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 ..............
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6 Table of contents Integrated 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 ......................Unpacking the delivery ....................
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Table of contents 7 Routing the cables ....................General guidelines – IEC ................... General guidelines – North America .............. Continuous motor cable shield/conduit and metal enclosure for equipment on the motor cable ............... Separate control cable ducts ................Implementing short-circuit and thermal overload protection ......Protecting the drive and input power cable in short-circuits ....
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8 Table of contents Additional information on the control connections .......... Connecting an interposing relay to DO ............Connecting EIA-485 fieldbus cable to the drive .......... PNP configuration for digital inputs ............. NPN configuration for digital inputs ............Connection examples of two-wire and three-wire sensors ..... Safe torque off ....................
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Table of contents 9 Manual self-protected combination motor controller – Type E USA (UL (NEC)) ......................Dimensions and weights ..................Free space requirements ..................Losses, cooling data and noise ................Terminal data for the power cables ..............Typical output cable sizes ..................Typical input cable sizes ..................
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10 Table of contents Frame R3 ........................Frame R4 ........................11 Resistor braking Contents of this chapter ..................Safety .......................... Operation principle ....................Selecting the brake resistor ................... Reference brake resistors ................Definitions ....................Selecting and routing the brake resistor cables ..........Minimizing electromagnetic interference ............
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Table of contents 11 Start-up including validation test ................. Competence ....................... Validation test reports ..................Validation test procedure ................Use ..........................Maintenance ......................Competence ....................... Fault tracing ......................Safety data ......................... Terms and abbreviations ................. TÜV certificate ....................Declarations of conformity ................Further information...
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.
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. •...
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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.
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.
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.
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.
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.
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: •...
Introduction 21 Introduction Contents of this chapter This chapter describes the intended audience and contents of the manual. It contains a flowchart of steps in checking the delivery, installing and starting up the drive. The flowchart refers to chapters/sections in this manual and to other manuals.
22 Introduction Quick installation and commissioning flowchart Task Identify the frame size: R0, R1, R2, R3 or R4. Type designation label (page 32) Plan the installation. Guidelines for planning the electrical installation (page 43) Check the ambient conditions, ratings and required cooling air flow.
Radio-frequency interference Safety integrity level (1…3) (IEC 61508, IEC 62061, IEC 61800-5-2) Safe torque off (IEC/EN 61800-5-2) Related documents You can find manuals on the Internet. See below for the relevant code/link. For more documentation, go to www.abb.com/drives/documents. ACH180 manuals...
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 ACH180 is a drive for controlling asynchronous induction motors, permanent magnet motors and ferrite assisted synchronous reluctance motors.
26 Operation principle and hardware description Simplified main circuit diagram The figure shows the simplified main circuit diagram of the drive. 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.
Operation principle and hardware description 27 Layout ■ Frame sizes R0…R1 Input power connection terminal EMC filter grounding screw PE connection (motor) Integrated control panel (page 33) Motor connection terminal Fixed control terminals Cooling fan (frame R1 only) Front cover Panel and PC tool port (RJ45) Model information label Type designation label...
28 Operation principle and hardware description ■ Frame R2 Input power connection terminal PE connection (motor) Fixed control terminals Integrated control panel (page 33) Motor connection terminal and brake Front cover resistor terminal Cooling fan Model information label Panel and PC tool port (RJ45) Cold configuration connection for CCA-01 Type designation label PE connection (input)
Operation principle and hardware description 29 ■ Frame R3 Input power connection terminal VAR screw Fixed control terminals Integrated control panel (page 33) Motor connection terminal and brake Front cover resistor terminal Cooling fan Model information label Panel and PC tool port (RJ45) Cold configuration connection for CCA-01 Type designation label PE connection (motor)
30 Operation principle and hardware description ■ Frame R4 Input power connection terminal VAR screw Fixed control terminals Integrated control panel (page 33) Motor connection terminal and brake Front cover resistor terminal Cooling fan Model information label Panel and PC tool port (RJ45) Cold configuration connection for CCA-01 Type designation label PE connection (motor)
32 Operation principle and hardware description Drive labels The drive has two labels: • model information label at the top of the drive • type designation label on the left side of the drive. ■ Model information label Drive type Serial number QR code for the serial number ■...
XXXX: Running item number that starts each week from 0001. ■ Type designation key The type designation shows the specifications and configuration of the drive. The table below presents the type code digits. Sample type code: ACH180-04S-25A0-4 Code Description ACH180 Product series Construction.
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34 Operation principle and hardware description Display (Home view): a) control location: Hand, Off or Auto b) status icon c) reference target value d) actual measured value e) left and right softkey actions. Status LED: • steady green: normal operation •...
