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User`s Manual ACS 400 AC Drives for Speed Control of 3 to 40 Hp

1. LOSS Code Description 1201 CONST SPEED SEL This parameter defines which digital inputs are used to select Constant Speeds O NOT SEL Constant speed function disabled 1 5 DI1 DI5 Constant Speed 1 is selected with digital inputs DI1 DI5 Digital input activated Constant Speed 1 activated 6 DI1 2 Three Constant Speeds 1 3 are selected with two digital inputs Constant Speed selection with digital inputs DI 2 Table 8 Constant Speed selection with digital inputs DIH 2 DI 1 DI 2 Function 0 0 No constant speed 1 0 Constant speed 1 1202 0 1 Constant speed 2 1203 1 1 Constant speed 3 1204 0 DI deactivated 1 DI activated 7 DI3 4 Three Constant Speeds 1 3 are selected with two digital inputs as in DI1 2 8 DI4 5 Three Constant Speeds 1 3 are selected with two digital inputs as in DI1 2 9 DI1 2 3 Seven Constant Speeds 1 7 are selected with three digital inputs Table 9 Constant Speed selection with digital inputs DI 2 3 DI1 DI2 DI3 Function 0 0 0 No constant speed 1 0 0 Constant speed 1 1202 0 1 0 Constant speed 2 1203 1 1 0 Constant speed 3 1204 0 0 1 Constant speed 4 1205 1 0 1 Constant speed 5 1206 0 1 1 Constant speed 6 1207 1 1 1 Constant speed 7 1208 0 DI deactivated 1 DI activated 10 DI3 4 5 Seven Constant Speeds 1 7 are selected with three digital inputs as in DI1 2 3
2. 131 Activating Modbus Protocol 132 Communication settings 133 Control Locations 134 Output signal source selection 135 Diagnostic Counters 137 COMMUNICATION esa ae NENNEN k anja 138 Introduction to Modbus 138 Register Read and Write 138 Register Mapping 139 Exception Codes ite cor aga decka idu Pedi hace kla daa 140 Function Codes oa in A AJ RR ia wea bec 140 The Control Word and the Status Word 141 References tice ead a at a ii 144 Actual Valiles cents taba 146 Fault and Alarm Status 148 Appendix A 225 aka geodet es 151 Local Control vs Remote Control 151 Local Control caia a id hale Na 151 Remote Control 152 Internal Signal Connections for the Macros 154 Appendix Base ak aaa nd NEE RECH a 157 ACS 400 Pump and Fan Control PFC Macro 157 INTTOQUCHON ica nit eo ec EEN 157 ACS 400 User s Manual vii PID Controller eiii adds ELE ua daa bota 159 Relay Outputs xe ee keene ee E Ga MR MERE 160 Adding More I O to ACS 400 160 Setting up NDIO modules 160 APPEN
3. M5 MOUNTING HARDWARE 4 PLACES WALL OR FLANGE ES 3 o amp 2 K gt E o re Rip R0 098 i f 6 5 0 256 NZ 3 155 1 6 104 149 1 5 868 107 1 4 215 TYP 65 1 2 561 59 1 2 325 925 0 20 984 3 PLACES 931 0 01 220 3 PLACES T FTSE lt m 8 s Kai m ERE ha ER Ri 1 TYP 7 119 2 4 694 L 172 ACS 400 User s Manual ACS 400 NEMA Type 12 amp 4 R3 Frame Size 279 6 11 007 o R3 3mm RO 128 e 132 9 5 232 S 11 0mm 0 433 126 0 4 961 2 TYP i d 1 R R6 5mm R0 256 S M6 MOUNTING rj HARDWARE 6 PLACES 3 5 WALL OR FLANGE X RM 5s i Em o O no ho 528 L P S to amp 2 8 o S S ej a A y 8 R3 5 R0 138 10 5 0 413 78 1 3 075 63 1 2 485 925 1 000 NOTES 945 1 772 1 DIMENSIONS MILLIMETERS INCHES 2 WEIGHT 18 5 kg 40 8 Ibs 3 USINY CONDUIT z ry A o i E GER n o NE AAA l d Ul oe ACS 400 User s Manual 173 ACS 400 NEMA Type 12 amp 4 R4 Frame Size p 309 9 12 201 166 2 6 544 H 159 0 6 261 4 TYP 62 6 2 466 E 5 8 E L3 32 e gs 2 Ba 5c y E oz o i ah 2 y zis g 8 SR 0 28 o 5 o t NOTES 1 DIMENSIONS MILLIMETERS INCHES
4. ACS 400 User s Manual 77 Group 11 Reference Select Reference commands can be given from the control panel or from two external locations The selection between the two external locations is made with parameter 1102 EXT1 EXT2 SEL For more information on control locations refer to Appendix A on page 151 Code Description 1101 KEYPAD REF SEL Selection of active control panel reference in local control mode 1 REF1 Hz Control panel reference is given in Hz 2 REF2 Control panel reference is given as a percentage 1102 EXT1 EXT2 SEL Sets the input used for selecting the external control location or fixes it to EXT1 or EXT2 The external control location of both Start Stop Direction commands and reference is determined by this parameter 1 5 DH DI5 External control location 1 or 2 is selected according to the state of the selected digital input DI1 DI5 where deactivated EXT1 and activated EXT2 6 EXT1 External control location 1 ExT1 is selected The control signal sources for EXT1 are defined with parameter 1001 Start Stop Direction commands and parameter 1103 reference 7 lt EXT2 External control location 2 EXT2 is selected The control signal sources for EXT2 are defined with parameter 1002 Start Stop Direction commands and parameter 1106 reference 8 COMM External control location 1 or 2 is chosen through serial communication 78
5. L Motor Check for motor compatibility The motor must be a three phase induction motor with input voltage from 208 to 240 V for ACS401 XXXX 2 X or 380 to 480 V for ACS401 XXXX 3 X and fy either 50 Hz or 60 Hz The motor nominal current must be less than the nominal output current of the ACS 400 See Sections G and T A Warning Ensure the motor is compatible for use with the ACS 400 The ACS 400 must be installed by a competent person If in doubt contact your local ABB sales or service office 16 ACS 400 User s Manual M Connection Examples DI configuration for NPN connection sink ACS 400 X1 SCR Ali AGND 10V m a 0 20 mA Al2 Ground the cable screen on the sourcing end AGND AO1 AGND 24V DCOM1 DH S DIS DIS DI4 DI5 DCOM2 J1 Analog inputs Jan 0 10 V Al2 0 4 20 mA RO1C ROIA pP RO1B RO2C RO2A RO2B p RS485 Multidrop application Other Modbus Devices DI configuration fo r PNP connection source ACS 400 X1 SCR AH AGND 10V Al2 AGND AO1 o N o n la o o a AGND s 24V 12 DI2 10 DCOM1 11 DH
6. Nominal motor Py kw Normal Duty Hp Input Current ly 3 JA Output Current loy A Max Output Current JA loNmax Nominal motor Pw kW 1 5 Heavy Duty Hp 2 Input current wun 3 JA TA Output Current lanup JA 7 5 Max Output current A TES loNHDmax Output Voltage U gt V 0 U Switching Frequency kHz 4 standard 8 Low Noise Protection Limits Overcurrent peak A 31 4 443 698 101 2 128 7 142 3 196 0 Overvoltage Running VDC 421 VDC 1 3 Upg Nominal 240 VAC input Start Inhibit VDC 1 18 Upc Nominal 240 VAC Undervoltage Running VDC 182 VDC 0 65 Upc Nominal 208 VAC Input Start Inhibit VDC 0 85 Upc Nominal Q 208 VAC Overtemperature C F 195 C 203 F Heat Sink Max Wire Sizes and Screw Torque of Connectors Power Terminals mm 10 AWG6 10 AWG6 35 AWG2 35 AWG2 Stranded Nm Stranded Stranded Stranded Torgue 3 2 3 7 Nm lb in Torque 1 3 Torque 1 3 Torque 3 2 28 32 Ib in d 15Nm 11 1 5Nm 13 3 7 Nm 28 13 Ib in 16 bim 32 Ib in Control Terminals 0 5 1 5 AWG22 AWG16 Torque 0 4 Nm Line Fuse 3 16 25 25 35 50 80 80 100 Bussmann Type KTK 15 KTK 25 KTK 25 KTK 35 JJS 50 JJS 80 JJS 80 JJS 100 Power Losses Power Circuit 60 Control Circuit 6 ACS 400 User s Manual 21 400V Series 3 Input 380 480V ACS401x
7. Erroneous Operation Due to Noise Possible control signals to gate drive board are faulty Replace the drive Decrease to proper voltage range With drive in stopped condition increase deceleration time by changing parameter 2203 or 2205 Does Overvoltage Still Occur During Deceleration YES Add dynamic braking option or replace drive with one of larger capacity Is Dynamic Braking Installed NO YES Check load inertia requirements ACS 400 User s Manual 43 Overcurrent Fault Indication With drive in stopped condition change YES acceleration time by changing parameter 2202 or 2204 if fault occurs only during acceleration Otherwise reduce load Does Output Current Exceed 150 of Rating Machine Jammed Or Motor Failure YES Clear jam or replace motor YES NO With drive in stopped condition increase acceleration time by changing parameter 2202 or 2204 Check Power Jransistors Are The Damaged Replace drive YES Does Fault Still Occur YES gt Decrease load inertia NO Remove noise sources Connect surge suppressors across relay and magnetic Rewire to eliminate motor full Erroneous Motor Started voltage starting contactar eol YES Operation Due to NO By Contacts Betwee YES gt Pepi a na nalof Provide line filter to remove Noise Drive and eplace drive with one o noise
8. 1003 DIRECTION 3 REQUEST 1601 RUN ENABLE O NOT SEL 1102 EXT1 EXT2 SEL 6 EXT1 1604 FAULT RESET SEL O KEYPAD 1103 EXT REF1 SELECT 1 A11 2008 MAXIMUM FREQ 60 Hz 1105 EXT REF1 MAX 60 Hz 2105 PREMAGN SEL O NOT SEL 1106 EXT REF2 SELECT O KEYPAD 2201 ACC DEC 1 2 SEL O NOT SEL 1201 CONST SPEED SEL 8 DI4 5 4001 PID GAIN 1 0 1401 RELAY OUTPUT 1 3 FAULT 1 4002 PID INTEG TIME 60s ACS 400 User s Manual 57 Application Macro Alternate This macro offers an I O configuration that is adopted to a sequence of DI control signals used when alternating the direction of rotation of the drive The value of parameter 9902 is 3 ALTERNATE Input signals Output signals Jumper Setting Start stop and direction An output AO Frequency DI1 2 Al 0 10 V Analog reference Al1 Relay output 1 Fault Al2 0 4 20 mA e Preset speed selection DI3 4 e Relay output 2 Running Ramp pair 1 2 selection DIS TH SCR TI SEAN External Reference 1 0 10 V lt gt 0 50 Hz ah RHO Reference voltage 10 VDC S AE Not used 6 AGND aris Output frequency 0 20 mA lt gt 0 50 Hz 9 24V 24 VDC 10 DCOM1 11 DI 1 Start fwd If DI1 state is the same as DI2 drive stops 12 DI2 Start rever
9. 13 DIS 14 DI4 Gs DIS 15 DCOM2 J1 Analog inputs E E JAM 0 10 V ACS 400 X3 SCR AGND a A in gt SCR 17 RO1C 18 ROTA M 19 RO1B j 20 RO2C 21 IRO2A d 22 RO2B J2 RS485 interf ACS 400 User s Manual 17 N Replacing the Cover Do not turn the power on before replacing the front cover Replacing the front cover for IP21 NEMA Type 1 1 First locate the bottom mounting clips 2 Click the retaining lever to its place 3 Replace the control panel Replacing the front cover to IP 21 NEMA Type 1 units from size ACS401x0163x and up 1 Hook the bottom end fingers of the lower part of the front cover Click the retaining lever to its place Hook the bottom end fingers Click the retaining levers into place a A o I Replace the control panel if available Replacing the front cover for IP54 NEMA Type 12 1 Replace the control panel 2 Replace the front cover 3 Carefully tighten the screws O Applying Power When power is applied to the ACS 400 the green LED comes on Note Before increasing motor speed check that the motor is running in desired direction P Environmental Information The package is made of corrugated cardboard and can be recycled 18 ACS 400 User s Manual Q Protection Features
10. ACS 400 User s Manual Code Description 0118 An Relative value of analog input 1 displayed in 0119 AI2 Relative value of analog input 2 displayed in 0121 DI5 amp RELAYS Status of digital input 5 and relay outputs 1 indicates that the relay is energized and 0 indicates that the relay is de energized ACS100 PAN IM ACS PAN I LII 000000101BIN DI5 Relay 2 status Relay 1 status 0122 AO Value of analog output signal in milliamperes 0124 ACTUAL VALUE 1 PID PFC controller actual value 1 ACT1 displayed in percent 0125 ACTUAL VALUE 2 PID PFC controller actual value 2 ACT2 displayed in percent 0126 CONTROL DEV Displays the difference between the reference value and the actual value of the PID PFC controller 0127 PID ACT VALUE Feedback signal actual value for PID PFC controller 0128 LAST FAULT Last recorded fault O no fault See Diagnostics on page 35 Can be cleared with the control panel by pressing UP and DOWN buttons simultaneously when in parameter set mode 0129 PREVIOUS FAULT Previous recorded fault See Diagnostics on page 35 Can be cleared with the control panel by pressing UP and DOWN buttons simultaneously when in parameter set mode 0130 OLDEST FAULT Oldest recorded fault See Diagnostics on page 35 Can be cleared with the control panel by pressing UP and DOWN buttons
11. Start stop DI1 5 An output AO Frequency Analog reference Al1 Relay output 1 Fault d Al1 0 10 V Actual value Al2 Relay output 2 Running AI2 0 4 20 mA Control location selection DI2 Constant speed DI3 Run enable DI4 1 SCR LO 2 AH EXT1 Manual or EXT2 PID reference 0 10 V 3 AGND 4 10V Reference voltage 10 VDC 5 AI2 Actual signal 0 20 mA PID 6 AGND G 7 AO1 Output frequency 0 20 mA lt gt 0 50 Hz 8 AGND N 9 24V 24 VDC 10 DCOM1 11 DI 1 Start Stop Activate to start ACS 400 Manual 12 DI2 EXT1 EXT2 Selection Activate to select PID control 13 DI 3 Constant speed 1 not used if PID control 14 DI4 Run enable deactivation always stops ACS 400 15 DI 5 Start Stop Activate to start ACS 400 PID 16 DCOM2 17 RO1C Relay output 1 programmable 18 ROTA gt Default operation Fault gt 17 connected to 18 19 ROTB 20 RO2C Relay output 2 programmable 21 ROZA Default operation Running gt 20 connected to 22 22 RO2B Note Constant speed is not considered while in PID control PID Note Parameter 2107 START INHIBIT should be 0 OFF PID control parameters group 40 do not belong to the Basic parameter set PID Control parameter values 1001 EXT 1 COMMANDS 1402 R
12. The general rule for cable screen effectiveness is the better and tighter the screen of the cable the lower the radiated emission level Example of an effective construction is presented in Figure 68 Braided metallic screen Inner insulator Insulation jacket Figure 68 Effective motor cable screen e g Olflex Servo FD 780 CP Lappkabel or MCCMK NK Cables Clamp the cable shield into the gland plate at the converter end and twist the cable screen wires together into a bundle not longer than five times its width and connect it to the terminal marked L at the bottom right hand corner of the converter if you are using cable without a separate PE conductor At the motor end the motor cable screen must be earthed 360 degrees with an EMC cable gland e g ZEMREX SCG Screened cable glands or the screen wires must be twisted together into a bundle not longer than five times its width and connected to the PE terminal of the motor ACS 400 User s Manual 163 Control Cables Control cables must be multi core cables with a braided copper wire screen The screen must be twisted together into a bundle not longer than five times its width and connected to terminal X1 1 digital and analogue I O or X3 1 or X3 5 RS485 Route the control cables as far away as possible from the mains and motor cables at least 20 cm Where control cables must cross power cables make sure they are at an angle as near 90 degrees as
13. 1 STD MODBUS Controlling commands can be received through Channel 1 standard Modbus protocol 2 DDCS Controlling commands can be received through the DDCS link 114 ACS 400 User s Manual Code Description 5007 DDCS BUS MODE Sets the operation mode of the DDCS link 1 FIELDBUS Fieldbus adapter is used in DDCS link The ACS 400 acts as the slave station on the DDCS link 2 10 EXTENSION Input output extension module type name NDIO is used on DDCS link The ACS 400 acts as the master station on the DDCS link and is capable of controlling the digital inputs and outputs of the extension module Note Value 2 IO EXTENSION should be used only when the PFC Pump Fan Control macro is selected 5008 DDCS LINK CTRL Controls the light intensity in the DDCS link The higher the value the higher the intensity 5009 IDDCS HW CONFIG HW configuration of the DDCS link 0 STAR Star configuration DDCS regeneration is off 1 RING DDCS link forms an optical ring DDCS regeneration is on ACS 400 User s Manual 115 Group 51 Ext Comm Module Parameters of this group need to be adjusted only when an external fieldbus communication module is installed Refer to communication module documentation for more information on these parameters Code Description 5101 FIELDBUSPAR 1 Parameter 1 of communication module on the DDCS link Value reflects the type of the connected communication
14. 8120 INTERLOCKS 0 6 1 4 DI4 Y 8121 REG BYPASS CTRL 0 1 1 O NO 8122 PFC START DELAY 0 10s 0 01 s 0 5s The maximum factor depending on the type of the frequency converter at 4 kHz switching frequency 72 ACS 400 User s Manual Group 99 Start up Data The Start up Data parameters are a special set of parameters for setting up the ACS 400 and for entering motor information Code Description 9901 LANGUAGE Language selection for the ACS PAN A control panel 0 ENGLISH 3 ITALIAN 6 DUTCH 9 FINNISH 12 reserved 1 ENGLISH AM 4 SPANISH 7 FRENCH 10 SWEDISH 2 GERMAN 5 PORTUGUESE 8 DANISH 11 RUSSIAN 9902 APPLIC MACRO Application macro selection This parameter is used to select the Application Macro which will configure the ACS 400 for a particular application Refer to Application Macros on page 53 for a list and description of available Application Macros 0 FACTORY 2 3 WIRE 4 MOTOR POT 6 PID CONTROL 8 PFC CONTROL 1 ABB STANDARD 3 ALTERNATE 5 HAND AUTO 7 PREMAGN 9905 MOTOR NOM VOLT Nominal motor voltage from motor rating plate This parameter sets the maximum output voltage supplied to the motor by the ACS 400 MOTOR NOM FREQ sets the frequency at which output voltage is equal to the MOTOR NOM VOLT The ACS 400 cannot supply the motor with a voltage greater than the input supply voltage See Figure 25 9906 MOTOR NOM C
