

  • Page 39: Unpacking The Delivery

    Mechanical installation 39 Unpacking the delivery The figure shows the drive package with its contents. Make sure that all of the items are present and that there are no signs of damage. Package contents: drive 2. installation accessories (cable clamps, metal grounding plate, screws, etc.) 3.

  • Page 40: Installing The Drive

    40 Mechanical installation Installing the drive ￭ To install the drive with screws Make marks onto the surface for the mounting holes. See the diagram below Dimensions and weights (page 121). 2. Drill the holes for the mounting screws. R2-R4 Frame size Mounting screws Metric...

  • Page 41: To Install The Drive To A Din Installation Rail For Frame Sizes R0 To R2

    Mechanical installation 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).

  • Page 42: To Install The Drive To A Din Installation Rail For Frame Sizes R3 And R4

    42 Mechanical installation ￭ To install the drive to a DIN installation rail for frame sizes R3 and R4 Use an IEC/EN 60715 top hat type installation rail, width × height = 35 × 7.5 mm (1.4 × 0.3 in). Move the locking part to the left.

  • Page 43: Guidelines For Planning The Electrical Installation

    ABB does not assume any liability whatsoever for any installation which breaches the local laws and/or other regulations. Furthermore, if the recommendations given by ABB are not followed, the drive may experience problems that the warranty does not cover.

  • Page 44: Selecting The Main Contactor

    44 Guidelines for planning the electrical installation To comply with European Union directives and United Kingdom regulations related to standard EN 60204-1, the disconnecting device must be one of these types: • switch-disconnector of utilization category AC-23B (IEC 60947-3) • disconnector that has an auxiliary contact that in all cases causes switching devices to break the load circuit before the opening of the main contacts of the disconnector (EN 60947-3)

  • Page 45: Selecting The Power Cables

    Guidelines for planning the electrical installation 45 Selecting the power cables ￭ General guidelines Select the input power and motor cables according to local regulations. • Current: Select a cable capable of carrying the maximum load current and suitable for the prospective short-circuit current provided by the supply network.

  • Page 46: Power Cable Types

    46 Guidelines for planning the electrical installation ￭ Power cable types Preferred power cable types This section shows the preferred cable types. Make sure that the selected cable type also complies with local/state/country electrical codes. Cable type Use as input power cabling Use as motor cabling and as brake resistor cabling Symmetrical shielded (or ar-...

  • Page 47: Alternate Power Cable Types

    Guidelines for planning the electrical installation 47 Alternate power cable types Cable type Use as input power cabling Use as motor cabling and as brake resistor cabling Yes with phase conductor Yes with phase conductor smaller than 10 mm 2 (8 AWG) smaller than 10 mm 2 (8 AWG) Cu, or motors up to 30 kW (40 hp).

  • Page 48: Not Allowed Power Cable Types

    ￭ Additional guidelines – North America ABB recommends the use of metallic conduit for power wiring. ABB also recommends the use of symmetrical shielded VFD cable between drive and motor(s). This table shows examples of methods for wiring the drive. Refer to NFPA 70 (NEC) along with state and local codes for the appropriate methods for your application.

  • Page 49: Metal Conduit

    Guidelines for planning the electrical installation 49 Wiring method Notes Free air Prefer symmetrical shielded VFD cable. Enclosures, air handlers, etc. Allowed internally in enclosures when in ac- cordance with UL. 1) Metallic conduit may be used as an additional ground path, provided this path is a solid path capable of handling ground currents.

  • Page 50: Grounding Requirements

    50 Guidelines for planning the electrical installation Insulation jacket Helix of copper tape or copper wire Copper wire shield Inner insulation Cable core Grounding requirements This section gives general requirements for grounding the drive. When you plan the grounding of the drive, obey all the applicable national and local regulations. The conductivity of the protective earth conductor(s) must be sufficient.

  • Page 51: Additional Grounding Requirements - Iec

    Guidelines for planning the electrical installation 51 earth conductor must be determined in a manner which produces a conductance equivalent to that which results from the application of this table. Cross-sectional area of the phase conduct- Minimum cross-sectional area of the corres- ponding protective earth conductor S (mm 2 ) S p (mm 2 )

  • Page 52: Additional Grounding Requirements - Ul (Nec)

    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 one individually shielded pair for each signal. Do not use common return for different analog signals.

  • Page 53: Relay Cable

    ￭ Relay cable The cable type with braided metallic shield (for example ÖLFLEX by LAPPKABEL, Germany) has been tested and approved by ABB. ￭ Control panel to drive cable Use EIA-485, Cat 5e (or better) cable with male RJ-45 connectors. The maximum length of the cable is 100 m (328 ft).

  • Page 54: General Guidelines - North America

    54 Guidelines for planning the electrical installation min. 300 mm (12 in) min. 300 mm (12 in) min. 500 mm (20 in) 90° min. 200 mm (8 in) min. 500 mm (20 in) Motor cable Input power cable Control cable Brake resistor or chopper cable (if any) ￭...

  • Page 55: Continuous Motor Cable Shield/Conduit And Metal Enclosure For Equipment On The Motor Cable

    Guidelines for planning the electrical installation 55 Input power cabling Motor cabling Conduit ￭ Continuous motor cable shield/conduit and metal enclosure for equipment on the motor cable To minimize the emission level when safety switches, contactors, connection boxes or similar equipment are installed on the motor cable between the drive and the motor: •...