Operation principle and hardware description 35 • Push the Back key to cancel a setting or return to the previous view. ■ Home view The Home view shows the reading of one of three measured signals. Select the page with the left and right arrow keys. The status bar at the top of the Home view shows: •...
36 Operation principle and hardware description ■ Options view To open the Options view, push the Back key in the Home view. In the Options view, you can: • set the reference • view the active fault • view a list of active warnings. ■...
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 Installation requirements: • Make sure that there is a minimum of 75 mm of free space at the top and bottom of the drive (at the cooling air inlet and outlet).
38 Mechanical installation • Install the drive inside a cabinet or enclosure. The drive has an IP20 (UL Open Type) ingress protection classification for cabinet installation. Examining the installation site Examine the installation site. Make sure that: • The installation site is sufficiently ventilated or cooled to remove heat from the drive.
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 (mounting template, cable clamps, metal grounding plate, screws, plastic or metal EMC screw, etc.) 3.
40 Mechanical installation Installing the drive You can install the drive: • with screws to a suitable surface (wall or assembly plate) • to a DIN installation rail. ■ To install the drive with screws Make marks onto the surface for the mounting holes. Use the mounting template that was delivered with the drive.
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Mechanical installation 41 5. Tighten the mounting screws.
42 Mechanical installation ■ To install the drive to a DIN installation rail Use an IEC/EN 60715 top hat type installation rail, width × height = 35 × 7.5 mm (1.4 × 0.3 in). DIN rail mounting kit is available for frames R0…R1 and R2. Refer to BDRK-01 Installation guide (3AXD10001526036 [multilingual]) for R0…R1 and...
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.
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)
Guidelines for planning the electrical installation 45 To comply with the EMC requirements of the CE mark, use one of the preferred cable types. See Preferred power cable types (page 45). Symmetrical shielded cable reduces electromagnetic emission of the whole drive system as well as the stress on motor insulation, bearing currents and wear.
46 Guidelines for planning the electrical installation Cable type Use as input power cabling Use as motor cabling and as brake resistor cabling Symmetrical shielded (or ar- mored) cable with three phase conductors and a shield (or armor), and separ- ate PE conductor/cable 1) A separate PE conductor is required if the conductivity of the shield (or armor) is not sufficient for the PE use.
■ 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.
48 Guidelines for planning the electrical installation Wiring method Notes Wireways Prefer symmetrical shielded VFD cable. Separate motor wiring from input power wiring and other low voltage wiring. Metallic Do not run outputs of multiple drives parallel. Bundle each cable (wiring) together and use separators where possible.
Guidelines for planning the electrical installation 49 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.
50 Guidelines for planning the electrical installation 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 )
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.
■ 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).
Guidelines for planning the electrical installation 53 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) ■...
54 Guidelines for planning the electrical installation 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: •...
Guidelines for planning the electrical installation 55 ■ 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).
56 Guidelines for planning the electrical installation ■ 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.
Guidelines for planning the electrical installation 57 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.
58 Guidelines for planning the electrical installation You can use the Safe torque off function of the drive to implement the Emergency stop function. Note: Pressing the stop (off) key on the control panel of the drive does not generate an emergency stop of the motor or separate the drive from dangerous potential.
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Guidelines for planning the electrical installation 59 230 V AC 230 V AC + 24 V DC Relay output Varistor RC filter Diode...
Electrical installation 61 Electrical installation Contents of this chapter This chapter contains instructions on the wiring of the drive. Required tools To do the electrical installation, you need the following tools: • wire stripper • screwdriver or wrench with a set of suitable bits. For motor cable terminals, the recommended screwdriver shaft length is 150 mm (5.9 in).
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.
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.
64 Electrical installation ■ When to disconnect the EMC filter The table shows different earthing systems, and when you need to disconnect the EMC filter (metal EMC screw). WARNING! Remove the metal EMC screw in systems other than the symmetrically grounded TN-S systems.
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.
66 Electrical installation ■ 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.
PE conductor for the line side, if the conductivity of the fourth conductor or shield does not meet the requirements for the PE conductor. Motor cable. ABB recommends to use a symmetrical shielded cable (VFD cable) as 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.
68 Electrical installation ■ 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.
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Electrical installation 69 M4x10, 2x 4. Strip the motor cable. 5. Ground the motor cable shield under the grounding clamp. Twist the motor cable shield into a bundle, mark it with yellow-green and connect it to the grounding terminal. 6. Connect the phase conductors of the motor cable to the T1/U, T2/V, and T3/W motor terminals.