15. Group 15 Analog Output Analog output is used to output the value of any parameter of the Operating Data group Group 1 as a current signal Output current minimum and maximum values are configurable as are the allowed minimum and maximum values for the observed parameter If analog output content maximum value parameter 1503 is set to less than minimum value parameter 1502 output current is inversely proportional to the value of the observed parameter Code Description 1501 AO CONTENT Content for analog output Number of any parameter of the Operating Data group Group 01 1502 AO CONTENT MIN Analog output content minimum Display depends on parameter 1501 1503 JAO CONTENT MAX Analog output content maximum Display depends on parameter 1501 1504 MINIMUM AO Minimum output current 1505 MAXIMUM AO Maximum output current 1506 AO FILTER Filter time constant for AO AO mA 1505 1504 p AO content 1504 e p AO content Figure 30 Analog output scaling ACS 400 User s Manual 85 Group 16 System Controls Code Description 1601 RUN ENABLE Selects the source of the run enable signal 0 NOT SEL The ACS 400 is ready to start without an external run enable signal 1 5 DM DI5 To activate the run enable signal the selected digital input must be activated If the voltage drops and deactivates the selected digital input
16. Two wire Start Stop Direction Start Stop is connected to digital input DI5 Direction is connected to digital input DIA DI4 deactivated Forward and DIA activated Reverse To control direction the value of parameter 1003 DIRECTION should be REQUEST 8 KEYPAD The Start Stop and Direction commands are given from the control panel when External control location 1 is active To control direction the value of parameter 1003 DIRECTION should be REQUEST 9 DHF 2R Start forward command is given when Dl1 activated and DI2 deactivated Start reverse command is given if DI1 is deactivated and DI2 is activated In other cases Stop command is given 10 COMM The Start Stop and Direction commands are given through serial communication Note In cases 1 3 6 direction is set with parameter 1003 DIRECTION Selecting value 3 REQUEST fixes the direction to Forward Note The stop signal must be activated before a Start command can be given 76 ACS 400 User s Manual 1002 EXT2 COMMANDS Defines the connections and the source of Start Stop and Direction commands for external control location 2 ExT2 Refer to parameter 1001 EXT1 COMMANDS above 1003 DIRECTION 1 FORWARD 2 REVERSE 3 REQUEST Rotation direction lock This parameter allows you to fix the direction of rotation of the motor to forward or reverse If you select 3 REQUEST the direction is set according to the given direction command
17. 1202 CONST SPEED 1 CONST SPEED 7 1208 Constant speeds 1 7 ACS 400 User s Manual 81 Group 13 Analog Inputs Code Description 1301 MINIMUM Al1 Relative minimum value of Al1 This value corresponds to the minimum reference set by parameter 1104 EXT REF1 MIN or 1107 EXT REF2 MIN Minimum Al cannot be greater than maximum Al See Figure 27 on page 80 1302 MAXIMUM Al Maximum value of Al1 This value corresponds to the maximum reference set by parameter 1105 EXT REF1 MAX or 1108 EXT REF2 MAX See Figure 27 on page 80 1303 FILTER Al1 Filter time constant for analog input Al1 As the analog input value changes 63 of the change takes place within the time specified by this parameter Note Even if you select 0 s for the filter time constant the signal is still filtered with a time constant of 25 ms due to the signal interface hardware This cannot be changed by any parameters Kai A Unfiltered signal 100 nj E Filtered signal t Time constant Figure 28 Filter time constant for analog input Al1 1304 MINIMUM Al2 Minimum value of Al2 This value corresponds to minimum reference set by parameter 1104 EXT REF1 MIN or 1107 EXT REF2 MIN Minimum Al cannot be greater than maximum Al 1305 MAXIMUM Al2 Maximum value of Al2 This value corresponds to maximum reference set by parameter 1105 EXT REF1 MAX or 1108 EXT REF2 MAX 1306 FILTER Al2 Filter time constant
18. 60 Hz ACS 400 User s Manual 49 Code Name User 9908 MOTOR NOM SPEED Nominal motor speed from motor name plate Range 0 3600 rpm Default 1750 rpm 9909 MOTOR NOM POWER Nominal motor power from name plate Range 0 1 134 1 HP Default 3 0 50 0 HP depending on the type of the frequency converter 9910 MOTOR COS PHI POWER FACTOR Nominal motor cos phi from name plate Range 0 50 0 99 Default 0 83 Group 01 OPERATING DATA 0128 LAST FAULT Last recorded fault 0 no fault See Diagnostics on page 35 Can be cleared with the control panel by pressing the UP and DOWN buttons simultaneously while in parameter set mode Group COMM 10 AND INPUTS 1003 DIRECTION Rotation direction lock 1 FORWARD 2 REVERSE 3 REQUEST If you select REQUEST the direction is set according to the given direction command Default 3 REQUEST or 1 FORWARD depending on the selected application macro Group 11 REFERENCE SELECT 1105 EXT REF1 MAX Maximum frequency reference in Hz Range 0 250 Hz Default value 60 Hz or 62 Hz depending on the selected application macro Group 12 CONSTANT SPEEDS 1202 CONST SPEED 1 Range for all constant speeds 0 250 0 Hz Default value 5 0 Hz 1203 CONST SPEED 2 Default value 10 0 Hz 1204 CONST SPEED 3 Default value 15 0 Hz 50 AC
19. c D3 Constant Speed selection cm DI4 Constant Speed selection DIS Premagnetise Activate to start premagnetising 16 DCOM2 17 RO1C Relay output 1 programmable 18 ROTA Default operation Fault gt 17 connected to 18 19 ROB 20 RO2C Relay output 2 programmable a ROZA E Default operation Running gt 20 connected to 22 Constant speed selection 0 open 1 connected DIS DIA Output Reference through Al1 Constant speed 1 1202 Constant speed 2 1203 Constant speed 3 1204 ol o Premagnetise parameter values 1001 EXT 1 COMMANDS Di1 2 1402 RELAY OUTPUT 2 2 RUN 1002 EXT 2 COMMANDS NOT SEL 1503 AO CONTENT MAX 60 Hz 1003 DIRECTION REQUEST 1601 RUN ENABLE O NOT SEL 1102 EXT1 EXT2 SEL EXT1 1604 FAULT RESET SEL O KEYPAD 1103 EXT REF1 SELECT Al 2008 MAXIMUM FREQ 60 Hz 1105 EXT REF1 MAX 2105 PREMAGN SEL 5 DI5 1106 EXT REF2 SELECT KEYPAD 2201 ACC DEC 1 2 sEL 0 NOT SEL 1201 CONST SPEED SEL 7 DI3 4 4001 PID GAIN 1 0 1401 RELAY OUTPUT 1 3 FAULT 1 4002 PID INTEG TIME 60 s 62 ACS 400 User s Manual Application Macro PFC Control This macro is intended for pump and fan control applications For more information see Appendix B on page 157 The value of parameter 9902 is 8 PFC CONTROL Input signals Start and sto p DI1 Analog reference Al1 Actual value Al2 Contr
20. s 40 S 50 S 60 J5 80 S 100 Power losses Power circuit 90 120 170 280 3380 450 560 660 900 1100 Control circuit 6 6 6 6 6 6 6 6 6 6 22 ACS 400 User s Manual A Power stages are designed for the continuous lo ynp current These values are valid when the altitude is less than 3300 ft 1000 m ASL See S Low noise setting programmable with optional control panel For ambient operating temperature 0 40 C derate Py and l to 80 Follow local rules for cable size see J Shielded motor cable is recommended Fuse type UL class CC or T Bussman Type KTK or JJS Use 60 C rated power cable 75 C if Tamo above 45 C Maximum cable lengths listed are based on capacitive coupling between motor wires and from motor wires to ground It may also be necessary to consider motor insulation requirements related to drive output dv dt xx U Product Conformity The ACS 400 complies with North American standard UL508C The ACS 400 400V Series complies with European requirements Low Voltage Directive 73 23 EEC with amendments EMC Directive 89 336 EEC with amendments Corresponding declarations and a list of main standards are available on request Note See ACS 400 EMC instructions An adjustable frequency drive and a Complete Drive Module CDM or a Basic Drive Module BDM as defined in IEC 61800 2 is not considered as a safety related device mentio
21. sticker in the language of your choice on the inside plastic shell as indicated above ACS 400 User s Manual 9 G Type Code and Model Designation The Type Code Label is attached to the right side of the unit cover on the heat sink ABB Industrial Products Made in USA U1 380 480 V For more information see ACS400 User s LISTED 45Y1 Type ACS401600432 u2 ee hn 6 2A t us Code 63996611 IND CONT EQ lou 6 6 A UH LI msn Ser no 1982800001 f2 0 250Hz EXCEPT 230 V Figure 12 ACS 400 type designation label ACS 401 6 004 3 2 AC Drive Product Type S Standard drive ACS 400 Product Family Input Bridge 0 6 pulse rectifier Enclosure Type 1 Wall mounted Operator Panel and Description 6 ACS PAN A operator panel US English documentation US conduit box Rated Output Power in kVA See ACS 400 rating tables Voltage Rating 2 208 240 V AC 3 380 480 V AC Enclosure Class 2 IP21 NEMA Type 1 5 IP54 NEMA Type 12 6 NEMA Type 4 Figure 13 Type code key A Serial number label is attached on upper part of the chokeplate between mounting holes Type ACS401600432 Code 63996611 Ser no 1982800001 Figure 14 Serial number label 10 ACS 400 User s Manual H Floating Network Make sure that no excessive emission is propagated to neighboring low voltage networks In some cases the natural suppression in transformer
22. the ACS 400 will coast to stop and not start until the run enable signal resumes 6 COMM The run enable signal is given through serial communication Command Word bit 3 1602 PARAMETER LOCK Parameter lock for control panel 0 LOCKED Parameter modification disabled 1 OPEN Panel operations are allowed and parameter modification is enabled 2 NOT SAVED Parameter values can be changed but they are not stored in permanent memory Note This parameter is not affected by macro selection Note Parameter writes through Standard Modbus or DDCS channels are not affected by this parameter 1604 FAULT RESET SEL Fault reset source Note Fault reset is always possible with control panel Note Option 6 START STOP should not be selected when start stop and direction commands are given through serial communication O KEYPAD Fault reset is executed from the control panel keypad 1 5 DH DIS Fault reset is executed from a digital input Reset is activated by deactivating the input 6 START STOP Fault reset is activated by Stop command 7 2 COMM Fault reset is executed through serial communication 1605 LOCAL LOCK Local lock When LOCAL LOCK is active 1 LOCKED panel cannot change to local mode 0 OPEN Control location can be changed from control panel 1 LOCKED Panel cannot change to local mode Note Option 1 LOCKED can be selected only in remote mode 86
23. upload Press 8 IHI ZEZA LIL ENTER MENU Note Drive must be stopped and in local control Parameter 1602 PARAMETER LOCK Must be set to 1 OPEN Copy parameters from drive to panel download Press amp cm zal trs RBS LL ENTER gt MENU Note Drive must be stopped and in local control Parameter 1602 PARAMETER LOCK must be set to 1 OPEN 32 ACS 400 User s Manual Diagnostic Displays When the red LED of the ACS 400 is on or blinking a fault is active The relevant fault message flashes in the panel display When the green LED of the ACS 400 is blinking an alarm is active The relevant alarm message is shown in the panel display Alarms 1 7 arise from button operation and green LED does not blink for them The alarm and fault messages disappear when MENU ENTER or the arrow buttons of control panel are pressed The message will reappear after a few seconds if the keypad is not touched and alarm or fault is still active OI IF HL IL fault code alarm code I el Figure 24 Fault and alarm messages Refer to the Diagnostics on page 35 section for a complete list of alarms and faults Resetting the Drive from the Control Panel To reset a fault when the red LED is on press the START STOP button Caution Resetting the fault may start the drive when in remote control To reset a fault when the red LED is blinking turn the power off
24. when displayed Refer to Figure 43 Value Display 0 125 1 125 2 1 25 3 0 125 Figure 43 Display with different decimal point locations when calculated value is 125 3406 P VAR 1 UNIT Process variable unit O NOTSEL 4 8 kh 12 mV 16 F 20 m h 24 GPM 28 MGD 1 A bes 9 C 13 kW 17 hp 21 dm s 25 PSI 29 inHg 2 V 6 h 10 Ib ft 14 W 18 MWh 22 bar 26 CFM 30 FPM 3 Hz 7 lt rpm 11 mA 15 kWh 19 m s 23 kPa 27 ft 31 Cst 104 ACS 400 User s Manual Code Description 3407 P VAR 2 SEL Selection of process variable 2 Number of any parameter of the group 1 OPERATING DATA 3408 P VAR 2 MULTIP Process variable 2 multiplier 3409 P VAR 2 DIVISOR Process variable 2 divider 3410 P VAR 2 SCALING Decimal point location of process variable 2 when displayed 3411 P VAR 2 UNIT Process variable 2 unit See parameter 3406 Example Assume that a two pole motor is directly connected to a roll 0 1 m in diameter and the line speed is to be displayed in m s The following settings are then needed 3401 DISPLAY SEL 2 PROCESS VAR 3402 P VAR 1 SEL 0103 OUTPUT FREQ 3406 P VAR 1 UNIT 19 m s Since 1 Hz output equals 1 rev s equals Pl 0 1 m s line speed or approximately 0 314 m s is output freq 314 1000 line speed m s Select 3403 P VAR 1 MULTIP 314 3404 P VAR 1 DIVISOR 1000 Since variable 0103 OUTPUT FREQ is
25. 0 1 s Os 3104 JAR OVERCURRENT 0 1 1 O DISABLE 3105 AR OVERVOLTAGE 0 1 1 O DISABLE 3106 AR UNDERVOLTAGE 0 1 1 O DISABLE 3107 JAR AI lt MIN 0 1 1 O DISABLE Group 32 SUPERVISION 3201 SUPERV 1 PARAM 102 137 1 103 3202 SUPERV 1 LIM LO 0 3203 SUPERV 1 LIM HI 0 3204 SUPERV 2 PARAM 102 137 1 103 3205 SUPERV 2 LIM LO 0 3206 SUPERV 2 LIM HI 0 Group 33 INFORMATION 3301 sW VERSION 0 0 0 0 f f f f 3302 TEST DATE yy ww Group 34 PROCESS VARIABLES 3401 DISPLAY SEL 1 2 1 1 STANDARD 3402 P VAR 1 SEL 102 137 1 104 3403 P VAR 1 MULTIP 1 9999 1 1 3404 P VAR 1 DIVISOR 1 9999 1 1 3405 P VAR 1 SCALING 0 3 1 1 3406 P VAR 1 UNIT 0 31 1 1 A 3407 P VAR 2 SEL 102 137 1 103 3408 P VAR 2 MULTIP 1 9999 1 1 3409 P VAR 2 DIVISOR 1 9999 1 1 3410 P VAR 2 SCALING 0 3 1 1 3411 P VAR 2 UNIT 0 31 1 3 Hz ACS 400 User s Manual 69 Code Name Range Resolution Default User S M Group 40 PID CONTROL 4001 PID GAIN 0 1 100 0 1 ii Y 4002 PID INTEG TIME 0 1 320 s 0 1 s ii Y 4003 PID DERIV TIME 0 10s 0 1s 0s 4004 PID DERIV FILTER 0 10s 0 1 s 1s 4005 ERROR VALUE INV 0 1 1 0 NO 4006 ACTUAL VAL SEL 1 9 1 1 AcT1 Y 4007 ACT1 INPUT SEL 1 2 1 2 A12 Y 4008 ACT2 INPUT SEL 1 2 1 2 A12 Y 4009 ACT MINIMUM 0 1000 1 0 4010 ACT1 MAXIM
26. 0043x 0053x 0113x 0303x 0413x 10 50 60Hz Frame Size Nominal Ratings See G Nominal Motor Py Hp Normal Duty nput Current wun A 6 2 Output Current loynp A 6 6 Max Output Current A 7 3 2NNDmax Nominal Motor Py 2 0 Heavy Duty nput current ly 4 7 Output Current low 4 9 Max Output current A 7 4 2Nmax Output Voltage Vo 0 V4 Switching Frequency 4 Standard 8 Low Noise Protection Limits Overcurrent peak A 20 3 27 5 37 48 64 76 Overvoltage Running 842 corresponds to 624 VAC input Start Inhibit 661 in input voltage range 380 415 VAC 765 in input voltage range 440 480 VAC Undervoltage Running VDC 333 corresponds to 247 VAC input Start Inhibit VDC 436 in input voltage range 380 415 VAC 505 in input voltage range 440 480 VAC Overtemperature C F 95 C 203 F Heat Sink Max Cable Length m ft 100 320 200 640 i 640 i 640 fgy 4kHz Max wire sizes and screw torque of connectors Power terminals mm Nm 10 AWG6 stranded 16 AWG4 35 AWG2 stranded lo in Torque 1 3 1 5 Nm 11 13 Ib in stranded Torque 3 2 3 7 Nm 28 Torque 32 Ib in 1 5 1 8 Nm 13 16 Ib in Control terminals 0 5 1 5 AWG22 AWG16 Torque 0 4 Nm Line fuse 3 10 15 15 20 30 40 50 60 80 100 Bussman Fuse Type KTK 10 KTK 15 KTK 15 KTK 20 krk 30
27. 2 WEIGHT 27 kg 59 5 Ibs 3 USINY CONDUIT R3 3mm R0 128 11 0mm 0 435 DNE R6 5mm R0 256 256 3 10 089 98 0 3 858 TYP M6 MOUNTING HARDWARE 6 PLACES WALL OR FLANGE L g E bd 3 3 amp amp de E s 3 d Mp g HL R3 5 R0 138 10 5 0 413 F 193 1 7 603 178 1 7 012 78 1 3 075 63 1 2 485 25 1 000 3 PLACES 045 a 3 PLACES 7 830 9 444 TYP 239 9 198 9 TYP L 194 4 17 6533 174 ACS 400 User s Manual AA EP ED PA ID ED 3AUA489002B5310 R0101 Rev B ACS400 US 04 Effective 01 16 01 Supercedes 2 1 99 ABB Automation Inc Drives amp Power Products Group 16250 W Glendale Drive New Berlin WI 53151 Telephone 262 785 8378 800 243 4384 Fax 262 780 5135
28. 8115 AUX MOT START D Sets the Start Delay for the auxiliary motors See parameter 8112 Low FREQ 1 and Figure 50 for more information 8116 AUX MOT STOP D Sets the Stop Delay for the auxiliary motors See parameter 8112 Low FREQ 1 for more information Frequency 8115 AUX MOT START D A a lt f max 8109 START FREQ 1 1 Hz Ei monde n ads adas in e crease during 8112LOWFREQ1 1 Hz jM K the Start Delay Mcrease during the Stop Delay min p Time 8116 AUX MOT STOP D Increasing flow Start Aux Motor 1 Decreasing Stop Start Y flow Stop Figure 50 Start Frequency Low Frequency Start Delay and Stop Delay 120 ACS 400 User s Manual Code Description 8117 NR OF AUX MOT Sets the number of auxiliary motors Relay outputs Start stop signals for the auxiliary motors are given through relay outputs In addition one relay output is used to connect the speed regulated motor to the ACS 400 ACS 400 relay outputs RO1 and RO2 can be used to control the motors It is also possible to use up to two optional external digital input output modules NDIO ACS 400 relay output 1 is used for Pump and Fan motor control if the value of 1401 RELAY OUTPUT 1 is 29 PFC Relay output 2 is used for Pump and Fan motor control if the value of 1402 RELAY OUTPUT 2 is 29 PFC Table 12 depicts the use
