ABB ACH180 Series Quick Installation And Start-Up Manual

—
ABB DRIVES FOR HVAC
ACH180 drives
Quick installation and start-up guide
Safety instructions
WARNING! Obey these instructions. If you ignore them, injury or death, or damage
to the equipment can occur. If you are not a qualified electrical professional, do
not do electrical installation or maintenance work.
•
Do not do work on the drive, motor cable, motor, or control cables when the drive is
connected to the input power. Before you start the work, isolate the drive from all
dangerous voltage sources and make sure that it is safe to start the work. Always wait for
5 minutes after disconnecting the input power to let the intermediate circuit capacitors
discharge.
•
Do not do work on the drive when a rotating permanent magnet motor is connected to it.
A rotating permanent magnet motor energizes the drive, including its input and output
terminals.
1. Unpack the delivery
Keep the drive in its package until you install it. After unpacking, protect the drive from dust,
debris and moisture.
Make sure that all of the items are present and that there are no signs of damage:
•
drive
•
installation accessories (mounting template, cable clamps, screws, etc.)
•
safety instructions
•
multilingual warning sticker sheet (residual voltage warning)
•
user interface guide (under the drive front cover)
•
quick installation and start-up guide.
2. Reform the capacitors
If the drive has not been powered up for a year or more, you must reform the DC link
capacitors. The manufacturing date is on the type designation label. Refer to
reforming instructions (3BFE64059629 [English]).
3. Select the cables and fuses
•
Select the power cables. Obey the local regulations.
•
Input power cable: ABB recommends to use symmetrical shielded cable (VFD cable)
for the best EMC performance.
•
Motor cable: Use symmetrical shielded cable (VFD cable) for the best EMC
performance. Symmetrical shielded cable also reduces bearing currents, wear, and
stress on motor insulation.
•
Power cable types: For IEC installations, use copper or aluminum cables (if
permitted). In North America, use only copper cables.
•
Current rating: max. load current.
•
Voltage rating: min. 600 V AC.
•
Temperature rating: For IEC installations, select a cable rated for at least 70 °C
(158 °F) maximum permissible temperature of conductor in continuous use. For
North America, select a cable rated for at least 75 °C (167 °F).
•
Size: Refer to Fuses and typical power cable sizes
Terminal data for the power cables for the maximum cable sizes.
•
Select the control cables. Use double-shielded twisted-pair cable for analog signals. Use
double-shielded or single-shielded cable for the digital, relay and I/O signals. Do not run
24 V and 115/230 V signals in the same cable.
•
Protect the drive and input power cable with the correct fuses. Refer to
power cable sizes.
4. Examine the installation site
The drive is intended for cabinet installation and has a degree of protection of IP20 / UL open
type as standard.
Examine the site where you will install the drive. Make sure that:
•
The installation site is sufficiently ventilated and hot air does not recirculate.
•
There is sufficient free space around the drive for cooling, maintenance, and operation.
Refer to Free space requirements.
•
The ambient conditions meet the specifications. Refer to
•
The installation surface is as close to vertical as possible and strong enough to support
the weight of the drive. Refer to Dimensions and weights.
•
The materials behind, above and below the drive are not flammable.
•
There are no sources of strong magnetic fields such as high-current single-core
conductors or contactor coils near the drive. A strong magnetic field can cause
interference or inaccuracy in the operation of the drive.
5. Install the drive
You can install the drive with screws, or to a DIN rail (top hat type, width × height = 35 mm ×
7.5 mm [1.4 in × 0.3 in]).
•
Install frame R0 drives vertically. R0 drives do not have a cooling fan.
•
You can install drives with frame sizes R1...R4 tilted by up to 90 degrees, from vertical to
fully horizontal orientation.
•
Do not install the drive upside down.
•
You can install several drives side by side.

