Upgrade from ABB ACS320 to ACH180 � Step-by-Step Guide

ABB ACH180 dedicated HVAC variable frequency drives.

Upgrading from the ACS320 to the new ACH180 HVAC VFD ensures continued efficiency and reliability in your HVAC applications. This guide will walk you through the replacement process, helping you select the appropriate ACH180 model, manage wiring and parameter setup, and address key considerations to ensure a smooth transition. 

Step 1: Selecting the Correct ACH180 HVAC VFD

Before replacing your ACS320 with the ACH180, proper sizing is crucial. Compare the power range, mounting methods, and dimensions of both drives to select the best-fit ACH180 model. 

Checklist for Proper Drive Selection:

• Motor Ratings – Record the nominal power, current, and voltage from your motor nameplate for use in the ratings comparison tables. 
• Speed/Frequency Command Type – Determine if the signal is 0-10 VDC, 4-20 mA, via communications, or another type. 
• Start/Stop Command Type – Identify whether the signal is controlled via relay closure, communications, or another method. 
• Control Panel and Keypad – If you're using a door-mounted control panel, ensure you select the appropriate replacement kit for the keypad. 
• Communication Protocols – If your system communicates via Modbus RTU, document all relevant communication settings. 
• I/O Requirements – Check for additional control or reference sources that require extra I/O options. 
• Pump Fan Control (PFC) Consideration– The ACH180 does not support PFC applications. If your system requires PFC, consider upgrading to the ACH580. 
• New Features in ACH180 – The ACH180 introduces additional switching frequencies and Safe Torque Off (STO) for enhanced safety and performance. 

Step 2: Wiring and Parameter Setup

Once you've selected the appropriate ACH180 model, carefully review electrical specifications and basic parameter settings for optimal installation. 

Power Wiring 

• R0 and R1 ACH180 drives use a top in, bottom out wiring design (See Figure 1). Check if your existing wire lengths are sufficient or if adjustments are needed. 
• R2, R3, and R4 ACH180 drives use a bottom in, bottom out wiring setup (See Figure 2). 

Control Wiring 

• ACH180 utilizes spring cage terminals (26-16 AWG) (See Figure 3). If connecting multiple conductors to a single terminal, consider alternative wiring methods. 
• ACH180 lacks expandable I/O (e.g., MREL-01). If additional relay outputs are needed, consider ACH580. 

Protection and Safety 

• To achieve 100 kA SCCR protection, use fuses or ABB Type E manual motor protectors (MMP) such as MS132 and MS165-xx. 
• The ACH180 supports Modbus backwards compatibility, making the transition from ACS320 easier. 

External Line Reactors 

• For input currents requiring external line reactors, refer to the ACH180 hardware manual, under the UL(NEC) ratings table's "Input with choke" column. 

Figure 1: ABB ACH180 dedicated HVAC variable frequency drive.  R0...R1 Top in wiring design.  
Image Source: https://search.abb.com/library/Download.aspx?DocumentID=3AXD50000955886&LanguageCode=en&DocumentPartId=1&Action=Launch

Figure 2: ABB ACH180 dedicated HVAC variable frequency drive.  R2...R4 bottom in wiring design.   Image Source: https://search.abb.com/library/Download.aspx?DocumentID=3AXD50000955886&LanguageCode=en&DocumentPartId=1&Action=Launch

Figure 3: ABB ACH180 dedicated HVAC variable frequency drive terminal data for the control cables.
Image Source:https://search.abb.com/library/Download.aspx?DocumentID=3AXD50000955862&LanguageCode=en&DocumentPartId=1&Action=Launch

Step 3: Programming and Commissioning

Once the ACH180 is wired and powered up, programming and commissioning are essential to ensure proper operation. 

Initial Setup and Alarm Resolution 

• Upon power-up, the ACH180 will, by default, set DI4 as Start Interlock 1. 
• This will trigger an "AFEE" alarm code if no interlock is used. 
• If the interlock is not needed, go to Parameter 20.41 and select the correct DI function. 

Commissioning Methods

• There are several ways to set up the ACH180 parameters for commissioning: 
• Graphical Interface - Use the built-in quick guide for simple setup. 
• Remote Control Panel - Program drive parameters using an external remote-control panel. 
• Drive Composer Pro - Use ABB's Drive Composer Pro software: 
  
  • For powered connections, use the BCBL cable. 
  • For unpowered programming, use the Cold Configurator with the necessary accessories. 

Control Panel and Communication Considerations

• Connect a control panel to the RJ45 control panel port to access standard parameter views. 
• If the ACH180's serial number contains an "A" in the center, it can only communicate with either the embedded serial bus or the remote panel, not both simultaneously. 
  
  • See the hardware manual for proper jumper settings to switch from the default setup and enable the embedded field bus.
• ACH180 units with serial numbers "B" or later can communicate with both the embedded serial bus and remote panels simultaneously. 

Final Preparation Before Installation

Before beginning the installation, ensure all control and parameter settings from the ACS320 are recorded. If the ACS320 cannot be powered, gather all non-parameter-related data for reference. 

Critical Pre-Installation Steps

1. Review power and control wiring lengths. 
2. Confirm the mounting requirements and dimensions for compatibility. 
3. Ensure the ACH180 meets your system's automation and communication needs. 
4. Document analog/relay outputs from the ACS320 and verify their landing points. 

By following this guide, you can streamline the replacement process and maximize the benefits of upgrading to the ACH180 HVACR drive. If your application requires expanded I/O, PFC capabilities, or additional features, consider transitioning to the ACH580 for advanced functionality. 

For more details, refer to the ACH180 user manual or contact Galco's technical support for assistance in selecting and installing the right ABB drive for your system.