  • Page 56: Separate Control Cable Ducts

    56 Guidelines for planning the electrical installation ￭ Separate control cable ducts Put 24 V DC and 230 V AC (120 V AC) control cables in separate ducts, unless the 24 V DC cable is insulated for 230 V AC (120 V AC) or insulated with an insulation sleeving for 230 V AC (120 V AC).

  • Page 57: Protecting The Drive, And The Input Power And Motor Cables Against Thermal Overload

    Guidelines for planning the electrical installation 57 ￭ Protecting the drive, and the input power and motor cables against thermal overload If the cables have the correct size for the nominal current, the drive protects itself and the input and motor cables against thermal overload. No additional thermal protection devices are needed.

  • Page 58: Implementing A Motor Temperature Sensor Connection

    58 Guidelines for planning the electrical installation Implementing a motor temperature sensor connection WARNING! IEC 61800-5-1 requires double or reinforced insulation between live parts and accessible parts when: • the accessible parts are not conductive, or • the accessible parts are conductive, but not connected to the protective earth.

  • Page 59: Implementing The Safe Torque Off Function

    161). Using a safety switch between the drive and the motor ABB recommends to install a safety switch between the permanent magnet motor and the drive output. The switch is needed to isolate the motor from the drive during maintenance work on the drive.
  • Page 60 60 Guidelines for planning the electrical installation inductively to other conductors in the control cable and form a risk of malfunction in other 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.

  • Page 61: Electrical Installation

    Electrical installation 61 Electrical installation Contents of this chapter This chapter describes how to: • measure the insulation • do the grounding system compatibility check • change the EMC filter connection • connect the power and control cables • install optional modules •...

  • Page 62: Measuring The Insulation Resistance

    Use a measuring voltage of 1000 V DC. The insulation resistance of an ABB motor must be more than 100 Mohm (reference value at 25 °C [77 °F]). For the insulation resistance of other motors, refer to the manufacturer’s instructions.

  • Page 63: Measuring The Insulation Resistance Of The Brake Resistor Circuit

    Electrical installation 63 ￭ Measuring the insulation resistance of the brake resistor circuit 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 electrical professional, do not do installation, commissioning or maintenance work.

  • Page 64: Compatibility Of Emc Filter With The Grounding System

    64 Electrical installation WARNING! Do not install a drive with the internal EMC filter connected 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 can cause danger or damage to the drive.
  • Page 65 Electrical installation 65 the product variant. Before you connect the drive to the input power, examine the screws and do the necessary actions shown in the table. Screw Screw material When to remove EMC screw or VAR screw label Symmetrically Corner-grounded IT systems (un- grounded TN-S sys-...

  • Page 66: Disconnecting The Emc Filter

    Note: • ABB does not guarantee the EMC performance, because the internal EMC filter is disconnected. • ABB does not guarantee the functioning of the ground leakage detector built inside the drive.

  • Page 67: Identifying The Grounding System Of The Electrical Power Network

    Electrical installation 67 ￭ Identifying the grounding system of the electrical power network WARNING! Only a qualified electrical professional may do the work instructed in this section. Depending on the installation site, the work may even be categorized as live working. Continue only if you are an electrical professional certified for the work.

  • Page 68: Connecting The Power Cables

    PE conductor. Motor cable Note: ABB recommends to use a symmetrical shielded cable (VFD cable) as the motor cable. Separate PE cable (motor side). Use a separate grounding cable for the motor side, if the conductivity of the shield is not sufficient, or if there is no symmetrically constructed PE conductor in the cable.

  • Page 69: Connection Procedure

    Electrical installation 69 ￭ Connection procedure 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 electrical professional, do not do installation, commissioning or maintenance work.
  • Page 70 70 Electrical installation M4x10, 2x 3. Strip the motor cable. 4. Ground the motor cable shield under the grounding clamp. 5. Twist the motor cable shield into a bundle, mark it with yellow-green and connect it to the grounding terminal. 6.

  • Page 71: Connecting The Control Cables

    Connecting the control cables Before you connect the control cables, make sure that all option modules are installed. Refer to Default I/O connection diagram (ABB standard macro) for the I/O connections of the ABB standard macro. For other macros, refer to ACS180 Firmware manual (3AXD50000467860 [English]).

  • Page 72: Default I/O Connection Diagram (Abb Standard Macro)

    72 Electrical installation ￭ Default I/O connection diagram (ABB standard macro) Connection Description Term. Digital I/O and relay output connections 24 V Aux. +24 V DC, max. 100 mA DGND Aux. voltage output common DGND Stop (0) / Start (1)

  • Page 73: Control Cable Connection Procedure

    Electrical installation 73 Connection Description Term. EIA-485 Modbus RTU Embedded Modbus RTU (EIA-485) AGND AGND SHIELD SHIELD Jumper Termination Modbus termination selection Termination Comm.Mode Communication mode selection Comm.Mode 1) Terminal size: 0.5 mm² … 1 mm² 2) Some types only, refer to Communication mode jumper J2 (page 78).
  • Page 74 74 Electrical installation 3. Insert the grounding clamp into the slot and fasten it with screw. M3x10, 1x R0/R1 M4x20, 2x R3: M3x12, 2x R4: M4x8, 2x R3/R4 4. Strip a part of the outer shield of the control cable for 360-degree grounding. 5.