29. ACS400 IF21 3 100 m 100 m ACS400 IF22 3 10m 10m ACS ACH 401 x016 3 x ACS400 1F31 3 100 m 100 m ACS ACH 401 x020 3 x ACS400 IF31 3 100 m 100 m ACS ACH 401 x025 3 x ACS400 IF41 3 100 m 100 m ACS ACH 401 x030 3 x ACS400 IF41 3 100 m 100 m ACS ACH 401 x041 3 x ACS400 IF41 3 100 m 100 m Conducted emission with input filters ACS400 IF11 3 and ACS400 IF21 3 complies with the limits for unrestricted distribution class in First Environment as specified in EN61800 3 EN50081 1 provided that maximum motor cable length is 30 m and switching frequency 4 kHz Line Current Harmonics The current harmonic levels under rated load conditions are available on request Distribution Networks Isolated from Earth Input filters designed for ACS 400 cannot be used in an isolated or high impedance earthed industrial distribution networks ACS 400 User s Manual 165 166 ACS 400 User s Manual Appendix D ACS 400 Dimensional Drawings ACS 400 NEMA Type 1 Enclosure R1 Frame Size 3 ugo 4 567 A R2 8 R0 108 209 3 8 240 98 0 3 858 S o E gt 87 0 3 425 re 197 E 87 0 nm R5 0 RO 197 a M o 2 Zo M5 MOUNTING 8 HARDWARE LN 4 PLACES Zo WALL OR FLANGE d LEzE S o Kal D go E Fr o Pa s S Sa a H BE 3 8 a s R2 5 R0 098 8 CONDUIT BOX wo r 124 9 4 915 6 5 0 256 3 91 9 3 619 gt 4 81 8 3 222 62 4 2 45
30. BUTTON DISABLED Control panel function is denied for any of the following reasons START STOP button is interlocked from digital input This can happen with certain digital input configurations Refer to chapter Application Macros REVERSE button is locked because shaft direction is fixed by parameter 1003 DIRECTION The drive is in remote control mode and START STOP and REVERSE buttons are not followed 6 PARAM LOCAL LOCK Control panel function is not allowed Parameter 1602 PARAMETER LOCK denies parameter editing Parameter 1605 LOCAL LOCK denies local control mode Ke FACTORY MACRO Control panel function is not allowed Factory macro is selected and denies the parameter modifications Factory macro is intended for applications where there is no control panel available 10 OVERCURRENT Overcurrent controller is active 11 7 OVERVOLTAGE Overvoltage controller is active 12 DC UNDERVOLTAGE Undervoltage controller is active 13 DIRECTION LOCK Rotation direction if fixed by parameter 1003 DIRECTION 14 SERIAL COMM LOSS Serial communication through Standard Modbus Channel is lost Check connections between the external control system and the ACS 400 Refer to parameters 5003 COMM FAULT TIME and 5004 COMM FAULT FUNC 15 MODBUS EXCEPTION Exception response is sent through Standard Modbus channel The bus master may be sending queries which cannot be processed by the ACS 400 Refer to Standard Serial Communicati
31. Caution Turning the power on again may start the drive immediately ACS 400 User s Manual 33 34 ACS 400 User s Manual Diagnostics General This chapter describes the various diagnostic displays of the ACS PAN and ACS100 PAN control panels and lists the most common causes for the particular display If the fault cannot be resolved using the given instructions please contact an ABB service representative Caution Do not attempt any measurement parts replacement or other service procedure not described in this manual Such action will void guarantee endanger correct operation and increase downtime and expense Alarm and Fault displays The seven segment display unit of ACS100 PAN indicates alarms and faults using codes ALxx or FLxx where xx is the corresponding alarm or fault code The alphanumeric display of ACS PAN control panel shows the alarm and fault codes together with a short message Alarms 1 7 arise from button operation Green LED blinks for codes greater than or equal to 10 The faults are indicated by a red LED The alarm and fault messages disappear when MENU ENTER or the arrow buttons of control panel are pressed The message will reappear after a few seconds if the keypad is not touched and the alarm or fault is still active Last three fault codes are stored into parameters 0128 0130 These fault memories can be cleared from the control panel by pressing the UP and DOWN buttons simultaneo
32. Default value 1 COAST Group 22 ACCELER DECELER 2202 ACCELER TIME 1 Ramp 1 time from zero to maximum frequency 0 MAXIMUM FREQ Range for all ramp time parameters is 0 1 1800 s Default value 5 0 s 2203 DECELER TIME 1 Ramp 1 time from maximum to zero frequency MAXIMUM FREQ 0 Default value 5 0 s 2204 ACCELER TIME 2 Ramp 2 time from zero to maximum frequency 0 MAXIMUM FREQ Default value 60 0 s 2205 DECELER TIME 2 Ramp 2 time from maximum to zero frequency MAXIMUM FREQ 0 Default value 60 0 s Group 26 MOTOR CONTROL 2606 U f RATIO Y U f below field weakening point 1 LINEAR 2 SQUARE LINEAR is preferred for constant torque applications SQUARE is preferred for centrifugal pump and fan applications to increase motor efficiency and to reduce motor noise Default value 1 LINEAR Group 33 INFORMATION 3301 SW VERSION Software version code S Parameters can be modified only when the drive is stopped 52 ACS 400 User s Manual Application Macros Application Macros are preprogrammed parameter sets They minimize the number of different parameters to be set during start up The Factory Macro is the factory set default macro Note The Factory Macro is intended for applications where there is NO control panel available If using the Factory Macro with control panel note that the parameters whose value depen
33. Hz 2503 CRIT FREQ 1 HI O 250 Hz 1 Hz 0 Hz 2504 CRIT FREQ 2 LO O 250 Hz 1 Hz 0 Hz 2505 CRIT FREQ 2 HI O 250 Hz 1 Hz 0 Hz Group 26 MOTOR CONTROL 2603 Up COMPENSATION O 60 V 400 V units 1V 10 V 2604 Up COMP RANGE O 250 Hz 1 Hz 60 Hz 2605 LOW NOISE 0 1 1 O OFF Y 2606 U f RATIO 1 2 1 1 LINEAR v 2607 SLIP COMP RATIO 0 250 1 0 Y Group 30 FAULT FUNCTIONS 3001 AI lt MIN FUNCTION 0 3 1 1 FAULT 3002 PANEL LOSS 1 3 1 1 FAULT 3003 EXTERNAL FAULT 0 5 1 O NOT SEL 3004 MOT THERM PROT 0 2 1 1 FAULT 3005 MOT THERM TIME 256 9999 s 1s 500 s 3006 MOT LOAD CURVE 50 150 1 100 3007 ZERO SPEED LOAD 25 150 1 70 3008 BREAK POINT 1 250Hz 1Hz 35 Hz 3009 STALL FUNCTION 0 2 1 O NOT SEL 3010 STALL CURRENT 0 5 ly 1 5 1 7 ly Y O 1 A 1 2 In 3011 STALL FREQ HI 0 5 50 Hz 0 1 Hz 20 Hz 3012 STALL TIME 10 400 s is 20 s 3013 JUNDERLOAD FUNC 0 2 1 O NOT SEL 3014 UNDERLOAD TIME 10 400 s 1s 20s 3015 JUNDERLOAD CURVE 1 5 1 1 3017 GROUND FAULT 1 2 1 1 FAULT 3022 Wl FLT LIMIT 0 100 1 0 3023 Al2 FLT LIMIT O 100 1 0 68 ACS 400 User s Manual Code Name Range Resolution Default User M Group 31 AUTOMATIC RESET 3101 NR OF TRIALS 0 5 1 0 3102 TRIAL TIME 1 0 180 0s 0 1 s 30 s 3103 DELAY TIME 0 0 3 0s
34. Motor Will Not Run 41 Motor Stalls during Acceleration 42 Overvoltage Fault Indication 43 Overcurrent Fault Indication 44 Overload Fault Indication 45 Undervoltage Fault Indication 46 External Fault Indication 47 No Operator Display 48 ACS 400 Basic Parameters 49 Application Macros 53 Application Macro Factory 0 54 Application Macro Factory 1 55 Application Macro ABB Standard 56 Application Macro 3 wite 57 Application Macro Alternate 58 Application Macro Motor Potentiometer 59 vi ACS 400 User s Manual Application Macro Hand Auto 60 Application Macro PID Control 61 Application Macro Premagnetize 62 Application Macro PFC Control 63 ACS 400 Complete Parameter List 65 Group 99 Start up Data 73 Group 01 Operating Data 74 Standard Serial Communication 129 Grounding and Termination
35. The ACS 400 has a number of protective features Overcurrent Overvoltage Undervoltage Overtemperature Output ground fault Output short circuit Input phase loss 3 I O terminal short circuit protection Motor overload protection see Section R Stall protection Underload The ACS 400 has the following LED alarm and fault indicators For location of LEDs see section E or if an ACS PAN A control panel is connected see Programming on page 25 Red LED off Green LED blinking ABNORMAL CONDITION ABNORMAL CONDITION ACS 400 cannot fully follow control commands Blinking lasts 15 seconds POSSIBLE CAUSES Acceleration or deceleration ramp is too fast in relation to load torque requirement Amomentary power interruption Red LED on Green LED on FAULT ACTION Apply a stop signal to reset fault Apply a start signal to restart the drive NOTE If the drive fails to start check that the input voltage is within the tolerance range POSSIBLE CAUSES Transient overcurrent Over undervoltage Overtemperature CHECK the supply line for disturbances the drive for mechanical problems that might cause overcurrent that the heat sink is clean Red LED blinking Green LED on FAULT ACTION Turn the power off Wait for the LED s to turn off Turn the power back on Caution This action may start the drive POSSIBLE CAU
36. below supervision limit 11 1 External control location 2 EXT2 selected 0 External control location 1 EXT1 selected 12 1 Run Enable signal received 0 No Run Enable signal received 13 to Unused 15 ACS 400 User s Manual 143 References References are 16 bit words comprised of a sign bit and a 15 bit integer A negative reference indicating reversed direction of rotation is formed by calculating the two s complement from the corresponding positive reference value Reference 1 Holding Register 40002 Reference 1 can be used as the frequency reference REF1 for the ACS 400 The signal source of external reference 1 REF1 must be set to COMM and external control location 1 EXT1 must be activated Refer to parameters 1103 EXT REF 1 SELECT and 1102 EXT1 EXT2 SEL Reference 2 Holding Register 40003 Reference 2 can be used as the frequency reference REF2 for the ACS 400 The signal source of external reference 2 REF2 must be set to COMM and External control location 2 EXT2 must be activated Refer to parameters 1106 EXT REF 2 SELECT and 1102 EXT1 EXT2 SEL Fieldbus Reference Scaling Fieldbus references are scaled as follows Reference 1 20000 EXT REF1 MAX Hz parameter 1105 Scaling Parameter 1104 EXT REF1 MIN is not used Reference 2 10000 EXT REF2 MAX parameter 1108 Scaling Parameter 1107 EXT REF2 MIN is not used Fieldbus Reference Fieldbus reference is selected by setting a reference
37. brackets is included with the type IP 54 NEMA Type 12 ACS 400 drives NEMA Type 4 gland plates must be punched for conduit routing holes In order to maintain the drive s enclosure rating use appropriate fittings for all conduit routing To open the front cover see Removing the Cover on page 7 Figure 18 Removing the front cover 12 ACS 400 User s Manual IP 21 NEMA Type 1 Assemble the conduit box by mating the two conduit box halves and securing them with two of the supplied screws with captive washers assembled box shown in Figure 19 After removing the cover from the drive position the conduit box as shown below so the holes in the conduit box line up with the appropriate holes in the drive A Figure 19 Positioning the conduit box for type IP 21 NEMA Type 1 drives Insert the two screws with captive washers into the appropriate hole on each side of the conduit box on the front side of the drive B Figure 20 Conduit with top two screws installed Insert the two self tapping screws into the two holes on the bottom of the drive C and tighten using a powered driver Take care not to overtighten Tighten the top two screws and use the supplied knockouts to route the appropriate cables ACS 400 User s Manual 13 J Cable Connections Table 4 Cable Terminal Description Note U1 V1 W1 3 power supply input Do not use 1 supply PE Protective Ground Follow local rules fo
38. counter increases by one every time the ACS 400 receives a character from the bus while it is still processing the previous message There might be two stations with the same station number Ambient noise levels may be too high 5213 SER FAULT MEM 1 Last Modbus exception code sent 5214 SER FAULT MEM 2 Previous Modbus exception code sent 5215 SER FAULT MEM 3 Oldest Modbus exception code sent 118 ACS 400 User s Manual Group 81 PFC Control Parameters for Pump Fan Control PFC Appendix B on page 157 gives detailed information on PFC Application Macros on page 53 describes the default signal connections Code Description 8103 REFERENCE STEP 1 Sets a percentage value that is added to the process reference when at least one auxiliary constant speed motor is running Default value is 0 Example An ACS 400 operates three parallel pumps that pump water to a pipe The pressure in the pipe is controlled The constant pressure reference is set by parameter 4020 INTERNAL SETPNT At low water consumption levels only the speed regulated pump is run When water consumption increases constant speed pumps are started first one pump and if the demand is still growing the other pump When water flow increases the pressure loss increases between the beginning measurement site and the end of the pipe By setting suitable reference steps parameters 8103 REFERENCE STEP1 an
39. displayed with 0 1 Hz resolution it is internally scaled so that value 10 represents 1 Hz Therefore 3405 P VAR 1 SCALING 1 must be selected ACS 400 User s Manual 105 Group 40 PID Control The PID Control Macro allows the ACS 400 to take a reference signal setpoint and an actual signal feedback and automatically adjust the speed of the drive to match the actual signal to the reference There exist two PID parameter sets group 40 for set 1 parameters and group 41 for set 2 parameters Normally only set 1 parameters are used Set 2 parameters can be taken in use by parameter 4016 PID PARAM SET Selection between parameter sets can be done eg through a digital input PID sleep function can be used to stop the regulation when the output of the PID controller falls below preset limit Regulation is resumed when the process actual value falls below the preset limit Alternatively sleep function can be activated and deactivated through a digital input CROSSREF shows the connections of internal signals when the PID Control macro is selected Code Description 4001 PID GAIN This parameter defines the gain of the PID Controller The setting range is 0 1 100 If you select 1 a 10 change in error value causes the PID Controller output to change by 10 4002 PID INTEG TIME PID controller integration time Defined as the time in which the maximum output is achieved if a constant error value ex
40. ect urur mai V D Loc I 7 ic I Me EE Uf OUTPUT LOC OUTPUT Menu Structure ACS 400 has a large number of parameters Of these only the so called basic parameters are initially visible The menu function LG is used to make the full parameter set visible OUTPUT display Parameter groups Parameters LOC LOC LOC 2 3 e 99 9902 OUTPUT MENU PAR Di 9902 iBi 9905 miri d To V nt Lu 9 Setting Parameter Value Press ENTER to view the parameter value To set a new value press and hold ENTER until SET is displayed ccuc 180 R bg ENTER xo Note SET blinks if the parameter value is altered SET is not displayed if the value cannot be altered Note To view the parameter default value press the UP DOWN buttons simultaneously ACS 400 User s Manual 31 Menu Functions Scroll the Parameter groups for the desired menu function Press and hold ENTER until the display blinks to start the function Note Parameter copying does not affect all parameters The excluded parameters are 9901 9905 9910 1605 1607 5002 5201 and all Group 51 parameters See ACS 400 Complete Parameter List on page 65 for a description of these parameters Select between basic and full menu Press and hold L L enren LL ENU Ne Visible if Full menu is active Copy parameters from panel to drive
41. enclosures use the same internal plastic shell as the IP21 enclosure but an internal fan is added to improve cooling This structure increases the dimensions compared to the IP 21 enclosure but does not require a de rating Dimensions Frame Size IP54 NEMA 12 Reference in mm 8 43 214 8 43 214 10 09 7256 10 09 256 3 86 98 6 30 160 Ho 0 0 1772 450 21 65 550 25 27 642 po 1 Laurian 9 96 253 11 00 280 12 28 312 Figure 3 IP 54 NEMA Type 12 amp 4 enclosures A complete set of dimensional drawings for the NEMA Type 12 amp 4 ACS 400 drives is located in Appendix D on page 167 ACS 400 User s Manual C Mounting the ACS 400 on a Wall A Warning Before installing the ACS 400 ensure the input power supply to the drive is off 1 The lid of the packing box provides a Wall Mounting Template Remove the lid from the box Figure 4 2 The ACS 400 should only be mounted vertically on a smooth solid surface free from heat dampness and condensation Ensure minimum air flow gaps of 8 in 200 mm above and below and 2 in 50 mm around the sides of the unit 1 Using the mounting template mark the position of the mounting holes 2 Drill the holes 3 Screw in four screws or affix nuts and bolts depending on the mounting surface Figure 5 3 IP 21 Position the ACS 400 onto the m
42. environment that is suitable for the selected enclosure Drives are available in either an IP21 NEMA Type 1 or an IP54 NEMA Type 12 enclosure The drive must be protected from airborne dust corrosive gases or liquids and conductive contaminants such as condensation carbon dust and metallic particles The IP54 NEMA Type 12 enclosure provides protection from airborne dust and light sprays or splashing water from all directions Storage and Transportation Storage Temperature 40 158 F 40 70 C Transportation Temperature 40 158 F 40 70 C ACS 400 User s Manual 3 B Dimensions in mm Units with IP 21 NEMA Type 1 Enclosures e D IA Dimensions Frame Size IP21 NEMA 1 Reference in mm R2 R3 4 92 125 4 92 125 7 99 203 7 98 203 3 86 98 3 86 98 6 30 160 6 30 160 12 52 318 16 42 417 20 79 528 24 38 619 8 24 209 8 71 221 9 77 248 11 07 281 14 14 359 18 07 459 22 48 571 26 08 662 CA Mass Ib kg 12 8 5 8 19 8 9 40 8 18 5 59 5 27 Figure 2 IP 21 NEMA Type 1 enclosures A complete set of dimensional drawings for the NEMA Type 1 ACS 400 drives is located in Appendix D on page 167 4 ACS 400 User s Manual Units with IP 54 NEMA Type 12 amp NEMA Type 4 Enclosures The IP 54 NEMA Type 12 amp 4 protection class has a different outer plastic cover The IP 54 NEMA Type 12 amp 4