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70 Electrical installation R0/R1 R2/R3/R4 11. Mark the second grounding connector of the input side (if any) with yellow-green and connect it to the PE terminal. Second PE conductor is required by the drive safety standard IEC/EN 61800-5-1. 12. Connect the phase conductors of the input power cable to the drive as follows. •...
Supply disconnecting device and fuses Input power wiring inside a metal conduit Protective earth (ground) conductor(s) Motor wiring inside a metal conduit Note: ABB recommends to use a symmetrical shielded cable (VFD cable) as the motor cable. Brake resistor (optional, for frames R2...R4 only).
72 Electrical installation ■ 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.
AGND Output frequency (0...20mA) Ref. voltage +10 V DC SCREEN SCREEN Signal cable shield (screen) Safe torque off (STO) (only on ACH180-04S) Safe torque off function. Connected at the factory. Drive starts SGND SGND only when both circuits are closed.
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Electrical installation 75 M4x20, 2x R3: M3x12, 2x R4: M4x8, 2x R3/R4 4. Strip a part of the outer shield of the control cable for 360° grounding. 5. Ground the bare shield 360° to the grounding plate with a grounding clamp. 6.
76 Electrical installation 8. Mechanically attach the control cables on the outside of the drive. Additional information on the control connections ■ Connecting an interposing relay to DO For applications where a second relay output is required, an interposing relay must be used.
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Electrical installation 77 With signal ground reference terminal Without signal ground reference terminal 100 ohm Fieldbus controller. Termination ON Drive. J1: Termination OFF; J2: Fieldbus Mode Drive. J1: Termination OFF; J2: Fieldbus Mode Drive at the end of the communication line. J1: Termination ON ;...
78 Electrical installation ■ PNP configuration for digital inputs Internal and external +24 V power supply connections for PNP (source) configuration are shown in the figure below. Internal +24 V power supply External +24 V power supply +24 V +24 V 0 V DC DGND DGND...
– type Mini-B cable. The maximum permitted length of the cable is 3 m (9.8 ft). • 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).
80 Electrical installation For information on the Drive composer PC tool, refer to Drive composer PC tool user's manual (3AUA0000094606 [English]). CCA-01 connection You can use the CCA-01 cold configuration tool to download software and change drive parameters without connecting the drive to the input power. The CCA-01 does not operate if the drive is powered.
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.
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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.
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Installation checklist 83 Make sure that … The motor and the driven equipment are ready for power-up.
Contents of this chapter This chapter contains 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).
• 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.
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. ■...
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88 Maintenance 3. Carefully lift the fan cover out of the drive. Note that the fan cover holds the cooling fan. 4. Disconnect the fan power cable. 5. Free the fan clips and remove the fan from the fan cover. 6.
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Maintenance 89 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.
90 Maintenance ■ To replace the cooling fan for frame size R2 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.
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Maintenance 91 Place cables into the slot. Keep cables on the right side of the plate. 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.
92 Maintenance ■ To replace the cooling fan for frame size R3 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.
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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.
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.
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Maintenance 95 6. Replace the fan. 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. 7. Connect the fan power cable. 8.
IEC ratings Output ratings Input Input cur- with Max. Light-duty Heavy-duty Nominal use rent choke current ACH180-04S-... Frame I max I Ld P Ld I Hd P Hd size 1-phase U n = 200 ... 240 V 02A4-1 0.37 0.37 0.25 03A7-1 0.55...
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98 Technical data Output ratings Input Input cur- with Max. Light-duty Heavy-duty Nominal use rent choke current ACH180-04S-... Frame I max I Ld P Ld I Hd P Hd size 12A2-1 23.9 21.1 17.6 12.2 11.6 3-phase U n = 200 ... 240 V 02A4-2 0.37...
Technical data 99 Output ratings Input Input cur- with Max. Light-duty Heavy-duty Nominal use rent choke current ACH180-04S-... Frame I max I Ld P Ld I Hd P Hd size 050A-4 55.7 50.0 81.0 50.0 22.0 48.0 22.0 45.0 22.0 ■...
100 Technical data Input Output ratings with Max. Nominal Light-duty Heavy-duty use Frame cur- choke cur- size rent ACH180-04S-... rent I max I Ld P Ld I Hd P Hd 048A-2 53.2 46.2 55.4 46.2 15.0 46.2 15.0 32.0 10.0 055A-2 50.2...
Example 1, IEC: How to calculate the derated current The drive type is ACH180-04S-17A0-4, which has a nominal output current ( I ) of 17 A at 400 V. Calculate the derated output current at 4 kHz switching frequency,...