  • Page 75: Additional Information On The Control Connections

    Electrical installation 75 6. Strip the ends of the control cable conductors. For stranded (multi-wire) conductors, install ferrules at the bare conductor ends. 7. Connect the conductors to the correct control terminals. 8. Mechanically attach the control cables on the outside of the drive. ￭...
  • Page 76 76 Electrical installation Connection examples are shown below. With signal ground reference terminal Without signal ground reference terminal 100 ohm Automation controller. Termination ON Drive. J1: Termination OFF; J2: Modbus mode Drive. J1: Termination OFF; J2: Modbus mode Drive at the end of the communication line. J1: Termination ON ;...

  • Page 77: Pnp Configuration For Digital Inputs

    Electrical installation 77 PNP configuration for digital inputs Internal and external +24 V power supply connections for PNP (source) configuration are shown in the figures below. Internal +24 V power supply External +24 V power supply +24 V +24 V 0 V DC DGND DGND...

  • Page 78: Connection Examples Of Two-Wire And Three-Wire Sensors

    78 Electrical installation Connection examples of two-wire and three-wire sensors The figures give examples of connections for a two-wire or three-wire sensor/transmitter that is supplied by the auxiliary voltage output of the drive. 4…20 mA AGND +24V DGND Process actual value measurement or reference, 4 … 20 mA, R in = 205 ohm. Note: The sensor power supply comes through its current output circuit, use AGND 4 …...

  • Page 79: Connecting A Pc

    Electrical installation 79 Drive. No J2. Drive. J2 exists. If your drive has jumper J2, follow the instructions below. When you need to connect a PC or an assistant control panel to the drive, set: • Jumper J2 on the front of the drive = Panel (default) •...
  • Page 80 80 Electrical installation • Use a USB to RJ45 converter. You can order it from ABB (BCBL-01, 3AXD50000032449). Connect the cable to the Panel and PC tool port (RJ45). For information on the Drive Composer PC tool, refer to Drive Composer PC tool user's manual (3AUA0000094606 [English]).

  • Page 81: Installation Checklist

    Installation checklist 81 Installation checklist Contents of this chapter This chapter contains a checklist for the mechanical and electrical installation of the drive. Checklist Examine the mechanical and electrical installation of the drive before start-up. Go through the checklist together with another person. WARNING! Obey the safety instructions of the drive.
  • Page 82 82 Installation checklist Make sure that … The insulation resistance of the input power cable, motor cable and motor is meas- ured according to local regulations and the manuals of the drive. The drive is attached securely on an even, vertical and non-flammable wall. The cooling air can flow freely in and out of the drive.
  • Page 83 Installation checklist 83 Make sure that … The motor and the driven equipment are ready for power-up.

  • Page 85: Maintenance

    Contents of this chapter The chapter contains the preventive maintenance instructions. Maintenance intervals The tables below show the maintenance tasks which can be 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).

  • Page 86: Recommended Maintenance Intervals After Start-Up

    • Maintenance and component replacement intervals are based on the assumption that the equipment is operated within the specified ratings and ambient conditions. ABB recommends annual drive inspections to ensure the highest reliability and optimum performance. • Long term operation near the specified maximum ratings or ambient conditions may require shorter maintenance intervals for certain components.

  • Page 87: Functional Safety Components

    The remaining mission time of 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 from the cooling air. The drive runs into overtemperature warnings and faults if the heatsink is not clean.

  • Page 88: Replacing The Cooling Fans

    Parameter 05.04 Fan on-time counter shows the running time of the cooling fan. After you replace the fan, reset the fan counter. Refer to the firmware manual. You can get replacement fans from ABB. Use only ABB specified spare parts. ￭...

  • Page 89: To Replace The Cooling Fan For Frame Size R2

    Maintenance 89 of the drive. As shown in the following figure, the side with the fan power cable is aligned to the double bars sign on the fan cover. 7. Connect the fan power cable. 8. Carefully put the fan cover into position in the drive. Make sure that the fan power cable is routed correctly.
  • Page 90 90 Maintenance Stop the drive and do the steps in section Electrical safety precautions (page 16) before you start the work. 2. Press the two clips by fingers to open the fan cover. 3. Carefully lift the fan cover out of the drive. Note that the fan cover holds the cooling fan.

  • Page 91: To Replace The Cooling Fan For Frame Size R3

    Maintenance 91 7. Connect the fan power cable. 8. Carefully put the fan cover into position in the drive. Make sure that the fan power cable is routed correctly. Push the cover to lock into position. ￭ To replace the cooling fan for frame size R3 WARNING! Obey the safety instructions of the drive.
  • Page 92 92 Maintenance Stop the drive and do the steps in section Electrical safety precautions (page 16) before you start the work. 2. Use a suitable flat screwdriver to open the fan cover. 3. Carefully lift the fan cover out of the drive. The fan cover holds the cooling fan. 4.
  • Page 93 Maintenance 93 5. Install the new fan into the fan cover. Make sure that the air flow is in the correct direction. The air flows in from the bottom of the drive and out from the top of the drive. 6.

  • Page 94: To Replace The Cooling Fan For Frame Size R4

    94 Maintenance ￭ To replace the cooling fan for frame size R4 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 electrical professional, do not do installation, commissioning or maintenance work.

  • Page 95: Capacitors

    Capacitor failure is usually followed by damage to the unit and an input cable fuse failure, or a fault trip. If you think that any capacitors in the drive have failed, contact ABB. ￭ Reforming the capacitors The capacitors must be reformed if the drive has not been powered (either in storage or unused) for a year or more.