43. for Al2 Refer to parameter 1303 FILTER AI Example To set the minimum allowed analog input value to 4 mA value for parameter 1301 MINIMUM Al1 1304 MINIMUM Al2 is calculated as follows Value 96 Desired minimum value Full range of the analog input 100 4 mA 20 mA 100 20 Note In addition to this parameter setting the analog input must be configured for 0 20 mA current signal Refer to section CROSSREF 82 ACS 400 User s Manual Group 14 Relay Outputs Code Description 1401 RELAY OUTPUT 1 Relay output 1 content Selects which information is indicated with relay output 1 0 NOT SEL Relay is not used and is de energized 1 READY The ACS 400 is ready to function The relay is energized unless no run enable signal is present or a fault exists and supply voltage is within range 2 RUN Relay energized when the ACS 400 is running 3 FAULT 1 Relay energized when power is applied and de energized upon a fault trip 4 FAULT Relay energized when a fault is active 5 ALARM Relay energized when an alarm is active To see which alarms cause the relay to energize Diagnostics on page 35 6 REVERSED Relay energized when motor rotates in reverse direction 7 SUPRV1 OVER Relay energized when first supervised parameter 3201 exceeds the limit 3203 See Group 32 Supervision on page 100 8 SUPRV1 UNDER Relay energized when first supervised p
44. input 5 constant speed motor A Run Enable signal is received through the digital input 2 and the PFC control is activated deactivated through the digital input 3 The default output signal is given through the analog output frequency Normally the automatic Pump and Fan Control is bypassed when the ACS 400 is in local control LOC is shown on the control panel display In this case the process PID controller is not in use and the constant speed motors are not started However by selecting value 2 REF2 for parameter 1101 KEYPAD REF SEL PFC reference can be given from the control panel in local control ACS 400 User s Manual 157 Mains Supply 3 Input Power ACS 400 Process Act Value x gt PI Process Ref Value 24 V supply 4 DI5 Interlock 2 DI4 Interlock 1 D RO2 RO Pump 1 Sei we On Off Pump 1 l Regulated speed Pen eee Pump 2 On Off Pump 2 E crecen Constant speed 24 V d c 230 V a c Figure 63 Operation Diagram for the Pump and Fan Control PFC Macro With the default settings automatic pump alternation is not in use Mains Supply 3 Input Power ACS 400 Process Act Value gt PI Process Ref Value 24 V supply DIS Interlock 2 DI4 Interlock 1 RO2 RO u 230VAC 230VAC Pump 1 On Off Pump 2 On Off Alternation Switchgear
45. manual Check the DDCS option module and optical fibers Check connections between the external control system and fieldbus adapter Refer to DDCS Option module manual and parameters 5003 5006 Reserved 2 Reserved 26 OUTPUT OVERLOAD Inverter overload condition The ACS 400 output current exceeds the ratings given in Specifications on page 21 of this manual 277 AUTOMATIC RESET ACS 400 is about to perform automatic fault reset operation As a result the drive may start after the reset operation Refer to parameter group 31 AUTOMATIC RESET PID SLEEP PID sleep function is active The drive may accelerate when the PID sleep function is deactivated Refer to parameters 4018 SLEEP SELECTION 4013 PID SLEEP DELAY 4014 PID SLEEP LEVEL and 4015 WAKE UP LEVEL 28 29 AUTOCHANGE The autochange function of Pump Fan Control block is active Refer to parameter group 81 PFC CONTROL and the appendix for more information 30 INTERLOCK Pump Fan Control interlocks are active The ACS 400 cannot start any motor when Autochange is used or the ACS 400 cannot start the speed regulated motor when Autochange is not used Note Alarms will not cause relay output RO1 RO2 to activate when the relay output is configured to indicate alarm condition in general Parameter 1401 RELAY OUTPUT 1 1402 RELAY OUTPUT 2 has value 5 ALARM or 13 FLT ALARM Note Alarms will be shown only if parameter 1608 DISPLAY AL
46. module Table 11 List of module types Value Module type 0 No module connected NPBA Profibus NMBA Modbus NIBA Interbus S NCSA CS31 bus NCAN CANopen NDNA DeviceNet NLON LONWORKS NMBP Modbus oi CO N OD om A wo mM Others 5102 5115 FIELDBUSPAR 2 FIELDBUSPAR 15 Refer to communication module documentation for more information on these parameters 116 ACS 400 User s Manual Group 52 Standard Modbus The ACS 400 can be connected to Modbus fieldbus system Parameters of this group are used to set up station number communication speed and parity Parameters 5206 5215 are diagnostic counters that can be used to debug the fieldbus system Refer to Standard Serial Communication on page 129 for more information Modifications of parameters in this group take effect on the next power up Code Description 5201 STATION NUMBER Sets the slave number for the ACS 400 in Modbus network Range 1 247 5202 COMM SPEED Defines the communication speed of the ACS 400 in bits per second bits s 3 300 bits s 48 4800 bits s 6 600 bits s 96 9600 bits s 12 1200 bits s 192 19200 bits s 24 2400 bits s 5203 PARITY Defines the parity to be used with the Modbus communication Parameter also defines the number of stop bits With Modbus communication the number of stop bits is 2 with no pari
47. of balance There may be a fault in the motor or motor cable Motor cable may be too long 38 ACS 400 User s Manual 16 DC BUS RIPPLE Ripple voltages on the DC bus are too large Input power supply phase may be missing Fuse may be blown 17 UNDERLOAD Motor load is too low Check for a problem in the driven equipment Refer to parameters 3013 3015 18 Reserved 19 DDCS LINK Problem with DDCS link Check the DDCS option module and the optic fibres Check the status of the fieldbus adapter Refer to appropriate fieldbus adapter manual Check connections between external control system and fieldbus adapter Alternatively check the status of the IO extension modules NDIO required by PFC block Refer also to DDCS Option Module Manual and parameters 5004 5007 20 Al OUT OF RANGE Analog input out of range Check Al level 21 26 HARDWARE ERROR Hardware error Contact factory Full display blinking ACS100 PAN Serial link failure Bad connection between the control panel and the COMM LOSS ACS PAN ACS 400 Note These faults are indicated by a red blinking LED and are reset by turning the power off for a while ACS 400 User s Manual 39 Troubleshooting Guide This section consists of a series of flowcharts to help determine the necessary corrective action for eight common problems that may occur during start up of your ACS 400 dr
48. on input line larger capacity Motor Control or gate drive board is faulty replace the drive 44 ACS 400 User s Manual Overload Fault Indication Load Too Large Motor Overheated 7 YES S V f Profile Correct NO gt YES More Than One Motor Connected To Output YES NO Is Electronic Thermal Motor Overload Set Correctly No YES Disconnect Wiring From Output Terminals Does Fault Still Occur NO YES Erroneous Operation Due To Noise YES NO Control or gate drive board is faulty replace the drive Decrease load within rating With drive in stopped condition change parameter 2606 With drive in stopped condition change parameter 3004 to 0 to disable thermal motor overload protection circuit Then install a thermal overload relay for each motor With drive in stopped condition check parameter 3004 correctly Check motor load Remove noise sources Connect surge suppressors across relay and magnetic contactor coils Provide line filter to remove noise on the input line ACS 400 User s Manual 45 Undervoltage Fault Indication Auto reset time delay to 3 Is Input AC Supply Correct YES 182VDC for 240V drive between Terminals Uc YES Change seconds Auto reset attempts to 5 NO gt NO Increase voltage to within proper specifications Check
49. stall protection Refer to Figure 36 3011 STALL FREQ HI This parameter sets the frequency value for the stall function Refer to Figure 36 3012 STALL TIME This parameter sets the time value for the stall function 3013 UNDERLOAD FUNCTION Removal of motor load may indicate a process malfunction The protection is activated if The motor torque drops below the load curve selected by parameter 3015 UNDERLOAD CURVE This condition has lasted longer than the time set by parameter 3014 UNDERLOAD TIME Output frequency is higher than 10 96 of the nominal frequency of the motor and higher than 5 Hz O NOT SEL Underload protection is not used 1 FAULT When the protection is activated the ACS 400 coasts to stop Fault indication is displayed 2 WARNING A warning indication is displayed 3014 UNDERLOAD TIME Time limit for underload protection 96 ACS 400 User s Manual Code Description 3015 UNDERLOAD CURVE This parameter provides five selectable curves shown in Figure 38 If the load drops below the set curve for longer than the time set by parameter 3014 the underload protection is activated Curves 1 3 reach maximum at the motor rated frequency set by parameter 9907 MOTOR NOM FREQ 3017 GROUND FAULT This parameter defines operation in case of ground fault is detected in the motor or in the motor cable 1 FAULT A fault indication is displayed and the ACS 4
50. this parameter 5004 COMM FAULT FUNC Communication fault function This applies both to standard Modbus and DDCS link 0 NOT SEL No operation 1 FAULT A fault indication is displayed and the ACS 400 coasts to stop 2 CONST SP 7 A warning indication is displayed and the speed is set according to parameter 1208 CONST SPEED7 3 LAST SPEED A warning indication is displayed and the speed is set to the level at which the ACS 400 was last operating This value is determined by the average speed over the last 10 seconds Caution If you select CONST SPEED 7 or LAST SPEED make sure that it is safe to continue operation in case communication is lost 5005 PROTOCOL SEL Defines what communication protocols are used Options 1 DDCS and 3 STD MDB DDCS should be selected only if a DDCS communication module is installed O NOT SEL No serial communication is active 1 DDCS DDCS serial communication is active 2 STD MODBUS Standard Modbus protocol is active 3 STD MDB DDCS Both standard Modbus and DDCS are active 5006 COMM COMMANDS The commands source protocol selection Although the ACS 400 can communicate simultaneously via several serial communication channels the controlling commands start stop direction and reference can be received only from a single communication channel selectable by this parameter 0 NOT SEL Controlling commands are not received via serial communication
51. wiring between main switch and the drive If fuse is blown check all three phases Damaged pre charge resistor input bridge or DC bus capacitor Replace the drive 46 ACS 400 User s Manual External Fault Indication Is the Value of Parameter 3003 Between 1 and 5 YES Fault Signal Present open or closed circuit between terminal 9 24VDC and hichever terminal ha YES NO Control board may be faulty replace the drive Fault has occurred in circuits outside of the drive Troubleshoot and correct the problem ACS 400 User s Manual 47 No Operator Display Is a Display Present NO Is There a Proper Input Power Supply To the Drive NO YES Approximately 24VDC Present at Terminal X1 97 NO YES Is Operator Panel Installed Correctly NO YES Operator panel is faulty replace the panel Apply power Increase voltage to within proper specifications Check wiring between main switch and the drive Damaged pre charge resistor or input diode bridge Replace the drive Remove and correctly operator panel Check pin connector for broken or bent pins before installing 48 ACS 400 User s Manual ACS 400 Basic Parameters The ACS 400 has a large number of parameters Of these only the so called basic parameters are initially visible Setting up only a few basic parameters is suffic
52. 0 138 L 10 5 0 413 F nam legt diji Ni ji Uu G LII PT 7 865 9 252 94 8 7 671 235 0 TYP 1 TYP 199 8 AA 194 4 17 6531 ll 170 ACS 400 User s Manual ACS 400 NEMA Type 12 amp 4 Enclosure R1 Frame Size R2 8 R0 108 iL m 239 5 9 430 mm da man 95 4 3 756 a 87 0 3 425 2 TYP o o s y 3 M5 MOUNTING m HARDWARE FI 5 4 PLACES g WALL OR FLANGE oe Bo 23g L z Sos EN D do E s 2 g od E o 8 z sE m m me si NA N R2 5 R0 098 155 1 6 105 e I 149 1 5 868 a 107 1 4 215 TYP 65 1 2 561 59 1 2 325 925 0 20 984 3 PLACES 931 0 21 220 3 PLACES S hl o NOTES zi 23 1 DIMENSIONS MILLIMETERS INCHES no 2 WEIGHT 58 kg 12 8 Ibs S 3 USINY CONDUIT GET NE di 4 oe ACS 400 User s Manual 171 ACS 400 NEMA 12 amp 4 Enclosure R2 Frame Size 107 0 4 213 wo Low se 2 d m w S 2 S e t m a Sg i no a o ato aes og om no o a o m m s NOTES 1 DIMENSIONS MILLIMETERS INCHES 2 WEIGHT 9 kg 19 8 Ibs 3 USINY CONDUIT 221 3 8 711 4 99 0 3 898 TYP R2 8 RO 108 d ft Ro 197
53. 00 coasts to stop 2 NO The fault indicator is suppressed and the ACS 400 continues operation normally 3022 Al1 FLT LIMIT Fault level for analog input 1 supervision See parameter 3001 Al lt MIN FUNCTION 3023 Al2 FLT LIMIT Fault level for analog input 2 supervision See parameter 3001 Al lt MIN FUNCTION lo IN Trip time 180 s 300 s 600 s OO fo ferk 0 02 04 06 08 1 0 1 2 lo output current In nominal current of the motor fo output frequency ferk break point frequency parameter 3008 BREAK POINT Figure 37 Thermal protection trip times when parameters 3005 MOT THERM TIME 3006 MOT LOAD CURVE and 3007 ZERO SPEED LOAD have default values ACS 400 User s Manual 97 Tm 100 80 60 40 20 N 2 4 fn Figure 38 Underload curve types Ty nominal torque of the motor fw nominal frequency of the motor 98 ACS 400 User s Manual Group 31 Automatic Reset The automatic reset system can be used for resetting overcurrent overvoltage undervoltage and analog input loss faults automatically The number of allowed automatic reset operations within a certain time is selectable Warning If parameter 3107 AR Al lt MIN is enabled the drive may restart even after a long stop when the analog input signal is restored Ensure that the use of this feature will not cause physical injury and or damage equipment Code
54. 1001 EXT 1 COMMANDS DI1P 2P P 1402 RELAY OUTPUT 2 2 RUN 1002 EXT 2 COMMANDS NOT SEL 1503 AO CONTENT MAX 60 Hz 1003 DIRECTION REQUEST 1601 RUN ENABLE 0 NOT SEL 1102 EXT1 EXT2 SEL EXT1 1604 FAULT RESET SEL 6 START STOP 1103 EXT REF1 SELECT AH 2008 MAXIMUM FREO 60 Hz 1105 EXT REF1 MAX 2105 PREMAGN SEL 0 NOT SEL 1106 EXT REF2 SELECT KEYPAD 2201 ACC DEC 1 2 sEL 5 DI5 1201 CONST SPEED SEL NOT SEL 4001 PID GAIN 1 0 1401 RELAY OUTPUT 1 3 FAULT 1 4002 PID INTEG TIME 60s ACS 400 User s Manual 55 Application Macro ABB Standard This general purpose macro is typical 2 wire I O configuration It gives two more preset speeds compared to Factory Macro 0 The value of parameter 9902 is 1 ABB STANDARD Input signals Output signals Jumper Setting Start stop and direction An output AO Frequency DI1 2 AN 0 10 V Analog reference Al1 Relay output 1 Fault Preset speed selection DI3 4 e Relay output 2 Running Ramp pair 1 2 selection DI5 Al2 0 4 20 mA S 1 SCR rT42 Alt External Reference 1 0 10 V lt gt 0 50 Hz 4 43 AGND 4 10V Reference voltage 10 VDC 5 Al2 Not used 6 AGND ma 7 A01 Output frequency 0 20 mA lt gt 0 50 Hz 8 AGND N 9 24V 24 VDC 10 DCOM1 TL DI 1 Start Stop Activate to s
55. 3 Second start Motor no 2 motor no 3 motor no 1 Third start Motor no 3 motor no 1 motor no 2 etc If some motors in the system are interlocked the Autochange logic skips them If all interlocks are active and no motor can be started an interlock alarm Alarm 30 is displayed Note The ACS 400 always coasts to stop when autochange is performed Note Autochange can also occur during PID sleep Note When the ACS 400 s power supply is switched off the values of the starting order counter and Autochange Interval counter are stored in the permanent memory The counters continue from the stored values after the power supply is switched on again 122 ACS 400 User s Manual Code Description 8120 1 DI INTERLOCKS Controls the use of the Interlock function he following table Interlock signals No of aux motors param 8117 ACS 400 digital inputs NDIO module 1 NDIO module 2 0 DI1 Motor 1 DI2 DI5 free Not used Not used DI1 Motor 1 DI2 Motor 2 DI3 DI5 free DI1 Motor 1 DI2 Motor 2 DI3 Motor 3 DI4 DI5 free DI1 Motor 1 DI2 Motor 2 DI3 Motor 3 DI4 Motor 4 DI5 free 2 DI2 Interlocks function is in use D interlock signals according to he following table Interlock signals No of aux motors param 8117 ACS 400 digital inputs NDIO module 1 NDIO module 2 DI1 free DI2 Moto