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( I ) by all the applicable derating factors. For example, drive type ACH180-04S-12A6-4 has a nominal output current of 12.6 A at 400 V. The switching frequency derating factor for this drive type is 0.68 at 8 kHz.
( I ) by all the applicable derating factors. For example, drive type ACH180-04S-25A0-4 has an output current of 21 A at 480 V. The switching frequency derating for this drive type is 0.7 at 8 kHz.
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100% I Ld and I Hd (°C) (°F) Ambient temperature Derating factor for I N, 100% I Ld and I Hd on ACH180-04S- 048A-2, 045A-4 (°C) (°F) Ambient temperature Derating factor for I N, 100% I Ld and I Hd on...
(1000 m <= x <= 2000 m) is: ■ Switching frequency derating Type Current multiplier with different switching frequencies ACH180-04S-... 2 kHz 4 kHz 8 kHz 12 kHz 1-phase U n = 200 ... 240 V...
106 Technical data Type Current multiplier with different switching frequencies ACH180-04S-... 2 kHz 4 kHz 8 kHz 12 kHz 02A6-4 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.
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Technical data 107 Min. Input short-cir- Nominal Voltage I 2 t ACH180- current cuit cur- current rating Bussmann type Size 04S-... rent A 2 s 03A7-1 C10G16 04A8-1 C10G16 06A9-1 12.6 1200 C10G20 07A8-1 17.3 2300 C10G25 09A8-1 21.8 6300 C14G40 12A2-1 23.9...
108 Technical data Min. Input short-cir- Nominal Voltage I 2 t ACH180- current cuit cur- current rating Bussmann type Size 04S-... rent A 2 s 25A0-4 31.8 20000 C22G50 033A-4 40.9 39000 C22G63 038A-4 49.0 60000 C22G80 045A-4 55.7 91150 C22G100 050A-4 55.7...
11700 FWP-150A 050A-4 55.7 11700 FWP-150A ■ Fuses (UL) Min. short- Input Nominal Voltage Buss- circuit cur- ACH180-04S- current current rating mann Type rent type 1-phase U n = 200 ... 240 V 02A4-1 JJN-6 UL class TULT 03A7-1 JJN-10...
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110 Technical data Min. short- Input Nominal Voltage Buss- circuit cur- ACH180-04S- current current rating mann Type rent type 04A8-1 JJN-15 UL class 06A9-1 12.1 JJS-70 UL class 07A8-1 16.5 JJN-25 UL class 09A8-1 20.7 JJN-35 UL class 12A2-1 22.7...
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Technical data 111 Min. short- Input Nominal Voltage Buss- circuit cur- ACH180-04S- current current rating mann Type rent type 3-phase U n = 440 ... 480 V 01A8-4 JJS-6 UL class 02A6-4 JJS-6 UL class 03A3-4 JJS-10 UL class 04A0-4...
You can use the circuit breakers listed below. 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 with circuit breakers not listed below.
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).
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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.
Note: Power losses are given for nominal supply voltage, default switching frequency, and rated output current/power. Changing these factors may result in increased power losses. Air flow Noise Typical power loss ACH180-04S-... m 3 /h BTU/h dB(A) 1-phase U n = 200 ... 240 V 02A4-1 32.00...
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118 Technical data Air flow Noise Typical power loss ACH180-04S-... m 3 /h BTU/h dB(A) 048A-2 319.00 1088.47 150.00 88.29 69.00 055A-2 319.00 1088.47 150.00 88.29 69.00 3-phase U n = 380 ... 480 V 01A8-4 30.00 102.36 02A6-4 40.00 136.49...
Technical data 119 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. ACH180- L1, L2, L3, T1/U, T2/V, T3/W, R-, R+/ 04S-... UDC+ Minimum Maximum Tightening...
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120 Technical data ACH180- L1, L2, L3, T1/U, T2/V, T3/W, R-, R+/ 04S-... 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...
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Technical data 121 ACH180- L1, L2, L3, T1/U, T2/V, T3/W, R-, R+/ 04S-... UDC+ Minimum Maximum Tightening Minimum Maximum Tightening torque torque lbf·in lbf·in 3-phase U n = 200 ... 240 V 02A4-2 10.6 03A7-2 10.6 04A8-2 10.6 06A9-2 10.6 07A8-2 10.6 09A8-2...
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122 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. •...
The table shows the external EMC filters. See also EMC compatibility and motor cable length (page 129). ACH180- EMC filter type 04S-... ABB order code Schaffner order code 1-phase U n = 200 ... 240 V 02A4-1 RFI-12 FS 21754-16.1-07 03A7-1 RFI-12 FS 21754-16.1-07...