  • Page 97: Technical Data

    Technical data 97 Technical data Contents of this chapter This chapter contains the technical specifications of the drive including the ratings, sizes and technical requirements, provisions for fulfilling the requirements for CE, UL and other approval marks. Electrical ratings ￭ IEC ratings Output ratings Input...
  • Page 98 98 Technical data Output ratings Input Input cur- with Max. Light-duty Heavy-duty Nominal use rent choke current ACS180-04... Frame I max I Ld P Ld I Hd P Hd size -12A2-1 23.9 21.1 16.7 12.2 11.6 3-phase U n = 208 ... 240 V -02A4-2 0.37 0.37...

  • Page 99: Ul (Nec) Ratings

    Technical data 99 Output ratings Input Input cur- with Max. Light-duty Heavy-duty Nominal use rent choke current ACS180-04... Frame I max I Ld P Ld I Hd P Hd size -050A-4 55.7 ￭ UL (NEC) ratings ACS180-04... Input Input Output ratings cur- with Max.

  • Page 100: Definitions

    100 Technical data ACS180-04... Input Input Output ratings cur- with Max. Light-duty use Heavy-duty use Frame rent choke current size I max I Ld P Ld I Hd P Hd -055A-2 59.6 79.2 50.2 15/20 3-phase U n = 440 ... 480 V -01A8-4 0.75 -02A6-4...

  • Page 101: Sizing

    Typical motor power in heavy-duty use (150% overload). ￭ Sizing ABB recommends the DriveSize tool for selecting the drive, motor and gear combination (https://new.abb.com/drives/software-tools/drivesize). You can also use the ratings tables. The minimum recommended nominal current of the motor is 40% of the drive nominal output current ( I ) .
  • Page 102 102 Technical data Switching frequency derating: Derating is not necessary at 4 kHz. Altitude derating: The derating factor for 1500 m is Surrounding air temperature derating: According to the temperature derating table, the derating factor of 17A0-4 drive's nominal output current at 55 °C surrounding air temperature is 0.95.
  • Page 103 Technical data 103 In this example, the derated output current is sufficient, because it is higher than the required current. Example 2, UL (NEC): How to calculate the required drive The application requires a maximum of 12.0 A of motor current with a 10% overload for one minute every ten minutes ( I ) at a switching frequency of 8 kHz.

  • Page 104: Surrounding Air Temperature Derating

    104 Technical data ￭ Surrounding air temperature derating Frame Rating Installation with 50mm space Install side-by-side between Derating factor for 100% 100% I Hd (°C) (°C) (°F) (°F) Ambient temperature Ambient temperature Derating factor for 100% 100% I N and I Ld on ACS180-...-1/2 (°C) (°C)
  • Page 105 Technical data 105 Frame Rating Installation with 50mm space Install side-by-side between Derating factor for 100% I Hd (°C) (°F) Ambient temperature Derating factor for 100% I n and I Ld on ACS180-...-1 (°C) (°F) Ambient temperature Derating factor for 100% I n and I Ld on ACS180-...-2...
  • Page 106 106 Technical data Frame Rating Installation with 50mm space Install side-by-side between Derating factor for 100% I Hd (°C) (°F) Ambient temperature Derating factor for 100% I n and I Ld on ACS180-...-1/2 (°C) (°F) Ambient temperature Derating factor for 100% I n and I Ld on ACS180-...-4...

  • Page 107: Altitude Derating

    Technical data 107 Frame Rating Installation with 50mm space Install side-by-side between Derating factor for 100% I n, I Ld and I Hd on ACS180-04x- 048A-2, 045A-4 (°C) (°F) Ambient temperature Derating factor for 100% I n, I Ld and I Hd on ACS180-04x- 055A-2, 038A-4,...
  • Page 108 108 Technical data Type Current multiplier with different switching frequencies ACS180-04... 2 kHz 4 kHz 8 kHz 12 kHz 1-phase U n = 208 ... 240 V -02A4-1 -03A7-1 -04A8-1 -06A9-1 -07A8-1 -09A8-1 -12A2-1 3-phase U n = 208 ... 240 V -02A4-2 -03A7-2 -04A8-2...

  • Page 109: Fuses

    Technical data 109 Type Current multiplier with different switching frequencies ACS180-04... 2 kHz 4 kHz 8 kHz 12 kHz -03A3-4 -04A0-4 -05A6-4 -07A2-4 -09A4-4 -12A6-4 -17A0-4 -25A0-4 -033A-4 -038A-4 -045A-4 -050A-4 Fuses The tables list the fuses for protection against short-circuits in the input power cable or drive.
  • Page 110 110 Technical data Min. short- Input Nominal Voltage I 2 t circuit cur- current current rating ACS180-04... ABB type rent A 2 s 1-phase U n = 208 ... 240 V -02A4-1 C10G10 -03A7-1 C10G16 -04A8-1 C10G16 -06A9-1 12.6 1200...

  • Page 111: Gr Or Ar -Type Fuses

    Technical data 111 Min. short- Input Nominal Voltage I 2 t circuit cur- current current rating ACS180-04... ABB type rent A 2 s -12A6-4 17.4 3000 C10G32 -17A0-4 25.2 6500 C10G40 -25A0-4 31.8 20000 C22G50 -033A-4 40.9 39000 C22G63 -038A-4...