56. 3 DELAY TIME x Automatic reset Trial time le A X X X Time Now Figure 39 Operation of automatic reset function In this example if the fault occurs at the moment Now it is automatically reset if parameter 3101 NR OF TRIALS value is greater than or equal to 4 ACS 400 User s Manual 99 Group 32 Supervision Parameters of this group are used together with relay output parameters 1401 RELAY OUTPUT 1 and 1402 RELAY OUTPUT 2 Any two parameters of the Operating Data Group Group 1 can be supervised Relays can be configured to be energized when the values of the supervised parameters are either too low or too high Code Description 3201 SUPERV 1 PARAM First supervised parameter number of the Operating Data group Group 01 3202 SUPERV 1 LIM LO First supervision limit low Display of this parameter depends on the selected supervised parameter 3201 3203 SUPERV 1 LIM HI First supervision limit high Display of this parameter depends on the selected supervised parameter 3201 3204 SUPERV 2 PARAM Second supervised parameter number of the Operating Data group Group 01 3205 SUPERV 2 LIM LO Second supervision limit low Display of this parameter depends on the selected supervised parameter 3204 3206 SUPERV 2 LIM HI Second supervision limit high Display of this parameter depends on the selected supervised parameter 3204 100 ACS 400
57. 400 User s Manual 149 150 ACS 400 User s Manual Appendix A Local Control vs Remote Control The ACS 400 can be controlled from two remote control locations or from the control panel Figure 59 below shows the ACS 400 control locations The selection between local control LOC and remote control REM is accomplished by pushing the MENU and ENTER buttons simultaneously when the ACS100 PAN is used and by pushing the LOC REM button when the ACS PAN is used Start Stop Direction Keypad Reference 1 REF1 Hz or Keypad Reference 2 REF2 EXT1 EXT2 Start Stop Direction Start Stop Direction External Reference 1 Hz External Reference 2 Figure 59 Control locations Local Control The control commands are given explicitly from the control panel when the ACS 400 is in local control Parameter 1101 KEYPAD REF SEL is used to select keypad reference which can be either REF1 Hz or REF2 If REF1 Hz is selected the type of reference is frequency and it is given to the ACS 400 in Hz If REF2 is selected the reference is given in per cent If PID Control macro or PCF macro is used reference REF2 is fed directly to the PID controller as percentage Otherwise reference REF2 is converted to frequency so that 100 corresponds to MAXIMUM FREQ parameter 2008 ACS 400 User s Manual 151 Remote Control When the ACS 400 is
58. 44 Actual value scaling The range of the analog input signal is set by parameters 1301 and 1302 or parameters 1304 and 1305 depending on the analog input used 108 ACS 400 User s Manual Code Description 4013 PID SLEEP DELAY Time delay for the sleep function see Figure 45 If the ACS 400 output frequency is below a set level parameter 4014 SLEEP LEVEL longer than PID SLEEP DELAY ACS 400 is stopped Alarm 28 is displayed when PID sleep is active 4014 PID SLEEP LEVEL Level for activation of sleep function see Figure 45 When the ACS 400 output frequency falls below the sleep level the sleep delay counter is started When the ACS 400 output frequency rises above the sleep level the sleep delay counter is reset 4015 WAKE UP LEVEL Level for deactivation of sleep function This parameter sets a process actual value limit for the sleep function see Figure 45 The limit floats with the process reference Non inverted error value parameter 4005 0 Applied wake up level is according to the following formula Limit parameter 1107 parameter 4015 set point parameter 1107 parameter 1108 parameter 1107 When the actual value is less than or equal to this value the sleep function is de activated See Figure 46 and Figure 48 Inverted error value parameter 4005 1 Applied wake up level is according to the following formula Limit parameter 1108 parameter 4015 parameter 1108 setpoin
59. 5 42 9 1 687 Ju 32 8 1 291 NOTES 1 DIMENSIONS MILLIMETERS INCHES 2 WEIGHT 5 8 kg 12 8 lbs RE ED 3 USINY CONDUIT 922 5 90 886 3 KNOCKOUTS 928 3 01 114 2 KNOCKOUTS p 5 854 4 573 148 7 TYP TYP L 119 9 on ACS 400 User s Manual 167 ACS 400 NEMA Type 1 Enclosure R2 Frame Size m m m 2215 8 711 o Y 99 0 3 898 m PL B L m Los se o o 0o D dm g 2 So L wo wo a gt 4 o d o m D d d o g 5 d M Y D gt o 3 8 m go ki S o u 5 M NOTES 1 DIMENSIONS MILLIMETERS INCHES 2 WEIGHT 9 kg 19 8 Ibs 3 USINY CONDUIT a R2 8 R0 108 e m S R0 197 114 5 4 508 TYP 98 0 3 858 TYP 8 3 0 325 TYP M5 MOUNTING HARDWARE 4 PLACES WALL OR FLANGE U p R2 5 R0 098 y CONDUIT BOX 125 9 4 956 6 5 0 256 92 0 3 620 ch 81 9 3 223 62 4 2 456 42 9 1 689 922 5 00 886 3 KNOCKOUTS 928 3 91 114 2 GEN J 119 2 4 694 168 ACS 400 User s Manual ACS 400 NEMA Type 1 Enclosure R3 Frame Size 571 1 22 484 545 0 21 457 248 3 71 0 2 795 126 0 4 961 m TYP 280 4 11 038 p 6 929 386 0 15 197 491 0 19 331 NOTES 1 DIMENSIONS MILLIMETERS INCHES 2 WEIGHT 18 5 kg 40 8 Ibs 3 USINY CONDUIT 152 9 6 01
60. 8 123 3 4 856 101 5 3 996 79 7 3 136 50 2 1 974 022 5 00 886 2 KNOCKOUTS 043 2 01 701 2 KNOCKOUTS 934 6 01 362 1 KNOCKOUT Kal R3 3mm R0 128 11 0mm 0 433 R6 5mm R0 256 M6 MOUNTING HARDWARE 6 PLACES WALL OR FLANGE TYP 528 0 20 787 R35 R0 138 L 10 5 0 413 99 0 3 898 amp 203 0 7 992 4 8 see e c BE d E s SCH Los 7 729 ACS 400 User s Manual 169 ACS 400 NEMA Type 1 Enclosure R4 Frame Size te o S S wm 281 2 11 070 N T 159 0 6 261 4 44 9 1 768 TYP 5 8 i Sn o o m So 5 P s R S E N 2 sn o Y on o s a C er E 4 5805 o 7 do N Z wo N S o 0 8 p e 4 Aa p 1 t k CONDUIT BOX F e o 2 123 2 4 851 101 4 3 991 m 79 5 3 131 50 0 1 970 922 5 00 886 2 KNOCKOUTS 943 2 01 701 2 KNOCKOUTS NOTES 934 6 01 362 1 DIMENSIONS MILLIMETERS INCHES 2 WEIGHT 27 kg 59 5 lbs 3 USINY CONDUIT 1 KNOCKOUT 187 8 7 394 R3 am R0 128 fees Omm os R6 5mm R0 256 M6 MOUNTING HARDWARE 6 PLACES WALL OR FLANGE 98 0 3 858 619 2 24 378 TYP R3 5 R
61. A Figure 64 In this example the automatic pump alternation is in use 158 ACS 400 User s Manual EXT REF2 EXT REF1 EXT1 EXT2 CONST KEYPAD SELECT SELECT SEL SPEED SEL REF SEL 1106 1103 1102 1201 1101 i i i INOT SEL Control i Terminals An Ex Analogue KEYPAD inputs T EXT2 iRemote AM 1 Remote Min freq Digital epp L Local t Max freq inputs Local 21 PID oean i Git sp DI1 DI5 All ACT hi Const Sp AIS PFC speeds l i Acc Dec Al AC AIZ ACTUAL1 i INPUT SEL l 4007 REF2 I l l ACTUAL 2 ACTUAL REF1 Hz I INPUT SEL dns SEL Keypad 4008 006 Ref Loc Remt 4 NC EP E TUNE sobne H Start Stop Direction O NOT SE Local 4 Start Stop DI1 EXT1 REQUEST O KEYPAD NOT SEL w Remote Gomm Direction EXT2 ere REVERSE4 U l _DI4 EXTI EXT2 DIRECTION RUN ENABLE io i e 1003 1601 Figure 65 The control signal connections of the Pump and Fan Control PFC macro PID Controller The ACS 400 has an internal PID controller which is in use when the PFC Control Macro is selected Key features of the PID controller are PID sleep function to stop regulation when the output of the PID co
62. ACS 400 User s Manual Code Description 1607 PARAM SAVE Parameter save function Selection 1 SAVE saves all altered parameters to permanent memory Value 0 DONE is displayed when all parameter are saved When parameters are altered through Standard Modbus or DDCS channels altered values are not automatically saved to permanent memory Instead this parameter must be used 0 DONE 1 SAVE Note Parameter modifications done from the control panel are normally stored immediately to permanent memory However if 1602 PARAMETER LOCK is set to 2 NOT SAVED modifications done from the control panel are saved only if this parameter 1607 is used 1608 DISPLAY ALARMS Controls the visibility of some of the alarms see Diagnostics on page 35 1 NO Some of the alarms are suppressed 2 YES All of the alarms are enabled ACS 400 User s Manual 87 Group 20 Limits Code Description 2003 MAX CURRENT Maximum output current The maximum output current that the ACS 400 will supply to the motor 2005 OVERVOLT CTRL DC overvoltage controller enable Fast braking of a high inertia load causes the DC bus voltage to rise to the overvoltage control limit To prevent the DC voltage from exceeding the trip limit the overvoltage controller automatically decreases the braking torque by increasing output frequency Caution If a braking chopper and a braking resistor are c
63. ACS 400 User s Manual Diagnostic Counters Diagnostic counters can be used for debugging the Modbus system Counters will roll over from 65535 to 0 The counter values are stored to permanent memory when power is disconnected Counters can be reset from the control panel by pressing the UP and DOWN buttons simultaneously when in parameter set mode or by writing a zero from serial communication channel 1 Note Parameters 5206 5212 are displayed in hexadecimal format by the control panel Table 18 Code Name Range User Group 52 STANDARD MODBUS 5206 BAD MESSAGES 0 65535 5207 GOOD MESSAGES 0 65535 5208 BUFFER OVERRUNS 0 65535 5209 FRAME ERRORS O 65535 5210 PARITY ERRORS O 65535 5211 CRC ERRORS O 65535 5212 BUSY ERRORS O 65535 5213 SER FAULT MEM 1 0 3 5214 SER FAULT MEM 1 0 3 5215 SER FAULT MEM 3 0 3 ACS 400 User s Manual 137 Communication This chapter describes the Modbus communication on ACS 400 drives Introduction to Modbus Modbus is a serial asynchronous protocol The Modbus protocol does not specify the physical interface Typical physical interface is RS485 Modbus is designed for integration with Modicon PLCs or other automation devices and the services closely correspond to the PLC architecture The ACS 400 drive looks like a Modicon PLC on the network If detailed information regarding the Modicon Modbus protocol is requir
64. ACS 400 User s Manual 1103 EXT REF1 SELECT This parameter selects the signal source of external reference 1 0 KEYPAD Reference is given from the control panel 1 Al1 Reference is given through analog input 1 2 Al2 Reference is given through analog input 2 3 Al1 JOYST 4 Al2 JOYST Reference is given through analog input 1 or 2 accordingly configured for a joystick The minimum input signal runs the drive at maximum reference in the reverse direction The maximum input signal runs the drive at maximum reference in the forward direction See Figure 26 See also parameter 1003 DIRECTION Caution Minimum reference for joystick should be 0 3 V 0 6 mA or higher If a O 10 V signal is used the ACS 400 will operate at maximum reference in the reverse direction if the control signal is lost Set parameter 3022 Al1 FAULT LIMIT to a value 3 or higher and parameter 3023 AI2 FAULT LIMIT to 1 FAULT and the ACS 400 will stop in case the control signal is lost A EXT REF 1 MAX EXT REF 1 MIN gt EXT REF 1 MIN 10V 20 mA FREE A MAX Hysteresis 4 of Full Scale v 2V 4mA EXT REF 1 MIN 0V 0mA 2 96 2 EXT REF 1 MIN Figure 26 Joystick control Maximum for external reference 1 is set with Parameter 1105 and minimum with Parameter 1104 5 DI3U 4D R Speed reference is given through digital inputs as motor potentiometer control Digital input DI3 increases the speed the U stands for u
65. ACS 400 User s Manual ACS 400 AC Drives for Speed Control of 3 to 40 Hp 230 Volt and 3 to 50 Hp 460 Volt AC Induction Motors ABB Automation Inc ACS 400 AC Drives for Speed Control of AC Induction Motors User s Manual ACS400 US 04 3AUA489002B5310 R0101 Rev B Effective 01 16 01 Supersedes 2 1 99 Copyright O 2001 ABB Automation Inc All Rights Reserved UD D ia o e lt Warning The ACS 400 should ONLY be installed by a qualified electrician Warning Dangerous voltages are present when input power is connected Wait at least 5 minutes after disconnecting the supply before removing the cover Measure the voltage at DC terminals U U before servicing the unit See Section E Warning Even when the motor is stopped there are dangerous voltages present at Power Circuit terminals U1 V1 W1 and U2 V2 W2 and U U Warning Even when power is removed from the input terminals of the ACS 400 there may be dangerous external voltages at relay terminals RO1A RO1B RO1C ROZA RO2B RO2C Warning The ACS 400 is not a field repairable unit Never attempt to repair a malfunctioning unit contact the factory or your local Authorized Service Center for replacement Warning The ACS 400 can start up automatically after an input voltage interruption if programmed for Automatic Restart after power outage Warning When the control terminals of two or more ACS 100 140 400 units are connected in parallel the aux
66. AIKO daras a aaa 161 ACS 400 EMC Instructions 161 Appendix DD sivi aka va aa ka EIER Rr xn x ku a 167 ACS 400 Dimensional Drawings 167 viii ACS 400 User s Manual Installation Study these installation instructions carefully before proceeding Failure to observe the warnings and instructions may cause a malfunction or personal hazard Preparation before installation To install the ACS 400 you need the following screwdrivers wire stripper tape measure 4 pieces of 5x12 mm screws or nuts and bolts depending on the mounting surface drill At this point it is a good idea to check the motor nameplate data and write down the following supply voltage nominal current nominal frequency and nominal speed Unpacking the unit The ACS 400 is packaged with this User s Manual Conduit Box Warning Stickers and a separate Installation Guide The Installation Guide gives a summary of the installation instructions described here To help you mark the mounting holes for installation of your ACS 400 a Wall Mounting Template is drawn on the lid of the box Remove the lid from the box and save it Step by step instructions The installation of the ACS 400 has been broken down in a number of steps that are listed on page 2 The steps must be carried out in the order shown At the right of each step reference is made to one or more Reference Sections on the following pages of this User s Man
67. ARMS is set to 1 YES ACS 400 User s Manual 37 Table 6 Faults 1 OVERCURRENT Output current is excessive Motor load may be too high Acceleration time may be too short parameters 2201 ACCELER TIME 1 and 2203 ACCELER TIME 2 Motor or motor cable is faulty or connected wrong 2 DC OVERVOLTAGE Intermediate circuit DC voltage is excessive Check the input power supply for static or transient overvoltages Deceleration time may be too short parameters 2202 DECELER TIME 1 and 2204 DECELER TIME 2 Brake chopper if present may be underdimensioned 3 ACS400 OVERTEMP ACS 400 heat sink temperature is excessive Temperature trip limit is 95 C Check air flow and fan operation Check motor power against unit power 4 SHORT CIRCUIT Fault current Possible reasons for this fault are There is a short circuit in the motor cable s or motor Supply disturbances 5 OUTPUT OVERLOAD Inverter overload condition The ACS 400 output current exceeds the ratings given in Specifications on page 21 of this manual 6 DC UNDERVOLTAGE Intermediate circuit DC voltage is not sufficient Input power supply phase may be missing Fuse may be blown 7 ANALOGUE INPUT 1 Analog input 1 loss Analog input value is less than MINIMUM Al1 1301 See also parameter 3001 Al lt MIN FUNCTION 8 ANALOGUE INPUT 2 Analog input 2 loss Analog input value is less than MINIMUM Al2 1306 See also paramet
68. DDCS ACS 400 User s Manual 133 Control Locations The ACS 400 drive can receive control information from multiple sources including digital I O analog I O keypad and Modbus fieldbus To control the ACS 400 via the serial communication channel 1 Modbus fieldbus it must be pprogrammed to accept control commands and or frequency references from this channel In addition ACS 400 must be in remote control The necessary parameters and their usage are listed in Table 15 Note especially that before any control commands can be given through serial communication channel 1 parameter 5006 COMM COMMANDS value must be set to STD MODBUS Further information on all the parameters and their alternative settings is given in ACS 400 Complete Parameter List on page 65 Table 15 Parameters for control command source selection A Setting for Code Parameter Name es e Standard Function Information g Modbus Group 50 COMMUNICATION 5006 COMM COMMAND O NOT SEL 1 STD MODBUS Defines the serial communication channel 1 STD MODBUS for the controlling commands start stop 2 DDCS direction and reference Must be set to 1 STD MODBUS Group 10 COMMAND INPUTS 1001 EXT1 COMMANDS O NOT SEL 10 COMM Enables the Control Word except bit 11 12D when EXT1 is selected as control T location 10 COMM 1002 EXT2 COMMANDS O NOT SEL 10 COMM Enables the Control Word except bit 11 1 e
69. Description 3101 NR OF TRIALS Sets the number of allowed autoresets within a certain time The time is defined with parameter 3102 TRIAL TIME The ACS 400 prevents additional autoresets and remains stopped until a successful reset is performed from the control panel or from a place selected by parameter 1604 FAULT RESET SEL 3102 TRIAL TIME The time within which a limited number of fault autoresets is allowed The allowed number of faults per this time period is given with parameter 3101 NR OF TRIALS 3103 DELAY TIME This parameter sets the time that the ACS 400 will wait after a fault occurs before attempting to reset If set to zero the ACS 400 will reset immediately 3104 AR OVERCURRENT 0 DISABLE 1 ENABLE If 1 is selected the fault motor overcurrent is reset automatically after the delay set by parameter 3103 and the ACS 400 resumes normal operation 3105 AR OVERVOLTAGE O DISABLE 1 ENABLE If 1 is selected the fault DC bus overvoltage is reset automatically after the delay set by parameter 3103 and the ACS 400 resumes normal operation 3106 AR UNDERVOLTAGE O DISABLE 1 ENABLE If 1 is selected the fault DC bus undervoltage is reset automatically after the delay set by parameter 3103 DELAY TIME and the ACS 400 resumes normal operation 3107 AR AI lt MIN O DISABLE 1 ENABLE If 1 is selected the fault analog input signal under minimum level is reset automatically after the delay set by parameter 310