To install the drive with screws
R0 R1
M1
M1
1. Make marks onto the surface for the
mounting holes. Use the mounting template
that was delivered with the drive.
2. Drill the holes for the mounting screws. If
necessary, install suitable plugs or anchors
into the holes.
3. Install the mounting screws into the holes.
Refer to Dimensions and weights for the
maximum screw diameter. Leave a gap
between the screw head and installation
surface.
4. Put the drive onto the mounting screws.
5. Tighten the mounting screws.

To install the drive to a DIN installation rail
DIN rail mounting kit is available for frames R0...R1 and R2. Refer to
guide (3AXD50000940615 [multilingual])
(3AXD50000940714 [multilingual])
Use the integrated lock to install frames R3 and R4 to a DIN installation rail:
1. Move the locking part to the left. If necessary, use a slotted screwdriver.
2. Push and hold the locking button down.
3. Put the top tabs of the drive onto the top edge of the DIN rail.
4. Put the drive against the bottom edge of the DIN rail.
5. Release the locking button.
6. Move the locking part to the right.
7. Make sure that the drive is correctly installed.
To move the drive, use a slotted screwdriver to open the locking part.
Note: For UL/CSA installations: Warning label 3AXD50001058098 (included in the delivery)
must be adhered near the drive and clearly visible.
6. Measure the insulation resistance
Drive: Do not do voltage tolerance or insulation resistance tests on the drive as testing can
damage the drive.
Input power cable: Before you connect the input power cable to the drive, measure its
insulation resistance according to local regulations.
Motor and motor cable:
1. Make sure that the motor cable is connected to the motor and disconnected from the
drive output terminals T1/U, T2/V and T3/W.
2. Use a voltage of 1000 V DC to measure the
insulation resistance between each phase
conductor and the protective earth conductor. The
insulation resistance of an ABB motor must be
more than 100 Mohm (at 25 °C [77 °F]). For the
insulation resistance of other motors, refer to the
manufacturer's instructions.
Note: Moisture inside the motor reduces the
insulation resistance. If you think that there is
moisture in the motor, dry the motor and do the
measurement again.
7. Make sure that the drive is compatible with the grounding
system
You can install all drive types to a symmetrically grounded TN-S system (center-grounded
wye). The drive is delivered with the EMC and VAR screws installed. The material of the screws
(plastic or metal) depends on the product variant. The table shows when to remove the metal
EMC screw (disconnect the internal EMC filter) or metal VAR screw (disconnect the varistor
circuit).
Screw Factory default
label screw material
EMC Metal
Plastic
VAR Metal
Plastic
1) Can install the metal screw (included in the drive delivery) to connect the internal EMC filter.
8. Connect the power cables

Connection diagram (shielded cables)
ACH180
L1
PE
3
Capacitor
2
PE L1
(L)
1. Disconnecting device.
2. Two protective earth (ground) conductors. Drive safety standard IEC/EN61800-5-1
requires two PE conductors, if the cross-sectional area of the PE conductor is less than
2
10 mm Cu or 16 mm
fourth conductor.
3. Use a separate grounding cable or a cable with a separate PE conductor for the line side,
if the conductivity of the fourth conductor or shield does not meet the requirements for
for the typical cable sizes and to
the PE conductor.
4. Use a separate grounding cable if the conductivity of the shield is not sufficient, or if
there is no symmetrically constructed PE conductor in the cable.
5. 360° grounding of the cable shield is required for the motor cable and brake resistor
cable (if used). It is also recommended for the input power cable.
Fuses and typical
6. Brake resistor and resistor cable (optional, for frames R2...R4 only).