  • Page 112: Ul (Nec) Fuses

    112 Technical data Min. short- Input Nominal Voltage I 2 t circuit cur- current current rating ACS180-04... Bussmann type rent A 2 s -17A5-2 21.2 2200 FWP-50G14F -25A0-2 27.2 5448 FWP-80G22F -033A-2 6650 FWP-100G22F -048A-2 11700 FWP-150A -055A-2 11700 FWP-150A 3-phase U n = 380 ...
  • Page 113 Technical data 113 Input Min. short-cir- Nominal Voltage Buss- current cuit current current rating ACS180-04... mann Type type -03A7-1 JJN-10 UL class T -04A8-1 JJN-15 UL class T -06A9-1 12.1 JJN-20 UL class T -07A8-1 16.5 JJN-25 UL class T -09A8-1 20.7 JJN-35...

  • Page 114: Alternate Short-Circuit Protection

    2. Fuses with a higher current rating than specified must not be used. 3. The UL listed fuses recommended by ABB are the required branch circuit protection per NEC. Circuit breakers listed in section Circuit breakers (UL) are also acceptable as branch circuit protection.
  • Page 115 Obey the manufacturer’s instructions. You can use the circuit breakers specified by ABB. You can also use other circuit breakers with the drive if they provide the same electrical characteristics. ABB does not assume any liability whatsoever for the correct function and protection of the circuit breakers not specified by ABB.

  • Page 116: Miniature Circuit Breakers (Ul)

    116 Technical data Miniature circuit breaker Network SC ACS180-04... Frame ABB type -033A-2 S203P-Z63NA -048A-2 Contact ABB -055A-2 Contact ABB 3-phase U n = 380 ... 415V -01A8-4 S203P-B4 -02A6-4 S203P-B6 -03A3-4 S203P-B6 -04A0-4 S203P-B8 -05A6-4 S203P-B10 -07A2-4 S203P-B16 -09A4-4...
  • Page 117 09A8-2 SU203M-C25 15A6-2 SU203M-C32 17A5-2 SU203M-C32 25A0-2 SU203M-C50 30.3 1850 033A-2 SU203M-C50 30.3 1850 048A-2 Contact ABB 4577 055A-2 Contact ABB 4577 3-phase U n = 440 ... 480 V 01A8-4 SU203M-C6 02A6-4 SU203M-C8 03A3-4 SU203M-C10 04A0-4 SU203M-C10 05A6-4 SU203M-C10...

  • Page 118: Manual Self-Protected Combination Motor Controller - Type E Usa (Ul (Nec))

    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 MS5100-100 as an alternative to the recommended fuses as a means of branch circuit protection. This is in accordance with the National Electrical Code (NEC).
  • Page 119 Technical data 119 Minimum enclosure volume Type ACS180- 1) 2) 3) Frame MMP type 04... dm 3 in 3 04A8-1 MS132-10 & S1-M3-25 06A9-1 MS165-16 07A8-1 MS165-20 09A8-1 MS165-25 12A2-1 MS165-32 3-phase U n = 208 ... 240 V 02A4-2 MS132-6.3 &...
  • Page 120 4) For all drives, the enclosure must be sized to accommodate the specific thermal considerations of the application as well as provide free space for cooling. Refer to the technical data. For UL only: The minimum enclosure volume is specified in the UL listing when applied with the ABB Type E MMP shown in the table.

  • Page 121: Dimensions And Weights

    Technical data 121 Dimensions and weights H2 H1 Frame Weight size 6.85 8.23 5.35 2.76 5.63 2.36 6.46 0.92 2.03 7.48 8.66 5.98 2.76 5.63 2.36 7.09 1.24 2.73 7.95 9.06 164.5 6.48 4.72 5.63 4.17 190.5 1.92 4.23 8.07 164.5 6.48 6.69...

  • Page 122: Free Space Requirements

    122 Technical data Free space requirements Frame size Above Below Sides 50 1) R1-R4 Note: 1) If ambinet temperature is below 40°C (104 F), modules can be installed side-by-side. Losses, cooling data and noise Drives with frame size R0 have natural convection cooling. Drives with frame size R1…R4 have a cooling fan.

  • Page 123: Typical Power Cable Sizes

    Technical data 123 Air flow Noise Typical power loss Frame ACS180-04... size m 3 /h BTU/h dB(A) -17A5-2 194.2 -25A0-2 394.2 1345 -033A-2 419.5 1431 -048A-2 563.8 1924 -055A-2 2330 3-phase U n = 380 ... 480 V -01A8-4 21.3 -02A6-4 30.9 -03A3-4...
  • Page 124 124 Technical data Cable conductor sizes (mm 2 ) ACS180-04... Frame -09A8-1 3×2.5 + 2.5 -12A2-1 3×2.5 + 2.5 3-phase U n = 208 ... 240 V -02A4-2 3×1.5 + 1.5 -03A7-2 3×1.5 + 1.5 -04A8-2 3×1.5 + 1.5 -06A9-2 3×1.5 + 1.5 -07A8-2 3×2.5 + 2.5...