70. Di when EXT2 is selected as control Ke location 10 COMM 1003 DIRECTION 1 FORWARD 3 REQUEST Enables rotation direction control as 2 REVERSE defined by parameters 1001 and 1002 3 REQUEST Group 11 REFERENCE SELECT 1102 EXT1 EXT2 SEL 1 Dil 8 COMM Enables external control location EXT1 m EXT2 selection by Control Word bit 11 8 COMM 1103 EXT REF1 SELECT O KEYPAD 8 COMM Fieldbus reference 1 is used when EXT1 1 all 9 COMM AI1 lis selected as control location See i or section References below for information 8 COMM 10 comm al1 jon the alternative settings 9 COMM Al1 10 COMM AI1 134 ACS 400 User s Manual z Setting for Code Parameter Name Pel de Standard Function Information g Modbus 1106 EXT REF2 SELECT O KEYPAD 8 COMM Fieldbus reference 2 is used when EXT2 i A1 9 COMM AI1 is selected as control location See m or section References below for information 8 COMM 10 COMMA 1 jon the alternative settings 9 COMM AI1 10 COMM AI1 Group 16 SYSTEM CONTROLS 1601 RUN ENABLE O NOT SEL 6 COMM The run enable signal is given through 1 5 DH DIS serial communication Control Word bit 6 COMM 3 1604 FAULT RESET SEL O KEYPAD ONLY 7 COMM Fault reset is executed through serial 1 5 DH DIS communication Control Word bit 7 6 START STOP 7 COMM Output signal source selection It is possible to control bot
71. E installation requirements see ABB publication CE US 02 CE Council Directives and Variable Speed Drives Contact your local ABB representative for specific IEC installation instructions 14 ACS 400 User s Manual K Control Terminals Main I O terminal X1 X1 Identification Description 1 SCR Terminal for signal cable screen Connected internally to chassis ground 2 Al1 Analog input channel 1 programmable Default O 10 V Rj 200 kQ J1 Al1 open lt gt 0 from frequency reference 0 20 mA R 500 Q J1 Al1 closed lt gt 0 fnom frequency reference Resolution 0 1 accuracy 1 3 AGND Analog input circuit common Connected internally to chassis ground through 1 MQ 10V 10 V 10 mA reference voltage output for analog input potentiometer accuracy 2 AI 2 Analog input channel 2 programmable Default 0 20 mA R 500 Q J1 AI2 closed lt gt 0 fnom frequency reference 0 10 V Ri 200 KQ J1 AI2 open lt gt 0 from frequency reference Resolution 0 1 96 accuracy 1 96 6 AGND Analog input circuit common Connected internally to chassis ground through 1 MO 7 AO1 Analog output programmable Default 0 20 mA load lt 500 Q lt gt 0 f y output frequency 8 AGND Common for DI return signals 9 24 V Auxiliary voltage output 24 V DC 250 mA reference to AGND Short circuit protected 10 DCOM1 Digital input common for DI1 DI2 and DI3 DI Config
72. E sets the maximum allowable operating load of the motor When set to 100 the maximum allowable load is equal to the value of Start up Data parameter 9906 MOTOR NOM CURRENT The load curve level should be adjusted if the ambient temperature differs from the nominal value Output current relative to 9906 MOTOR NOM CURR A 150 3006 MOT LOAD CURVE 100 l 3007 ZERO SPEED LOAD 50 7 i Frequency 3008 BREAK POINT Figure 35 Motor load curve ACS 400 User s Manual 95 Code Description 3007 ZERO SPEED LOAD This parameter defines the maximum allowable current at zero speed relative to 9906 MOTOR NOM CURR Refer to Figure 35 3008 BREAK POINT Break point of motor load curve Refer to Figure 35 for an example of a motor load curve See Figure 37 3009 STALL FUNCTION This parameter defines the operation of the stall protection The protection is activated if the output current becomes too high compared to the output frequency refer to Figure 36 O NOT SEL Stall protection is not used 1 FAULT When the protection is activated the ACS 400 coasts to stop Fault indication is displayed 2 WARNING A warning indication is displayed The indication disappears in half the time set by parameter 3012 STALL TIME VLE 3010 STALL CURRENT Frequency 3011 STALL FREQ HI Figure 36 Motor stall protection 3010 STALL CURRENT Current limit for
73. ECT 2201 ACC DEC 1 2 SEL 0 NOT SEL 1201 CONST SPEED SEL O NOT SEL 4001 PID GAIN 2 5 1401 RE LAY OUTPUT 1 4002 PID INTEG TIME 3s ACS 400 User s Manual 63 64 ACS 400 User s Manual ACS 400 Complete Parameter List Initially only the so called basic parameters shaded grey in Table 7 are visible Use the appropriate menu function of the control panel to make the full parameter set visible S Parameters can be modified only when the drive is stopped M Default value depends on the selected macro Table 7 Full parameter set Code Name Range Resolution Default User S M Group 99 START UP DATA 9901 LANGUAGE O 11 1 O ENGLISH 9902 APPLIC MACRO 0 13 1 O FACTORY Y 9905 MOTOR NOM VOLT 200 208 220 230 240 230 V Y 380 400 415 440 460 460 V 480 V 9906 MOTOR NOM CURR 0 5 ly 1 5 ly 0 1A 1 0 ly Y 9907 MOTOR NOM FREQ O 250 Hz 1 Hz 60 Hz Y 9908 MOTOR NOM SPEED 0 3600 rpm 1 rpm 1750 rpm Y 9909 MOTOR NOM POWER 0 1 134 HP 0 1 HP 3 50 HP Y Size Dependent 9910 MOTOR COS PHI 0 50 0 99 0 01 0 83 Y MOTOR POWER FACTOR Group 01 OPERATING DATA 0102 SPEED 0 9999 rpm 1 rpm Fi 0103 OUTPUT FREQ O 250 Hz 0 1 Hz gt 0104 CURRENT 0 1 A 0105 TORQUE 100 100 0 1 0106 POWER 0 1 kW 0107 DC BUS VOLTAGE 0 999 9 V 0 1 V 0109 O
74. ELAY OUTPUT 2 2 RUN 1002 EXT 2 COMMANDS 1503 AO CONTENT MAX 60 Hz 1003 DIRECTION 1601 RUN ENABLE 4 DI4 1102 EXT1 EXT2 SEL 1604 FAULT RESET SEL O KEYPAD 1103 EXT REF1 SELECT 2008 MAXIMUM FREQ 60 Hz 1105 EXT REF1 MAX 2105 PREMAGN SEL 0 NOT SEL 1106 EXT REF2 SELECT 2201 ACC DEC 1 2 SEL 0 NOT SEL 1201 CONST SPEED SEL 4001 PID GAIN 1 0 1401 RELAY OUTPUT 1 4002 PID INTEG TIME 60 s ACS 400 User s Manual 61 Application Macro Premagnetize This macro is intended for those applications where the drive must start very quickly Building up the flux in the motor always takes time With the Premagnetize Macro this delay can be eliminated The value of parameter 9902 is 7 PREMAGN Input signals Output signals Jumper Setting Start stop and direction An output AO Frequency Dl1 2 Al 0 10 V Analog reference Al1 Relay output 1 Fault AI2 0 4 20 mA Preset speed selection DI3 4 Relay output 2 Running j Premagnetize DI5 SCR 422 An External Reference 1 0 10 V lt gt 0 50 Hz ri H 3 AGND 4 10V Reference voltage 10 VDC 5 AI2 Not used 6 AGND may 7 AO1 Output frequency 0 20 mA lt gt 0 50 Hz 8 AGND 9 24V 24 VDC 10 DCOM1 14 Di Start Stop Active to start ACS 400 i DI2 Fwd Rev Activate to reverse rotation
75. ELERATOR ENABLED Step 6 CW 0000 0000 0110 1111 When this value is written the ramp function generator RFG input is released The drive state changes to OPERATING The drive will accelerate to the given reference and will follow the reference This example assumes that the ACS 400 is in remote control that external control place 1 EXT1 is the active control place as selected by parameter 1102 and that EXT1 start and stop commands are received through serial communication parameter 1001 142 ACS 400 User s Manual Table 24 The Status Word Bit Value Description 0 1 READY TO SWITCH ON 0 NOT READY TO SWITCH ON 1 1 READY TO OPERATE 0 OFF1 ACTIVE 2 1 OPERATION ENABLED 0 Not ready OPERATION INHIBITED 3 0 1 FAULT 0 No fault 4 1 OFF2 inactive 0 OFF2 ACTIVE 5 1 OFF3 inactive 0 OFF3 ACTIVE 6 1 SWITCH ON INHIBITED 0 7 1 Alarm is active See the Diagnostics section for a list of relevant alarms 0 No alarm 8 1 OPERATING Actual value equals reference value is within tolerance limits 0 Actual value differs from reference value is outside tolerance limits 9 1 Drive control location REMOTE 0 Drive control location LOCAL 10 1 The value of first supervised parameter equals to or is greater than supervision limit Refer to Group 32 Supervision 0 The value of first supervised parameter is
76. ER With the given setting the relay 1 is 7 SUPRV1 OVER activated when supervised parameter 1 8 SUPRV1 UNDER given by parameter 3201 is above the 9 SUPRV2 OVER limit given by parameter 3203 10 SUPRV2 UNDER 31 STARTED 1402 RELAY OUTPUT 2 As above e g 7 SUPERV1 Relay output 2 function OVER See above Group 32 SUPERVISION 3201 SUPERV 1 PARAM 102 137 e g 131 SERIAL Number of supervised parameter 1 Any LINK DATA 1 parameter of the group 1 OPERATING DATA 3202 SUPERV 1 LIM LO O 255 e g 100 Lower supervision limit for supervised parameter 1 3203 SUPERV 1 LIM HI O 255 e g 100 Upper supervision limit for supervised parameter 1 3204 SUPERV 2 PARAM 102 137 e g 132 SERIAL Number of supervised parameter 1 Any LINK DATA 2 parameter of the group 1 OPERATING DATA 3205 SUPERV 2 LIM LO O 255 e g 100 Lower supervision limit for supervised parameter 2 3206 SUPERV 2 LIM HI O 255 e g 100 Upper supervision limit for supervised parameter 2 Table 17 Analog output control 1 Setting for Code Parameter Name SEMENA Standard Function Information g Modbus Group 01 OPERATING DATA 0133 SER LINK DATA 3 O 255 Controlling data for the analog output Group 15 ANALOG OUTPUT 1501 AO CONTENT 102 137 e g 133 Directs the contents of parameter 133 to the analog output 1503 AO CONTENT MAX 255 Analog output scaling upper limit 20 mA reached when value 255 is written to parameter 133 136
77. MUM AO 0 0 20 0 mA 0 1 mA 0 mA 1505 MAXIMUM AO 0 0 20 0 mA 0 1 mA 20 0 mA 1506 FILTER AO 0 10s 0 1s 0 1s Group 16 SYSTEM CONTROLS 1601 RUN ENABLE 0 6 1 jd Y 1602 PARAMETER LOCK 0 2 1 1 OPEN 1604 FAULT RESET SEL 0 7 1 hi Y 1605 LOCAL LOCK 0 1 1 0 OPEN 1607 PARAM SAVE 0 1 1 O DONE 1608 DISPLAY ALARMS 0 1 1 0 NO Group 20 LIMITS 2003 MAN CURRENT 0 5 ly 1 5 1 7 ly 0 1 A 1 5 ly 2005 OVERVOLT CTRL 0 1 1 1 ENABLE 2006 UNDERVOLT CTRL 0 2 1 1 ENABLE TIME 2007 MINIMUM FREQ O 250 Hz 1Hz 0 Hz 2008 MAXIMUM FREQ 0 250Hz 1Hz ii Y Group 21 START STOP 2101 START FUNCTION 1 4 1 1 RAMP 2102 STOP FUNCTION 1 2 1 1 COAST 2103 TORO BOOST CURR 0 5 ly 1 5 1 7 ly 0 1 A 1 2 ly 2104 STOP DC INJ TIME O 250 s 0 1 s Os 2105 PREMAGN SEL 0 6 1 Y 2106 PREMAGN MAX TIME 0 0 130 0 s 0 1 s 2 0 s 2107 START INHIBIT 0 1 1 1 ON ACS 400 User s Manual 67 Code Name Range Resolution Default User S M Group 22 ACCEL DECEL 2201 ACC DEC 1 2 SEL 0 5 1 ji viv 2202 ACCELER TIME 1 0 1 1800s 0 1 1s 5s 2203 DECELER TIME 1 0 1 1800 s 0 1 1 s 5s 2204 ACCELER TIME 2 0 1 1800s 0 1 1s 60 s 2205 DECELER TIME 2 0 1 1800 s 0 1 1 s 60 s 2206 RAMP SHAPE 0 3 1 O LINEAR Group 25 CRITICAL FREQ 2501 CRIT FREQ SEL 0 1 1 0 OFF 2502 CRIT FREQ 1 LO 0 250 Hz 1Hz 0
78. OL SEL 0 3 1 O NOT SEL Y 5006 COMM COMMANDS 0 2 1 O NOT SEL Y 5007 DDCS BUS MODE 1 2 1 1 FIELDBUS Y 5008 DDCS LINK CTRL 0 15 1 8 5009 DDCS HW CONFIG 0 1 1 0 RING Group 51 EXT COMM MODULE 5101 FIELDBUSPAR1 15 E 5115 Group 52 STANDARD MODBUS 5201 STATION NUMBER 1 247 1 1 5202 COMM SPEED 3 6 12 24 48 96 192 96 9600 bits s 5203 PARITY 0 2 1 0 NONE 5206 BAD MESSAGES 0 FFFF 1 5207 GOOD MESSAGES 0 FFFF 1 5208 BUFFER OVERRUNS O FFFF 1 5209 FRAME ERRORS 0 FFFF 1 5210 PARITY ERRORS 0 FFFF 1 5211 CRC ERRORS 0 FFFF 1 5212 BUSY ERRORS O FFFF 1 5213 SER FAULT MEM 1 O 255 1 5214 SER FAULT MEM 2 O 255 1 5215 SER FAULT MEM 3 O 255 1 Group 81 PFC CONTROL 8103 REFERENCE STEP 1 0 0 100 0 1 0 8104 REFERENCE STEP 2 0 0 100 0 1 96 0 8105 REFERENCE STEP 3 0 0 100 0 1 0 8109 START FREQ 1 0 0 250 Hz 0 1 Hz 60 Hz 8110 START FREQ 2 0 0 250 Hz 0 1 Hz 60 Hz 8111 START FREQ 3 0 0 250 Hz 0 1 Hz 60 Hz 8112 Low FREQ 1 0 0 250 Hz 0 1 Hz 30 Hz 8113 Low FREQ 2 0 0 250 Hz 0 1 Hz 30 Hz 8114 Low FREQ 3 0 0 250 Hz 0 1 Hz 30 Hz 8115 AUS MOT START D 0 0 3600 s 0 1s 1s Gs 8116 AUX MOT STOP D 0 0 3600 s 0 1s 1s Gs 8117 NR OF AUX MOT 0 3 1 1 ACS 400 User s Manual 71 Code Name Range Resolution Default User S M 8118 AUTOCHNG INTERV 0 0 336 h 0 1 h 0 0 h NOT SEL 8119 AUTOCHNG LEVEL 0 0 100 0 0 1 50
79. PNT 2 EXTERNAL Process reference is read from a source defined with parameter 1106 EXT REF2 SELECT The ACS 400 must be in remote mode REM is shown on control panel display Process reference to PID controller can also be given from the control panel in local mode LOC is shown on control panel display if the panel reference is given as percentage i e value of parameter 1101 KEYPAD REF SEL 2 REF2 4020 INTERNAL SETPNT Sets a constant process reference for the PID controller PID controller follows this reference if parameter 4019 SET POINT SEL is set to 1 INTERNAL PID input Process actual value WAKE UP DELAY A parameter 4017 mad Wake up level Time PID Output Output freguency ty SLEEP DELAY parameter 4013 SLEEP LEVEL parameter 4014 Time STOP START Figure 45 Sleep function operation 110 ACS 400 User s Manual 4015 WAKE UP A NON INVERTED ERROR VALUE A LEVEL 1108 EXT REF2 MAX 100 75 SETPOINT APPLIED WAKE UP LEVEL 0 1107 EXT REF2 MIN gt Figure 46 Example of how the applied wake up level floats with the set point here parameter 4015 WAKE UP LEVEL equals to 75 PID control non inverted case INVERTED ERROR VALUE A 4015 WAKE UP LEVEL 0 1108 EXT REF2 MAX 60 96 APPLIED WAKE UP LEVEL 100 SETPOINT 1107 EXT REF 2 MIN d gt Figure 47 Example of how a
80. QUEST 1601 RUN ENABLE O NOT SEL 1102 EXT 1 EXT2 SEL EXT1 1604 FAULT RESET SEL O KEYPAD 1103 EXT T REF1 SELECT DI3U 4D 2008 MAXIMUM FREQ 60 Hz 1105 EXT T REF1 MAX 60 Hz 2105 PREMAGN SEL O NOT SEL 1106 EXT T REF2 SELECT 0 KEYPAD 2201 ACC DEC 1 2 SEL 0 NOT SEL 1201 co NST SPEED SEL 5 DIS 4001 PID GAIN 1 0 1401 RE LAY OUTPUT 1 3 FAULT 1 4002 PID INTEG TIME 60s ACS 400 Users M anual 59 Application Macro Hand Auto This macro offers an I O configuration that is typically used in HVAC applications The value of parameter 9902 is 5 HAND AUTO Input signals Output signals Jumper Setting Start stop DI1 5 and rev An output AO Frequency DI2 4 AN1 0 10 V Two an references Al1 Al2 Relay output 1 Fault Al2 0 4 20 mA Control location selection DI3 Relay output 2 Running 1 SCR LL 2 Alt External Reference 1 0 10 V lt gt 0 50 Hz Hand Control H 3 AGND 4 10V Reference voltage 10 VDC O 5 Al2 External reference 2 0 20 mA lt gt 0 50 Hz Auto Control 6 AGND a 7 AO 1 Output frequency 0 20 mA lt gt 0 50 Hz 8 AGND mn 9 24V 24 VDC 10 DCOM1 11 DI 1 Start Stop Activate to start ACS 400 Hand 12 DI2 Forward R
81. REF1 MIN O 250 Hz 1Hz 0 Hz 1105 EST REF1 MAX O 250 Hz 1 Hz G Y 1106 EXT REF2 SELECT 0 10 1 T viv 1107 EXT REF2 MIN 0 100 1 0 1108 EXT REF2 MAX 0 500 1 100 Group 12 CONSTANT SPEEDS 1201 CONST SPEED SEL 0 10 1 t viv 1202 CONST SPEED 1 O 250 Hz 0 1 Hz 5 Hz 1203 CONST SPEED 2 O 250 Hz 0 1 Hz 10 Hz 1204 CONST SPEED 3 O 250 Hz 0 1 Hz 15 Hz 1205 CONST SPEED 4 O 250 Hz 0 1 Hz 20 Hz 1206 CONST SPEED 5 O 250 Hz 0 1 Hz 25 Hz 1207 CONST SPEED 6 O 250 Hz 0 1 Hz 40 Hz 1208 CONST SPEED 7 O 250 Hz 0 1 Hz 50 Hz Group 13 ANALOG INPUTS 1301 MINIMUM AH O 100 1 0 1302 MAXIMUM Al1 O 100 1 100 1303 FILTER AU 0 10s 0 1 s 0 1 s 1304 MINIMUM Al2 O 100 1 0 66 ACS 400 User s Manual Code Name Range Resolution Default User M 1305 MAXIMUM Al2 O 100 1 100 1306 FILTER Al2 0 10 s 0 1 s 0 1 s Group 14 RELAY OUTPUTS 1401 RELAY OUTPUT 1 O 31 1 T Y 1402 RELAY OUTPUT 2 0 81 1 id v 1403 RELAY 1 ON DELAY 0 3600 s 0 1s 1s Os 1404 RELAY 1 OFF DELAY 0 3600 s 0 1s 1s Os 1405 RELAY 2 ON DELAY O 3600 s 0 1s 1s Os 1406 RELAY 2 OFF DELAY O 3600 s 0 1s 1s Os Group 15 ANALOG OUTPUT 1501 AO CONTENT 102 137 1 103 1502 AO CONTENT MIN i 0 0 Hz 1503 AO CONTENT MAX i G Y 1504 MINI
82. S 400 User s Manual Code Name User S Group 13 ANALOG INPUTS 1301 MINIMUM AH Minimum value of Al1 in per cent Defines relative analog input value where frequency reference reaches minimum value Range 0 100 Default value 0 Group 15 ANALOG OUTPUT 1503 AO CONTENT MAX Defines output frequency where analog output reaches 20 mA Default value 60 0 Hz or 62 Hz depending on the selected application macro Note Analog output content is programmable Values given here are valid only if other analog output configuration parameters have not been modified Description of all parameters is given in ACS 400 Complete Parameter List on page 65 Group 20 LIMITS 2003 MAX CURRENT Maximum output current Range 0 5 ly 1 5 1 7 I where ly is nominal current of the ACS 400 Default value 1 5 ly 2008 MAXIMUM FREQ Y Maximum output frequency Range 0 250 Hz Default value 60 Hz or 62 Hz depending on the selected application macro The maximum factor depending on the type of the frequency converter at 4 kHz switching frequency The table continues on the next page ACS 400 User s Manual 51 Code Name User S Group 21 START STOP 2102 STOP FUNCTION Conditions during motor stopping 1 COAST Motor coasts to stop 2 RAMP Ramp deceleration as defined by the active deceleration time 2203 DECELER TIME 1 or 2205 DECELER TIME 2
83. SE Output ground fault Short circuit DC bus ripple too large CHECK theinsulation in the motor circuit Output overload protection see Section S Note Whenever the ACS 400 detects a fault condition the fault relay activates The motor stops and the ACS 400 will wait to be reset If the fault still persists and no external cause has been identified contact your local ABB sales or service office ACS 400 User s Manual 19 R Motor Overload Protection If the motor current lout exceeds nominal current ly of the motor for a prolonged period the ACS 400 automatically protects the motor from overheating by tripping The trip time depends on the extent of the overload lout In the output frequency and from Times given apply to a cold start lout In 0 gt Output frequency 0 35 Hz S Drive Overload Protection lout t AN lt max Duty cycle t T lo _ se T 10 min T time Imax lo MN 1 5 Heavy Duty rating Ambient temperature Oamp max is 104 F 40 C 1 4 122 F 50 C is permissible 1 3 if l5 is derated to 90 12 Normal Duty rating 1 1 1 0 Duty cycle 0 14 0 2 0 3 0 4 0 5 20 ACS 400 User s Manual T Specifications Notes for the following tables are on page 23 200 V Series 3 Input 208 240V ACS401x 0004x 10 50 60Hz Frame Size Unit Nominal Ratings See G amp M