Connection procedure (shielded cables)
For the tightening torques, refer to
1. Attach the residual voltage warning sticker in the local
language to the drive.
2. Install the grounding plate.
3. Strip the motor cable.
4. Ground the motor cable shield under the grounding
clamp for 360° grounding.
Ambient conditions.
5. Twist the motor cable shield into a bundle and mark it
with yellow-green insulation tape. Install a cable lug
and connect the shield to the grounding terminal.
6. Connect the phase conductors of the motor cable to
terminals T1/U, T2/V and T3/W.
7. Frames R2...R4: If you use a brake resistor, connect
the resistor cable to terminals R- and UDC+. Use a
shielded cable and ground the shield under the
grounding clamp for 360° grounding.
8. Frames R2...R4: Make sure that the R- and UDC+
terminal screws are tightened. Do this step also if you
do not connect cables to the terminals.
9. Strip the input power cable.
10. If the input power cable has a shield, twist the shield
into a bundle, mark it and connect it to the grounding
terminal.
11. Connect the PE conductor of the input power cable to
R2...R4
the grounding terminal. If necessary, use a second PE
conductor.
12. 3-phase drives: Connect the phase conductors of the
input power cable to terminals L1, L2 and L3.
1-phase drives: Connect the phase and neutral
conductors to terminals L and N.
13. Mechanically attach the cables on the outside of the
M1
drive.
9. Connect the control cables

Connection procedure
Do the connections according to the default control connections of the HVAC default macro.
Keep the signal wire pairs twisted as near to the terminals as possible to prevent inductive
coupling. The tightening torque for the terminal connections is 0.5 ...0.6 N·m (4.4 ...5.3 lbf·in).
1. Remove the front cover.
BDRK-01 Installation
for R0...R1 and BDRK-02 Installation guide
for R2.
ohm
U1-PE, V1-PE, W1-PE
Grounding systems
Symmetrically Corner-grounded
grounded TN-S delta, midpoint- (ungrounded or
systems (center- grounded delta high-resistance
grounded wye) and TT systems
Do not remove Remove
1)
Do not remove Do not remove Do not remove
Do not remove Do not remove
Do not remove Do not remove Do not remove
T1/ T2/ T3/
R+
L2 L3 R- UDC-
UDC+ U V W
5
6
V1
U1 W1
M PE
1
3
L2 L3
(N)
2
Al. For example, you can use the cable shield in addition to the
Terminal data for the power cables.
R2...R4
Bottom in
2. Install the grounding plate.
3. Strip a part of the outer shield of the control cable for
grounding the shield.
4. Use a 360° grounding clamp to connect the outer
shield to the grounding plate.
5. Strip the control cable conductors. For stranded
(multi-wire) conductors, install ferrules at the bare
conductor ends.
6. Connect the conductors to the correct control
terminals. Insert the conductor into a push-in
terminal. To release, push the open/close button all
the way down firmly with a flathead screwdriver.
7. Connect the shields of the twisted pairs and
grounding wires to the SCREEN terminal.
8. Mechanically attach the control cables on the outside
of the drive.

Default I/O connections (HVAC default)
1...10 kohm
1)
1)
Max. 500 ohm
U1
M
V1
3~
W1
PE
IT systems
grounded)
Remove
Remove
1) Reference signal (0...10 V)