  • Page 125: Terminal Data For The Power Cables

    Technical data 125 Terminal data for the power cables The first table shows the terminal data in SI units. The second table shows the terminal data in imperial units. ACS180- L1, L2, L3, T1/U, T2/V, T3/W, R-, R+/ 04... UDC+ Minimum Maximum Tightening...
  • Page 126 126 Technical data ACS180- L1, L2, L3, T1/U, T2/V, T3/W, R-, R+/ 04... UDC+ Minimum Maximum Tightening Minimum Maximum Tightening torque (sol- (sol- torque (sol- (sol- id/stran- id/stran- id/stran- id/stran- ded) ded) ded) ded) mm 2 mm 2 mm 2 mm 2 N·m N·m...
  • Page 127 Technical data 127 ACS180- L1, L2, L3, T1/U, T2/V, T3/W, R-, R+/ 04... UDC+ Minimum Maximum Tightening Minimum Maximum Tightening torque torque lbf·in lbf·in 3-phase U n = 208 ... 240 V -02A4-2 10.6 -03A7-2 10.6 -04A8-2 10.6 -06A9-2 10.6 -07A8-2 10.6 -09A8-2...

  • Page 128: Terminal Data For The Control Cables

    128 Technical data Note: • The minimum specified wire size does not necessarily have sufficient current carrying capacity at maximum load. • The terminals do not accept a conductor that is one size larger than the maximum specified wire size. •...

  • Page 129: Electrical Power Network Specification

    ACS180-04x-xxxx-4 drives: 3-phase 380 … 480 V AC -15% ... +10% Network type Public low-voltage networks. Symmetrically grounded TN-S system, IT (ungrounded), corner-grounded delta. Consult ABB before con- necting to other systems (for example, TT, or midpoint grounded delta). ACS180-04N-...-4 doesn't support corner-grounded delta...

  • Page 130: Motor Connection Data

    130 Technical data Rated conditional 65 kA when protected by fuses given in the fuse tables. short-circuit current I cc (IEC 61800-5-1) Short-circuit current US and Canada: The drive is suitable for use on a circuit capable of protection delivering not more than 100 kA symmetrical amperes (rms) at 480 V maximum when protected by fuses given in the fuse table.
  • Page 131 Technical data 131 Frame Maximum motor cable length Standard drive, without external options With external output chokes Note: In multimotor systems, the calculated sum of all motor cable lengths must not exceed the maximum motor cable length given in the table.

  • Page 132: Emc Compatibility And Motor Cable Length

    132 Technical data EMC compatibility and motor cable length To comply with the EMC limits in the European EMC Directive (standard IEC/EN 61800-3), use these maximum motor cable lengths for the 4 kHz switching frequency. Frame Maximum motor cable length, 4 kHz Class 2 Class 3 Class 1...

  • Page 133: Control Connection Data

    Technical data 133 Frame Maximum motor cable length, 4 kHz Class 2 Class 3 Class 1 1) Category C1 with conducted emissions only. Radiated emissions are not compatible when measured with the standard emission measurement setup and must be measured on cabinet and machine installations for each case.

  • Page 134: Brake Resistor Connection Data

    (IEC 61800-5-1, IEC/EN 61800-5-1 and UL 61800-5-1. IEC 60439-1, Rated conditional short-circuit current is as defined in IEC 60439-1. UL 61800-5-1) Energy efficiency data (ecodesign) Energy efficiency data according to IEC 61800-9-2 is available from the ecodesign tool (https://ecodesign.drivesmotors.abb.com/).

  • Page 135: Protection Classes

    Technical data 135 Protection classes Degree of protection IP20. The drive must be installed in a cabinet to fulfill the require- (IEC/EN 60529) ments for shielding from contact. Enclosure types UL open type. For indoor use only. (UL 61800-5-1) Overvoltage category (IEC 60664-1) Protective classes (IEC/EN 61800-5-1)
  • Page 136 136 Technical data Requirement Operation installed for sta- Storage in the Transportation in tionary use protective pack- the protective package Surrounding air tem- For frame size R0: -40 … +70 °C -40 … +70 °C perature at heavy -10 … +50 °C (14 … 122 °F) (-40 …...

  • Page 137: Storage Conditions

    Technical data 137 Requirement Operation installed for sta- Storage in the Transportation in tionary use protective pack- the protective package Free fall Not allowed 76 cm (30 in) 76 cm (30 in) Storage conditions Store the drive in humidity controlled enclosed environments. Keep the drive in its package.

  • Page 138: Disposal

    Contact your local ABB distributor for further information on environmental aspects. End of life treatment must follow international and national regulations. For more information on ABB end of life services, refer to new.abb.com/service/end-of-life-services. Applicable standards...

  • Page 139: Markings

    Technical data 139 IEC/EN 61800-5- Adjustable speed electrical power drive systems – Part 5-1: Safety 1:2007+AMD1:2016 requirements – Electrical, thermal and energy EN 61800-5- 1:2007+A1:2017+A11:2021 IEC 61800-9-2:2017 Adjustable speed electrical power drive systems – Part 9-2: Ecodesign for power drive systems, motor starters, power electronics and their driven applications –...

  • Page 140: Emc Compliance (Iec/En 61800-3:2004 + A1:2012)

    Product is compliant with the People’s Republic of China Electronic Industry Standard (SJ/T 11364-2014) about hazardous substances. The EFUP is 20 years. China RoHS II Declaration of Conformity is available from https://library.abb.com. WEEE mark At the end of life the product should enter the recycling system at an appropriate collection point and not placed in the normal waste stream.

  • Page 141: Category C1

    Technical data 141 Drive of category C4: drive of rated voltage equal to or above 1000 V, or rated current equal to or above 400 A, or intended for use in complex systems in the second environment. ￭ Category C1 This is applicable to ACS180-04S-...-1/-4 drives with an external EMC C1 filter.