84. UM 0 1000 1 100 4011 ACT2 MINIMUM O 1000 1 0 4012 ACT2 MAXIMUM O 1000 1 100 4013 PID SLEEP DELAY 0 0 3600 s 0 1 1s 60 s 4014 PID SLEEP LEVEL 0 0 120 Hz 0 1 Hz 0 Hz 4015 WAKE UP LEVEL 0 0 100 0 1 0 4016 PID PARAM SET 1 7 1 6 SET 1 4017 WAKE UP DELAY 0 60s 0 01 s 0 50 s 4018 SLEEP SELECTION 0 5 1 O INTERNAL Y 4019 SET POINT SEL 1 2 1 2 EXTERNAL 4020 INTERNAL SETPNT 0 0 100 0 0 1 40 Group 41 PID CONTROL 2 4101 PID GAIN 0 1 100 0 1 je 4102 PID INTEG TIME 0 1 320 s 0 1 s P 4103 PID DERIV TIME 0 10s 0 1s 0s 4104 PID DERIV FILTER 0 10s 0 1s 1s 4105 ERROR VALUE INV 0 1 1 0 NO 4106 ACTUAL VAL SEL 1 9 1 1 ACT1 Y 4107 ACT1 INPUT SEL 1 2 1 2 A12 Y 4108 ACT2 INPUT SEL 1 2 1 2 A12 Y 4109 ACT1 MINIMUM 0 1000 1 0 4110 ACT1 MAXIMUM O 1000 1 100 4111 ACT2 MINIMUM O 1000 1 0 4112 ACT2 MAXIMUM 0 1000 1 100 4119 SET POINT SEL 1 2 1 2 EXTERNAL 4120 INTERNAL SETPNT 0 0 100 0 0 1 40 0 70 ACS 400 User s Manual Code Name Range Resolution Default User S M Group 50 COMMUNICATION 5001 DDCS BIT RATE 1 2 4 8 1 1 Mbits s Y 5002 DDCS NODE NR 1 254 1 1 Y 5003 COMM FAULT TIME 0 1 60 s 0 1 s 1s 5004 COMM FAULT FUNC 0 3 1 D NOT SEL 5005 PROTOC
85. URR Nominal motor current from motor nameplate The allowed range is 0 5 ly 1 5 ly of ACS 400 9907 MOTOR NOM FREQ Nominal motor frequency from motor nameplate field weakening point See Figure 25 9908 MOTOR NOM SPEED Nominal motor speed from motor nameplate 9909 MOTOR NOM POWER Nominal motor power from motor nameplate 9910 MOTOR COS PHI MOTOR POWER FACTOR Nominal motor cos phi from motor nameplate Output voltage MOTOR NOM VOLT TEA l MOTOR NOM FREQ B Output frequency Figure 25 Output voltage as a function of output frequency ACS 400 User s Manual 73 Group 01 Operating Data This group contains drive operating data including actual signals and fault memories Actual Signal values are measured or calculated by the drive and they cannot be set by the user Fault memories can be cleared by the user from the control panel Code Description 0102 SPEED Displays the calculated speed of the motor rpm 0103 OUTPUT FREQ Displays the frequency Hz applied to the motor Also shown in OUTPUT display 0104 CURRENT Displays the motor current as measured by the ACS 400 Also shown in OUTPUT display 0105 TORQUE Output torque Calculated value of torque on the motor shaft in of motor nominal torque 0106 POWER Displays the measured motor power in kW Note ACS100 PAN will not display the unit KW 0107 DC BUS VOLTAGE Displays t
86. UTPUT VOLTAGE 0 480 V 0 1 V 0110 ACS400 TEMP O 300 F 0 1 F 0111 EXTERNAL REF 1 0 250 Hz 0 1 Hz zi 0112 EXTERNAL REF 2 O 100 0 1 x 0113 CTRL LOCATION 0 2 1 0114 RUN TIME R O 9999 h 1h K 0115 kWh COUNTER R 0 9999 kWh 1 kWh 2 0116 APPL BLK OUTPUT O 100 0 1 96 S 0117 DI1 DI4 STATUS 0000 1111 1 z 0 15 decimal 0118 Jart 0 100 0 1 96 0119 JAI2 0 100 0 1 96 z 0121 DI5 amp RELAYS 0000 0111 1 0 7 decimal 0122 ao O 20 mA 0 1 mA 0124 ACTUAL VALUE 1 O 100 0 1 96 e ACS 400 User s Manual 65 Code Name Range Resolution Default User S M 0125 ACTUAL VALUE 2 O 100 0 1 si 0126 CONTROL DEV 100 100 0 1 0127 PID ACT VALUE 100 100 0 1 0128 LAST FAULT O 26 1 z 0129 PREVIOUS FAULT 0 26 1 0130 OLDEST FAULT O 26 1 0131 SER LINK DATA 1 0 255 1 z 0132 SER LINK DATA 2 0 255 1 0133 SER LINK DATA 3 0 255 1 0134 PROCESS VAR 1 0135 PROCESS VAR 2 0136 RUN TIME 0 00 99 99 kh 0 01 kh 0137 MWh COUNTER O 9999 MWh 1 MWh e Group 10 COMMAND INPUTS 1001 EXT COMMANDS 0 10 1 viv 1002 EXT2 COMMANDS 0 10 1 n viv 1003 DIRECTION 1 3 1 Y viv Group 11 REFERENCE SELECT 1101 KEYPAD REF SEL 1 2 1 1 REF1 Hz 1102 EXT1 EXT2 SEL 1 8 1 Y viv 1103 EXT REF1 SELECT 0 10 1 G viv 1104 EST
87. User s Manual Value of supervised parameter hi 3203 lo 3202 Energized 1 De energized 0 Energized 1 De energized 0 A Parameter 1401 RELAY OUTPUT 1 1402 RELAY OUTPUT 2 value is SUPRV1 OVER or SUPRV2 OVER B Parameter 1401 RELAY OUTPUT 1 1402 RELAY OUTPUT 2 value is SUPRV1 UNDER or SUPRV2 UNDER Note Case LOW lt HIGH represents a normal hysteresis Case A Is for monitoring when if the supervised signal exceeds a given limit Case B Is for monitoring when if the supervised signal falls below a given limit Figure 40 Operating data supervision using relay outputs when LOW lt HIGH ACS 400 User s Manual 101 Value of supervised parameter LOW 3202 HI 3203 energized 1 de energized 0 energized 1 de energized 0 A Parameter 1401 RELAY OUTPUT 1 1402 RELAY OUTPUT 2 value is SUPRV1 OVER or SUPRV2 OVER B Parameter 1402 RELAY OUTPUT 1 1402 RELAY OUTPUT 2 value is SUPRV1 UNDER or SUPRV2 UNDER Note Case LOW gt HIGH represents a special hysteresis with two separate supervision limits Depending on whether the supervised signal has gone below value HIGH 3203 or above value LOW 3202 determines which limit is being used Initially HIGH is used until the signal goes above value LOW After this the limit used is LOW until the signal goes back below value HIGH A Initially the relay is de energized B Initially the relay is energized Figure 41 Operating
88. alues Actual values are read only values containing information on the operation of the drive Actual values are 16 bit words containing a sign bit and a 15 bit integer A negative value is given as two s complement of the corresponding positive value Actual Value 1 Holding Register 40005 Actual output frequency Scaling 5000 50 Hz Actual Value 2 Holding Register 40006 Actual output current Scaling 10 2 1 A 146 ACS 400 User s Manual From any state From any state From any state Emergency Stop Emergency Off Fault OFF3 CW Bit2 0 OFF2 CW Bit1 0 ban OFF3 OFF2 W Bit4 W Bit3 1 SW Bit5 0 ACTIVE ACTIVE SW Bit4 0 FAULT SW Bit3 1 t 0 1 0 D CW Bit7 1 From any state OFF1 CW Bit0 0 SWITCH ON MAINS OFF INHIBITED SW Bit6 1 f 0 1 0 Power ON CW Bit0 0 D j NOT READY MAH TO SWITCH ON SW Bito 0 gt O D CW Bit3 0 CW xxxx xxxx xxxx x110 TN OPERATION READY TO ER SW Bit2 0 EE GEN SwircH ON SW Bit0 1 CW xxxx xxxx xxxx x111 READY TO m OPERATE SW Bitt 1 Oo O CW Bit5 0 F CW Bit3 1 and ai SW Bit12 1 OPERATION T ENABLED SW Bit2 1 i CW Bit6 0 A A CW Bit5 1 RFG ACCELERATOR ENABLED i CW Bit6 1 OPERATING SW Bit8 1 i This state transition also occurs if the fault is reset from any other source e g digital input State Output current mmm CW Control Word f Output frequency SW Status Word RFG Ram
89. an Low Voltage and EMC Directives Directive 73 23 EEC as amended by 93 68 EEC and Directive 89 336 EEC as amended by 93 68 EEC The EMC Directive defines the requirements for immunity and emissions of electrical equipment used in European Economic Area The EMC product standard EN 61800 3 covers ihe requirements stated for frequency converters ACS 400 frequency converters comply with the requirements stated in EN 61800 3 for Second Environment and First Environment restricted distribution Product standard EN 61800 3 Adjustable speed electrical power drive systems Part 3 EMC product standard including specific test methods defines First Environment as environment that includes domestic premises It also includes establishments directly connected without intermediate transformers to a low voltage power supply network which supplies buildings used for domestic purposes Second Environment includes establishments other than those directly connected to a low voltage power supply network which supplies buildings used for domestic purposes With ACS 400 no RFI filter is needed in Second Environment C Tick Marking A C tick mark is attached to the ACS 400 frequency converters to verify that the unit follows the provisions of the Australian Statuary Rules No 294 1996 Radiocommunication Compliance Labelling Incidental Emissions Notice and the Radiocommunication Act 1989 and the Radiocommunication Regulations 1993 of New Zealand T
90. anel extension cable provided with the option package PEC 98 0008 Follow the instructions delivered with the option package Route the control panel cable as far away as possible from the mains and motor cables at least 20 cm Also the cable routing must be done so that the distance from the sides of the converter is at least 20 cm to avoid excessive radiation to the cable 164 ACS 400 User s Manual Additional Instructions to Comply with EN61800 3 First Environment Restricted Distribution and AS NZS 2064 1997 Class A Always use an optional RFI filter as specified in Table 29 and follow the instructions in the filter package for all cable screen connections The motor cable lengths have to be limited as specified in Table 29 and the cable must have effective screen according to Figure 68 At the motor end the cable screen must be earthed 360 degrees with an EMC cable gland e g Zemrex SCG screened cable glands Table 29 Maximum motor cable lengths with input filters ACS400 IF11 3 ACS400 IF41 3 and switching frequency 4 kHz or 8 kHz Switching Frequency Converter Type Filter 4 kHz 8 kHz ACS ACH 401 x004 3 x ACS400 IF11 3 100 m 2 ACS400 IF22 3 10m 10m ACS ACH 401 x005 3 x ACS400 1F11 3 100 m 7 ACS400 IF22 3 10m 10m ACS ACH 401 x006 3 x ACS400 1F11 3 100 m ACS400 IF22 3 10m 10m ACS ACH 401 x009 3 x ACS400 1F21 3 100 m 100 m ACS400 IF22 3 10m 10m ACS ACH 401 x011 3 x
91. arameter 3201 drops below the limit 3202 See Group 32 Supervision on page 100 9 SUPRV2 OVER Relay energized when second supervised parameter 3204 exceeds the limit 3206 See Group 32 Supervision on page 100 10 SUPRV2 UNDER Relay energized when second supervised parameter 3204 drops below the limit 3205 See Group 32 Supervision on page 100 11 AT SET POINT Relay energized when output frequency is equal to reference frequency 12 FAULT RST Relay energized when the ACS 400 is in a fault condition and will reset after the programmed autoreset delay refer to parameter 3103 DELAY TIME 13 FLT ALARM Relay is energized when fault or alarm occurs To see which alarms and faults cause the relay to energize refer to section Diagnostics on page 35 14 EXT CONTROL Relay is energized if external control is selected 15 REF 2 SEL Relay is energized if EXT2 is selected 16 CONST FREQ Relay is energized when a constant speed is selected 17 REF LOSS Relay is energized when reference or active control place is lost 18 OVERCURRENT Relay is energized when overcurrent alarm or fault appears 19 OVERVOLTAGE Relay is energized when overvoltage alarm or fault appears 20 ACS400 TEMP Relay is energized when ACS 400 overtemperature alarm or fault exists ACS 400 User s Manual 83 Code Description 21 ACS OVERLOAD Relay is energized when ACS 400 overloa
92. ard DI2 activated Reverse To control direction the value of parameter 1003 DIRECTION should be REQUEST 3 DI1P 2P Three wire Start Stop Start Stop commands are given by means of momentary push buttons the P stands for pulse The Start push button is normally open and connected to digital input DI1 The Stop push button is normally closed and connected to digital input DI2 Multiple Start push buttons are connected in parallel multiple Stop push buttons are connected in series 4 DI1P 2P 3 Three wire Start Stop Direction Start Stop connected as with DI1P 2P Direction is connected to digital input DI3 DI3 deactivated Forward DI3 activated Reverse To control Direction the value of parameter 1003 DIRECTION should be REQUEST 5 DI1P 2P 3P Start Forward Start Reverse and Stop Start and Direction commands are given simultaneously with two separate momentary push buttons the P stands for pulse The Stop push button is normally closed and connected to digital input DI3 The Start Forward and Start Reverse push buttons are normally open and connected to digital inputs DI1 and DI2 respectively Multiple Start push buttons are connected in parallel and multiple Stop push buttons are connected in series To control direction value of parameter 1003 DIRECTION should be REQUEST 6 DI5 Two wire Start Stop connected to digital input DI5 DI5 deactivated Stop and DI5 activated Start 7 DI5 4
93. arted When the time set with parameter 8115 AUX MOT START D is elapsed and if the output frequency is still above value 8110 START FREQ 2 1 Hz the second auxiliary motor is started After the second auxiliary motor is started the ACS 400 output frequency is decreased by value 8110 START FREQ 2 8113 LOW FREQ 2 Note Start Frequency 2 should be within limits 8112 Low FREQ 2 and 2008 MAXIMUM FREQ 1 8111 START FREQ 3 Sets a frequency limit see Figure 50 When the ACS 400 output frequency exceeds the value 8111 START FREQ 3 1 Hz and two auxiliary motors are running the Start Delay counter is started When the time set with parameter 8115 AUX MOT START Dis elapsed and if the output frequency is still above value 8111 START FREQ 3 1 Hz the third auxiliary motor is started After the third auxiliary motor is started the ACS 400 output frequency is decreased by value 8111 START FREQ 3 8114 LOW FREQ 3 Note Start Frequency 3 should be within limits 8112 Low FREQ 3 and 2008 MAXIMUM FREQ 1 ACS 400 User s Manual 119 Code Description 8112 LOW FREQ 1 Sets a frequency limit see Figure 50 When the ACS 400 s output frequency falls below the value 8112 LOW FREQ 1 1 Hz and one auxiliary motor is running the Stop Delay counter is started When the time set with parameter 8116 AUX MOT STOP D is elapsed and if the output frequency is still below the value 8112 LOW FREQ 1 1 Hz
94. ata address received in the query is not an allowable ADDRESS address for the slave ACS 400 Address outside groups 03 ILLEGAL DATA A value contained in the query data field is not an VALUE allowable value for the slave ACS 400 Value outside min tax limits ACS 400 Parameter is read only ACS 400 Message is too long ACS 400 Parameter write not allowed when start is active ACS 400 Parameter write not allowed when factory macro is selected Function Codes The ACS 400 supports the Modbus function codes given in Table 21 If any other function codes are used the ACS 400 returns an exception response with error code 01 illegal function Table 21 Function codes Code Description 03 Read holding registers 06 Preset single register 16 10 Hex Preset multiple registers 140 ACS 400 User s Manual The Control Word and the Status Word Holding registers 40001 Control Word 40004 Status Word The Control Word CW is the principal means for controlling the drive from a fieldbus system lt is effective when The drive is in external remote control and the controlling commands are received through serial communication channel set by parameters 1001 EXT1 COMMANDS 1002 EXT2 COM MANDS and 1102 EXT1 EXT2 SEL and Serial communication channel that is used for the controlling is Standard Modbus parameter 5006 COMM COMMANDS is set to 1 STD MODBUS The Control Word detailed in Tab
95. bus fieldbus connection Communication settings of Channel 1 can be configured by the user To control the ACS 400 via Modbus the ACS 400 must be programmed to accept control commands and or frequency references from Channel 1 Channel 0 is reserved for drive control panels ACS PAN and ACS100 PAN and for the Drive Window PC tool Optional serial communication features The ACS 400 can also be connected to a number of other fieldbuses using special fieldbus adapter modules These adapters are connected using an optical DDCS link DDCS Distributed Drives Control System For more information on these options contact your supplier ACS 400 Channel 1 Channel 0 Connector X3 Modbus fieldbus RS485 ri ACS100 PAN ACS PAN gt gt Connector for optional DDCS communication module Drive Window Figure 55 Standard serial communication features of ACS 400 ACS 400 User s Manual 129 Data Flow Master PLC Fieldbus Fieldbus a sjisenbeg M H JelewueJegq gt LOV sen eA IT 4 MS POM SNIS JIH seoueiejeu MO PIOM J03u0 gt Figure 56 Structure of a fieldbus system ACS 400 User s Manual 130 Grounding and Termination RS485 Bus The RS485 network should not be directly grounded at any point All the devices on the network should be well groun
96. d on digital input DI4 cannot be modified from the panel Parameter Values Selecting an application macro with parameter 9902 APPLIC MACRO Will set all other parameters except the group 99 Start up Data parameters the parameter lock 1602 the parameter save 1607 and groups 50 52 serial communication parameters to their default values Default values of certain parameters depend on the selected macro These are listed with the description of each macro Default values for other parameters are given in ACS 400 Complete Parameter List on page 65 Connection Examples In the following connection examples please note All the digital inputs are connected using negative NPN logic ACS 400 User s Manual 53 Application Macro Factory 0 This macro is intended for applications where there is NO control panel available It provides a general purpose 2 wire I O configuration The value of parameter 9902 is O FACTORY DI4 is not connected Input signals Output signals Jumper Setting Start stop and direction DI1 2 An output AO Frequency Analog reference Al1 Relay output 1 Fault Constant speed 1 DI3 Relay output 2 Running Ramp pair 1 2 selection DI5 1 SCR Layali External Reference 1 0 10 V lt gt 0 50 Hz 23 AGND 4 10V Reference voltage 10 VDC 5 Al2 No