128 Technical data Electrical power network specification Voltage (U1) ACH180-04S-xxxx-1 drives: 1-phase 200 … 240 V AC -15% ... +10% ACH180-04S-xxxx-2 drives: 3-phase 200 … 240 V AC -15% ... +10% ACH180-04S-xxxx-4 drives: 3-phase 380 … 480 V AC -15% ... +10% Network type Public low-voltage networks.
Technical data 129 Current See the rating information. Switching frequency 4, 8, or 12 kHz ■ Motor cable length Operational functionality and motor cable length The drive is designed to operate with optimum performance with the following maximum motor cable lengths. The motor cable lengths may be extended with output chokes as shown in the table.
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130 Technical data Frame Maximum motor cable length, 4 kHz Class 2 Class 3 1-phase U n = 200 ... 240 V 3-phase U N = 230 V AC (200, 208, 220, 230, 240 V) 3-phase U n = 380 ... 415 V With optional external EMC filter 1-phase U n = 200 ...
Technical data 131 Frame Maximum motor cable length, 4 kHz Class 2 Class 3 Control connection data Analog inputs (AI1, Voltage signal, single- 0 … 10 V DC (10% overrange, 11 V DC max.) AI2) ended R in = 38 kohm Current signal, single- 0 …...
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/). Protection classes Degree of protection IP20 (cabinet installation): Standard enclosure. The drive must be...
Technical data 133 Ambient conditions Environmental limits for the drive are given below. The drive must be used in a heated indoor controlled environment. Requirement Operation installed for sta- Storage in the Transportation in tionary use protective pack- the protective package Installation site alti- 0 …...
134 Technical data Materials ■ Drive Refer to ACH180 and ACS180 Recycling instructions and environmental information (3AXD50000613342 [English]). ■ Package • Cardboard • Molded pulp • PE (suspension film package, plastic bag). ■ Package materials for options, accessories and spare parts •...
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...
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. BTL (BACnet Testing Laboratories) mark Product has BACnet conformance certificate.
400 A, or intended for use in complex systems in the second environment. ■ Category C1 This is applicable to ACH180-04S-...-1, ACH180-04S-…-2 and ACH180-04S-...-4 drives with an external EMC C1 filter. The drive complies with the conducted emission limits of the standard with the following provisions:...
138 Technical data ■ Category C2 This is applicable to ACH180-04S-...-1 drives with an internal EMC C2 filter. The drive complies with the standard with the following provisions: The motor and control cables are selected as specified in this manual.
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Drive 2. An EMC plan for preventing disturbances is drawn up for the installation. A template is available from the local ABB representative. 3. The motor and control cables are selected as specified in this manual. 4. The drive is installed according to the instructions given in this manual.
140 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.
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...
Dimension drawings 143 Dimension drawings Contents of this chapter The chapter contains the dimension drawings of the drive. The dimensions are in millimeters and inches.
Resistor braking 149 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.
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150 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...
152 Resistor braking ACH180- Example resistor R min R max P BRcont P BRmax 2) 3) 04S-... types Danotherm/Power- 050A-4 19.7 CBT-H 760 D HT 406 16R / R4-30B05 1) Frame size R0/R1 doesn't support brake resistor. 2) Braking cycle differs from that of the drive. Refer to brake resistor manufacturer’s documentation. 3) If brake resistors from other manufacturers are used, the characteristics must agree with the values in the table.
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.
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154 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...
Resistor braking 155 Mechanical and electrical installation of brake resistor 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.
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156 Resistor braking With these parameter settings, the drive generates a fault and coasts to a stop on brake resistor overtemperature.
The Safe torque off function 157 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.
158 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 –...
The Safe torque off function 159 Wiring For the electrical specifications of the STO connection, see the technical data of the control unit. ■ Connection principle Single ACH180 drive, internal power supply + 24 V DC SGND UDC+ UDC- Drive Control unit Control logic To motor...
160 The Safe torque off function Single ACH180 drive, external power supply 24 V DC + 24 V DC SGND UDC+ UDC- Drive Control unit Control logic To motor Activation switch...
The Safe torque off function 161 ■ Wiring examples Single ACH180 drive, internal power supply SGND Drive Safety PLC Safety relay Single ACH180 drive, external power supply 24 V DC SGND Drive Safety PLC Safety relay...
The Safe torque off function 163 Multiple ACH180 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.
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 •...
The Safe torque off function 165 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.
166 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.
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The Safe torque off function 167 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: •...
168 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.
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The Safe torque off function 169 • 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.
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 166). Use only spare parts approved by ABB. Record all maintenance and proof test activities in the machine logbook. ■ Competence...
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.
172 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.
174 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”...
The Safe torque off function 175 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...
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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.
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