  • Page 142: Category C3

    142 Technical data WARNING! To prevent radio-frequency interference, do not use a category C2 drive on a low-voltage public network that supplies domestic premises. ￭ Category C3 This is applicable to drives with an internal EMC C3 filter. The drive complies with the standard with the following provisions: The motor and control cables are selected as specified in this manual.
  • Page 143 Technical data 143 Medium voltage network Neighboring network Point of measurement Low voltage Equipment (victim) Equipment Supply transformer Static screen Drive 2. An EMC plan for preventing disturbances is drawn up for the installation. A template is available in Technical guide No. 3 EMC compliant installation and configuration for a power drive system (3AFE61348280 [English]).

  • Page 144: Ul Checklist

    144 Technical data UL checklist WARNING! Operation of this drive requires detailed installation and operation instructions provided in the hardware and software manuals. The manuals are provided in electronic format in the drive package or on the Internet. Keep the manuals with the drive at all times. Hard copies of the manuals can be ordered through the manufacturer.

  • Page 145: Disclaimers

    ABB and its affiliates are not liable for damages and/or losses related to such security breaches, any unauthorized access, interference, intrusion, leakage and/or...

  • Page 147: Dimension Drawings

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

  • Page 148: Frame R0

    148 Dimension drawings Frame R0...

  • Page 149: Frame R1

    Dimension drawings 149 Frame R1...

  • Page 150: Frame R2

    150 Dimension drawings Frame R2 [9.055] 19,2 [.756] [.240] [.220] 19,2 [.756] 28,3 [1.114] [7.953] 16,7 [.657] 23,1 [.907] 190,5 [7.500] 61,4 13,5 [.532] [2.415] [2.165] [.256] 86,8 [3.415] 80,4 [3.165] 74,1 [2.915] 67,7 [2.665]...

  • Page 151: Frame R3

    Dimension drawings 151 Frame R3...

  • Page 152: Frame R4

    152 Dimension drawings Frame R4...

  • Page 153: Resistor Braking

    Resistor braking 153 Resistor braking Contents of this chapter The chapter describes how to select the brake resistor and cables, protect the system, connect the brake resistor and enable resistor braking. Safety WARNING! Do not do work on the brake resistor or the resistor cable when the drive is energized.
  • Page 154 154 Resistor braking 2. Calculate resistance R with Equation 1. 3. Calculate energy E with Equation 2. Rpulse 4. Select the resistor so that the following conditions are met: • The rated power of the resistor must be greater than or equal to P Rmax Resistance R must be between R and R...

  • Page 155: Reference Brake Resistors

    Resistor braking 155 WARNING! Do not use a brake resistor with a resistance below the minimum value specified for the particular drive. The drive and the internal chopper are not able to handle the overcurrent caused by the low resistance. ￭...

  • Page 156: Definitions

    156 Resistor braking 3) If brake resistors from other manufacturers are used, the characteristics must agree with the values in the table. Definitions The maximum braking capacity of the drive, when the length of the BRmax braking pulse is at most 1 minute for each 10 minutes ( P ×...

  • Page 157: Protecting The System In Brake Circuit Fault Situations

    The drive has a brake thermal model which protects the brake resistor against overload. ABB recommends to enable the thermal model at start up. ABB recommends to equip the drive with a main contactor for safety reasons even when you have enabled the resistor thermal model. Wire the contactor so that it opens in case the resistor overheats.

  • Page 158: Mechanical And Electrical Installation Of Brake Resistor

    158 Resistor braking ABB recommends that you also wire the thermal switch to a digital input of the drive, and configure the input to cause a fault trip at resistor overtemperature indication. Θ +24V Drive input power connection with a main contactor...

  • Page 159: Electrical Installation

    Resistor braking 159 ￭ Electrical installation Measuring the insulation See the electrical installation instructions of the drive. Connecting power cables See the electrical installation instructions of the drive. Connection the control cables Connect the thermal switch of the brake resistor as described in Protecting the system against thermal overload (page 157).

  • Page 161: The Safe Torque Off Function

    The Safe torque off function 161 The Safe torque off function Contents of this chapter This chapter describes the Safe torque off (STO) function of the drive and gives instructions for its use. Description The Safe torque off function can be used, for example, as the final actuator device of safety circuits (such as an emergency stop circuit) that stop the drive in case of danger.

  • Page 162: Compliance With The European Machinery Directive And The Uk Supply Of Machinery (Safety) Regulations

    162 The Safe torque off function The Safe torque off function complies with these standards: Standard Name IEC 60204-1:2021 Safety of machinery – Electrical equipment of machines – Part 1: General requirements EN 60204-1:2018 IEC 61000-6-7:2014 Electromagnetic compatibility (EMC) – Part 6-7: Generic standards –...

  • Page 163: Wiring

    The Safe torque off function 163 Wiring For the electrical specifications of the STO connection, see the technical data of the control unit. ￭ Connection principle Single ACS180 drive, internal power supply + 24 V DC SGND UDC+ UDC- Drive Control unit Control logic To motor...

  • Page 164: Single Acs180 Drive, External Power Supply

    164 The Safe torque off function Single ACS180 drive, external power supply 24 V DC + 24 V DC SGND UDC+ UDC- Drive Control unit Control logic To motor Activation switch...