Embedded fieldbus connection
Connect the fieldbus to the EIA-485 Modbus RTU terminal which is on the front of the drive.
To configure Modbus RTU communication with the embedded fieldbus:
1. Connect the fieldbus cables and the necessary I/O signals.
2. Use the jumpers to set the termination and bias settings.
3. Power up the drive and set the necessary parameters.
A connection example is shown below.
3)
4
-
G R +
1)
Termination ON
Termination OFF
J1
Modbus mode
J2
Automation
Drive
controller
1) The devices at the ends of the fieldbus must have termination set to ON. All other devices
must have termination set to OFF.
2) Attach the cable shields together at each drive, but do not connect them to the drive.
Connect the shields only to the grounding terminal in the automation controller.
3) Connect the DGND conductor to the signal ground reference terminal in the automation
controller.
10. Start up the drive
WARNING! Before you start up the drive, make sure that the installation is
completed. Make sure also that it is safe to start the motor. Disconnect the motor
from other machinery, if there is a risk of damage or injury.
For information on the user interface, refer to the
(3AXD50000955909 [English]).
1. Power up the drive.
2. Set the unit (international or US).
3. Go to Motor data view.
4. Set the motor type:
• AsynM: Asynchronous motor
• PMSM: Permanent magnet synchronous motor
• EC Ti: Ferrite assisted synchronous reluctance motor.
5. Set the motor control mode:
Scalar: Frequency reference. Do not use this mode for
permanent magnet synchronous motors.
Use this mode when:
• The number of motors can change.
• The nominal motor current is less than 20% of the nominal
drive current.
Vector: Speed reference. This is suitable for most cases. The
drive does an automatic standstill ID run when the drive is
started for the first time.
6. Set the nominal motor values.
7. Press the Auto/Hand key to start the motor and check the
direction of rotation. If the direction is incorrect, you can:
• change the Motor phase order setting, or
• change the phase order of the motor cable.
8. Go to Motor control view.
9. Set the start and stop mode.
R0...R1
Top in
10. Set the acceleration and deceleration times.
11. Set the maximum and minimum frequencies (or speeds).
12. Tune the drive parameters to the application. You can also use the Assistant control panel
(ACH-AP-...) or the Drive Composer PC tool.
Warnings and faults
WARNING! If you activate the automatic fault reset or automatic restart functions
of the drive control program, make sure that no dangerous situations can occur.
These functions reset the drive automatically and continue operation after a fault
or supply break. If these functions are activated, the installation must be clearly
marked as defined in IEC/EN 61800-5-1, subclause 6.5.3, for example, "THIS
MACHINE STARTS AUTOMATICALLY".
Code Description
2310 Overcurrent. The output current is more than the internal limit. This can be
caused by an earth fault or phase loss.
2330 Earth leakage. A load unbalance that is typically caused by an earth fault in the
motor or the motor cable.
2340 Short circuit. There is a short circuit in the motor or the motor cable.
3130 Input phase loss. The intermediate DC circuit voltage oscillates.
3181 Wiring or earth fault. The input and motor cable connections are incorrect.
3210 DC link overvoltage. There is an overvoltage in the intermediate DC circuit.
3220 DC link undervoltage. There is an undervoltage in the intermediate DC circuit.
3381 Output phase loss. All three phases are not connected to the motor.
5091 Safe torque off. The Safe torque off (STO) function is on.
6681 EFB communication loss. Break in embedded fieldbus communication.
AFF6 Identification run. The motor ID run occurs at the next start.
FA81 Safe torque off 1: Safe torque off circuit 1 is broken.
FA82 Safe torque off 2: Safe torque off circuit 2 is broken.
Digital I/O
21 24 V Aux. +24 V DC, max 200 mA
22 DGND Aux. voltage output common
8 DI1 Stop (0) / Start (1)
9 DI2 Not configured
10 DI3 Constant speed selection
11 DI4 Start interlock 1 (1 = allow start)
12 DCOM Digital input common
18 DO Running
19 DO COM Digital output common
20 DO SRC Digital output auxiliary voltage
Analog I/O
14 AI1/DI5 Speed reference (0...10V)
13 AGND Analog input circuit common
15 AI2 Not used
16 AGND Analog output circuit common
17 AO Output frequency (0...20mA)
23 10V Ref. voltage +10 V DC
24 SCREEN Signal cable shield (screen)
Safe torque off (STO) (only on ACH180-04S)
1 S+ Safe torque off (STO). Both circuits
must be closed for the drive to start.
2 SGND
The drawing shows the simplified
3 S1
connection of a safety circuit through
safety contacts. If STO is not used,
4 S2
leave the factory-installed jumpers in
place. See also section Safe torque
off (STO).
Relay output
5 NC
Damper control
6 COM
7 NO
EIA-485 Modbus RTU
25 B+
26 A-
Embedded Modbus RTU (EIA-485)
27 DGND
28 SHIELD
Jumper
J1 Termination Modbus termination selection
2)
1)
Termination OFF Termination ON
J1
J1
Modbus mode
Modbus mode
J2 J2
Drive
Drive
ACH180 User interface guide
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4 5
6
7
8
9
10
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