  • Page 165: Wiring Examples

    The Safe torque off function 165 ￭ Wiring examples Single ACS180 drive, internal power supply SGND Drive Safety PLC Safety relay Single ACS180 drive, external power supply 24 V DC SGND Drive Safety PLC Safety relay...

  • Page 166: Multiple Acs180 Drives, Internal Power Supply

    166 The Safe torque off function Multiple ACS180 drives, internal power supply +24 V SGND SGND SGND Drive Control unit Activation switch...

  • Page 167: Multiple Acs180 Drives, External Power Supply

    The Safe torque off function 167 Multiple ACS180 drives, external power supply 24 V DC – +24 V SGND SGND SGND Drive Control unit Activation switch ￭ Activation switch In the wiring diagrams, the activation switch has the designation [K]. This represents a component such as a manually operated switch, an emergency stop push button switch, or the contacts of a safety relay or safety PLC.

  • Page 168: Cable Types And Lengths

    The contacts of the switch or relay must open/close within 200 ms of each other. ￭ Cable types and lengths • ABB recommends double-shielded twisted-pair cable. • Maximum cable lengths: • 300 m (1000 ft) between activation switch [K] and drive control unit •...

  • Page 169: Operation Principle

    The Safe torque off function 169 Operation principle The Safe torque off activates (the activation switch is opened, or safety relay contacts open). 2. The STO inputs of the drive control unit de-energize. 3. The control unit cuts off the control voltage from the output IGBTs. 4.

  • Page 170: Start-Up Including Validation Test

    170 The Safe torque off function Start-up including validation test To ensure the safe operation of a safety function, validation is required. The final assembler of the machine must validate the function by performing a validation test. The test must be performed at initial start-up of the safety function 2.
  • Page 171 The Safe torque off function 171 Action Test the operation of the STO function when the motor is stopped. • Give a stop command for the drive (if running) and wait until the motor shaft is at a standstill. Make sure that the drive operates as follows: •...

  • Page 172: Use

    172 The Safe torque off function Open the activation switch, or activate the safety functionality that is wired to the STO connection. 2. The STO inputs on the drive control unit de-energize, and the control unit cuts off the control voltage from the output IGBTs. 3.
  • Page 173 The Safe torque off function 173 • The Safe torque off function is ineffective against deliberate sabotage or misuse. • The 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.

  • Page 174: Maintenance

    If any wiring or component change is needed after start-up, or the parameters are restored, do the test given in section Validation test procedure (page 170). Use only spare parts approved by ABB. Record all maintenance and proof test activities in the machine logbook. ￭ Competence...

  • Page 175: Fault Tracing

    See the firmware manual of the drive control program for the indications generated by the drive, and for details on directing fault and warning indications to an output on the control unit for external diagnostics. Any failures of the Safe torque off function must be reported to ABB.

  • Page 176: Safety Data

    176 The Safe torque off function Safety 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.
  • Page 177 The Safe torque off function 177...

  • Page 178: Terms And Abbreviations

    178 The Safe torque off function • The STO is a type A safety component as defined in IEC 61508-2. • Relevant failure modes: • The STO trips spuriously (safe failure) • The STO does not activate when requested • A fault exclusion on the failure mode “short circuit on printed circuit board”...

  • Page 179: Tüv Certificate

    The Safe torque off function 179 Term or Reference Description abbreviation IEC 61508 Average frequency of dangerous failures per hour, that is, average frequency of a dangerous failure of a safety related system to perform the specified safety function over a given period of time PFH diag IEC/EN 62061 Average frequency of dangerous failures per hour for the...

  • Page 180: Declarations Of Conformity

    180 The Safe torque off function ￭ Declarations of conformity...
  • 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 185: Accessories

    Accessories 185 Accessories Contents of this chapter This chapter contains a description and technical data of accessories 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 electrical professional, do not do installation, commissioning or maintenance work.

  • Page 186: Bdrk-01 Din Rail Mounting Kit

    186 Accessories BDRK-01 DIN rail mounting kit BDRK-01 is applicable to ACS180 frame size R0 and R1 drives. ￭ Dimensions 1 [.039] 7.5 [.295] 17.1 [.673] 70 [2.756] Unit: mm [in]...

  • Page 187: Installation

    Accessories 187 ￭ Installation M4x16, 2x 2 N·m 2 2 2 2 3 3 3...

  • Page 188: Bdrk-02 Din Rail Mounting Kit

    188 Accessories BDRK-02 DIN rail mounting kit BDRK-02 is applicable to ACS180 frame size R2 drive. ￭ Dimensions 1 [.039] 7.5 [.295] 120 [4.724] 17.1 [.673] Unit: mm [in]...

  • Page 189: Installation

    Accessories 189 ￭ Installation M4x16, 4x 2 N·m 2 2 2...

  • Page 190: Bmbc-01 Mounting Bracket For Cca-01 Adapter

    BMBC-01 is applicable to ACS180 frame size R1 drive. You can connect 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...

  • Page 191: Further Information

    Product and service inquiries Address any inquiries about the product to your local ABB representative, quoting the type designation and serial number of the unit in question. A listing of ABB sales, support and service contacts can be found by navigating to www.abb.com/contact-centers.
  • Page 192 3AXD50000467945D © Copyright 2024 ABB. All rights reserved. Specifications subject to change without notice.

This manual is also suitable for:

Acs180 seriesAcs180-04s-02a4-1Acs180-04s-04a8-1Acs180-0412a2-1Acs180-02a4-2Acs180-03a7-2 ... Show all

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