97. d 8104 REFERENCE STEP2 the process reference is increased along with the increasing pumping capacity The reference steps compensate the growing pressure loss and prevent the pressure drop at the end of the pipe 8104 REFERENCE STEP 2 Sets a percentage value that is added to the process reference when at least two auxiliary constant speed motors are running Default value is 0 See parameter 8103 REFERENCE STEP1 8105 REFERENCE STEP 3 Sets a percentage value that is added to the process reference when at least three auxiliary constant speed motors are running Default value is 0 See parameter 8103 REFERENCE STEP1 8109 START FREQ 1 Sets a frequency limit See Figure 50 on page 120 When ACS 400 output frequency exceeds value 8109 START FREQ 1 1 Hz and no auxiliary motors are running the Start Delay counter is started When the time set with parameter 8115 AUX MOT START D is elapsed and if the output frequency is still above value 8109 START FREQ 1 1 Hz the first auxiliary motor is started After the first auxiliary motor is started ACS 400 output frequency is decreased by value 8109 START FREQ 1 8112 LOW FREQ 1 Note Start Frequency 1 should be within limits 8112 Low FREQ 1 and 2008 MAXIMUM FREQ 1 8110 START FREQ 2 Sets a frequency limit see Figure 50 When the ACS 400 output frequency exceeds value 8110 START FREQ 2 1 Hz and one auxiliary motor is running the Start Delay counter is st
98. d alarm or fault exists 22 UNDERVOLTAGE Relay is energized when undervoltage alarm or fault exists 23 Al1 Loss Relay is energized when Al1 signal is lost 24 Al2 Loss Relays energized when Al2 signal is lost 25 MOT OVR TEMP Relay is energized when motor overtemperature alarm or fault exists 26 STALL Relay is energized when stall alarm or fault exists 27 UNDERLOAD Relay is energized when underload alarm or fault exists 28 PID SLEEP Relay is energized when PID sleep function is active 29 PFC Relay output is reserved for PFC control Pump Fan Control This option should be selected only when PFC control macro is used 30 AUTOCHANGE Relay is energized when PFC autochange operation is performed This option should be selected only when PFC control macro is used 31 STARTED Relay is energized when drive receives start command even if Run Enable signal is not present Relay is de energized when stop command is received or fault occurs 1402 RELAY OUTPUT 2 Relay output 2 content Refer to parameter 1401 RELAY OUTPUT 1 1403 RO 1 ON DELAY Switch on delay for relay 1 Selected controlling signal 1404 RO 1 OFF DELAY RS 1405 Switch off delay for relay 1 RO 2 ON DELAY ES gege D Switch on delay for relay 2 Relay status 1406 RO 2 OFF DELAY 1403 ON DELAY 1404 OFF DELAY Switch off delay for relay 2 Figure 29 84 ACS 400 User s Manual
99. data supervision using relay outputs when LOW gt HIGH 102 ACS 400 User s Manual Group 33 Information Code Description 3301 SW VERSION Software version 3302 TEST DATE Displays the test date of the ACS 400 yy ww ACS 400 User s Manual 103 Group 34 Process Variables Parameters of this group can be used to create custom process variables Values of process variables can be seen in parameters 0134 PROCESS VAR 1 and 0135 PROCESS VAR 2 AND optionally in the ACS PAN output display Value is calculated by taking given parameter from the operating data group Group 1 and multiplying and dividing it with given coefficients The unit and number of decimal digits is configurable See example below Code Description 3401 DISPLAY SEL Selects displayed variables for the output display of the ACS PAN control panel Process variable 1 Frequency reference 1 STANDARD Panel displays standard variables 2 PROCESS VAR Panel displays process variables See Figure 42 OUTPUT Process variable 2 Figure 42 ACS PAN output display when process variable display is selected 3402 P VAR 1 SEL Selection of process variable 1 Number of any parameter of the group 1 OPERATING DATA 3403 P VAR 1 MULTIP Process variable 1 multiplier 3404 P VAR 1 DIVISOR Process variable 1 divider 3405 P VAR 1 SCALING Decimal point location of process variable 1
100. ded using their corresponding earthing terminals As always the grounding wires should not form any closed loops and all the devices should be earthed to a common ground The RS485 network must be terminated using 120 Q resistors at both ends of the network Use DIP switch to connect or disconnect the termination resistors The termination should not be done on the intermediate stations on the network as shown in Figure 57 Terminated Terminated 00000 00000 00000 00000 Figure 57 Termination for the RS485 link AN connections may only be made with the drive disconnected from the power source ACS 400 User s Manual 131 Activating Modbus Protocol As a factory setting Channel 1 is not operational To activate standard Modbus protocol for Channel 1 set parameter 5005 PROTOCOL SEL to 2 STD MODBUS After this single modification the ACS 400 is ready to communicate via Channel 1 using the default communication settings given in Table 13 making parameter read and write possible The following sections describe how to configure the ACS 400 for more sophisticated communication and control Table 13 Default communication settings of Channel 1 Station number 1 Communication speed 9600 bps Parity bit none Stop bits two Number of data bits 8 Note Protocol must be reactivated after the communication settings are cha
101. e or 0 8 Ip at 40 C 2606 U f RATIO U f ratio below field weakening point 1 LINEAR 2 SQUARE Linear is preferred for constant torque applications Square for centrifugal pump and fan applications Square is more silent for most operating frequencies 2607 SLIP COMP RATIO A squirrel cage motor will slip under load The slip can be compensated by increasing the frequency as the motor torque increases This parameter defines the gain for the slip 100 means full slip compensation 0 means no slip compensation ZE compensation range Ee HES f Hz Field weakening point Figure 33 Operation of IR compensation ACS 400 User s Manual 93 Group 30 Fault Functions ACS 400 can be configured to respond as desired to certain abnormal external conditions analog input fault external fault signal and panel loss In these cases the drive can either continue operation at current speed or at a set constant speed while showing an alarm ignore the condition or trip on a fault and stop Motor thermal protection parameters 3004 3008 provide a means of adjusting the motor load curve For example limiting the load near zero speed might be necessary if the motor does not have a cooling fan Stall protection parameters 3009 3012 includes parameters for stall frequency stall time and current Code Description 3001 AI lt MIN FUNCTION Operation in case of Al signal drop
102. eactivated the ACS 400 is stopped and the motor coasts to stop and fault indication is displayed 94 ACS 400 User s Manual Code Description 3004 MOT THERM PROT Motor overtemperature function This parameter defines the operation of the motor thermal protection function which protects the motor from overheating O NOT SEL 1 FAULT Displays a warning indication at the warning level 97 5 of the nominal value Displays a fault indication when the motor temperature reaches the 100 level The ACS 400 coasts to stop 2 WARNING A warning indication is displayed when the motor temperature reaches the warning level 95 of the nominal value 3005 MOT THERM TIME Time for 63 temperature rise This is the time within which the motor temperature reaches 63 of the final temperature rise Figure 34 shows motor thermal time definition If thermal protection according to UL requirements for NEMA class motors is desired use this rule of thumb MOTOR THERM TIME equals 35 times t6 t6 in seconds is the time that the motor can safely operate at six times its rated current given by the motor manufacturer The thermal time for a Class 10 trip curve is 350 s for a Class 20 trip curve 700 s and for a Class 30 trip curve 1050 s Motor load A Temp Rise gt l 100 7 gt er l H t Mot therm time Figure 34 Motor thermal time 3006 MOT LOAD CURVE Motor current maximum limit MOTOR LOAD CURV
103. ed contact your ABB supplier for a copy of the Modbus Protocol Guide Register Read and Write The ACS 400 has all drive parameter control and status information mapped into a 4xxxx register area This holding register area can be read from an external device and an external device can modify the register values by writing to them There are no setup parameters for mapping the data to the 4xxxx register The mapping is predefined and corresponds directly to the ACS 400 parameter grouping All parameters are available for both reading and writing The parameter writes are verified for correct value and for valid register addresses Some parameters never allow writes including Group 1 actual values some allow only zero write including Group 1 fault memories some parameters allow write only when the drive is stopped including Group 99 setup variables and some can be modified at any time including e g Group 22 acceleration and deceleration ramp times Note Parameter writes through Channel 1 Standard Modbus are always volatile i e modified values are not automatically stored to permanent memory Parameter 1607 PARAM SAVE can be used to save all altered values 138 ACS 400 User s Manual Register Mapping The drive parameters are mapped to the 4xxxx area so that 40001 40099 are reserved for drive control registers 40101 40199 is reserved for the actual values parameter group 1 e 40201 40299 is reserv
104. ed for parameter group 2 e 40301 40399 is reserved for fault and alarm information e other parameter groups 49901 49999 is reserved for the start up data Register addresses 4GGPP are shown in Table 19 In this table GG is the group number and PP is the parameter number within the group Table 19 Parameter mapping 4GGPP GG PP 40001 40006 00 Drive control registers 01 Control word 02 Reference 1 03 Reference 2 04 Status word 05 Actual value 1 06 Actual value 2 40102 40130 01 OPERATING DATA 02 SPEED 30 OLDEST FAULT 41001 41003 10 COMMAND INPUTS 01 EXT1 COMMANDS 02 EXT2 COMMANDS 03 DIRECTION 41101 41108 11 REFERENCE SELECT 01 KEYPAD REF SEL 08 CONST SPEED 7 49901 49908 99 START UP DATA 02 APPLIC MACRO 08 MOTOR NOM SPEED The register addresses between the groups are invalid No reads or writes are allowed for these addresses If there is an attempt to read or write outside the parameter addresses the Modbus interface will return an exception code to the controller ACS 400 User s Manual 139 Exception Codes The ACS 400 supports the standard Modbus exception codes These are shown in Table 20 Table 20 Exception codes Code Name Meaning 01 ILLEGAL The function code received in the query is not an allowable FUNCTION action for the slave ACS 400 Unsupported Command 02 ILLEGAL DATA The d
105. election signal O NOT SEL The first ramp pair is used ACCELER TIME 1 DECELER TIME 1 1 5 DI1 DI5 Ramp pair selection is done through a digital input DI1 to DI5 Digital input deactivated Ramp pair 1 ACCELER TIME 1 DECELER TIME 1 is used Digital input activated Ramp pair 2 ACCELER TIME 2 DECELER TIME 2 is used 2202 ACCELER TIME 1 Ramp 1 time from zero to maximum frequency 0 MAXIMUM FREQ 2203 DECELER TIME 1 Ramp 1 time from maximum frequency to zero MAXIMUM FREQ 0 2204 ACCELER TIME 2 Ramp 2 time from zero to maximum frequency 0 MAXIMUM FREQ 2205 DECELER TIME 2 Ramp 2 time from maximum frequency to zero MAXIMUM FREQ 0 2206 RAMP SHAPE Acceleration deceleration ramp shape selection O LINEAR 1 FAST S CURVE 2 MEDIUM S CRV 3 SLOW S CURVE Output frequency A MAXIMUM FREQ Linear S curve Time Ramp time Figure 31 Definition of acceleration deceleration ramp time ACS 400 User s Manual 91 Group 25 Critical Freq In some mechanical systems certain speed ranges can cause resonance problems With this parameter group it is possible to set up to two different speed ranges that the ACS 400 will skip over Code Description 2501 CRIT FREQ SEL Critical frequencies activation 0 OFF 1 0N 2502 CRIT FREQ 1 LO Critical frequency 1 start Note If LOW gt HI no c
106. em with two motors There is a thermal relay in the supply circuit of M2 126 ACS 400 User s Manual Code Description 8121 REG BYPASS CTRL Regulator by pass control provides a simple control mechanism without a PID regulator By pass control is needed in special applications only Examples are given in Figure 53 and Figure 54 0 NO Process PID regulator is in use 1 YES The process PID regulator is bypassed The signal connected to the PID Controller actual value pin parameter 4006 ACTUAL VAL SEL is used as the PFC frequency reference The automatic start and stop of constant speed motors is referred to this actual value signal instead of the output of the PID regulator Measured Inlet Flow Reference for the Pumping Station 3 E Outlet Phi Inlet Pipe 1 di au y Pipe 2 Outlet Sewage Tank 3 Outlet P1 Pipe 3 P2 y Contactors Acs 400 F3 y 7 7f Mains 3 3 4 Figure 53 Regulator bypass control The capacity of the pumping station outlet flow follows the measured inlet flow Output Frequency Maximum frequency Start freq 2 Start freq 1 Low freq 2 Low freq 1 Minimum pe Control Signal frequency a b C a No auxiliary motors running b One auxiliary motor running c Two auxiliary motors running Figure 54 The relation between the control signal and
107. er 3001 Al lt MIN FUNCTION 9 MOTOR OVERTEMP Motor overtemperature condition as estimated by the ACS 400 Refer to parameters 3004 3008 10 PANEL LOSS Panel communication loss Control panel is disconnected when the drive is receiving start stop and direction commands from the panel Drive is in local control mode LOC is shown in the control panel display or Drive is in remote control mode REM is shown and is programmed to accept start stop direction or reference from the panel Refer to parameters in groups 10 COMMAND INPUTS and 11 REFERENCE SELECT See also parameter 3002 PANEL LOSS 11 PARAMETERING Parameter values are inconsistent MINIMUM Al1 gt MAXIMUM Al1 parameters 1301 1302 MINIMUM AI2 gt MAXIMUM AI2 parameters 1304 1305 MINIMUM FREQ gt MAXIMUM FREQ parameters 2007 2008 PFC block tries to use the I O extension module NDIO but the DDCS link is not programmed properly 12 MOTOR STALL Motor stall This may be caused by excessive load or insufficient motor power Refer to parameters 3009 3012 13 SERIAL COMM LOSS Serial communication through Standard Modbus Channel is lost Check connections between external control system and the ACS 400 e Refer to parameters 5003 COMM FAULT TIME and 5004 COMM FAULT FUNC 14 EXTERNAL FAULT SIGNAL External fault is active See parameter 3003 EXTERNAL FAULT 15 OUTPUT EARTH FAULT Ground fault The load on the input power system is out
108. everse Activate to reverse rotation direction Hand 13 DI 3 EXT1 EXT2 Selection Activate to select auto control 14 DI 4 Forward Reverse Auto 15 DI 5 Start Stop Activate to start ACS 400 Auto 16 DCOM2 17 ROTC Relay output 1 programmable 18 ROTA gt Default operation Fault gt 17 connected to 18 19 ROTB Do RO2C Relay output 2 programmable 21 ROZA gt Default operation Running gt 20 connected to 22 22 RO2B Note Parameter 2107 START INHIBIT should be 0 OFF Hand Auto parameter values 1001 ExT T 1 COMMANDS E 1402 RELAY OUTPUT 2 2 RUNJ 1002 ExT T 2 COMMANDS DI5 4 1503 AO CONTENT MAX 60 Hz 1003 DIRECTION REQUEST 1601 RUN ENABLE O NOT SEL 1102 EXT1 EXT2 SEL DI3 1604 FAULT RESET SEL O KEYPAD 1103 EXT REF1 SELECT AM 2008 MAXIMUM FREQ 60 Hz 1105 EXT REF1 MAX 60 Hz 2105 PREMAGN SEL O NOT SEL 1106 EXT T REF2 SELECT 2 A12 2201 ACC DEC 1 2 SEL O NOT SEL 1201 co NST SPEED SEL O NOT SEL 4001 PID GAIN 1 0 1401 RE LAY OUTPUT 1 3 FAULT 1 4002 PID INTEG TIME 60s 60 ACS 400 User s Manual Application Macro PID Control This macro is intended for use with different closed loop control systems such as pressure control flow control etc The value of parameter 9902 is 6 PID CTRL Input signals Output signals Jumper Setting
109. function The time is counted only when the ACS 400 Start signal is on See parameter 8119 AUTOCHNG LEVEL for information on the operation of the Autochange 0 0 NOT SEL This setting switches off the Autochange function Note The ACS 400 always coasts to stop when autochange is performed Warning If the Autochange function is used the Interlocks must be in use In the Autochange system there is a contactor between the ACS 400 s output terminals and the speed controlled motor The contactor is damaged if opened without first interrupting the ACS 400 inverter bridge switching The inverter switching is interrupted when the Interlock is switched off and the ACS 400 coasts to stop ACS 400 User s Manual 121 Code Description 8119 AUTOCHNG LEVEL Sets the operation limit for the Autochange logic This parameter can be used to deny Autochange when the Pump Fan system is operating near maximum capacity When the output from the PID PFC control block exceeds the level set by this parameter Autochange operation is not possible Output frequency A f MAX No aux 1 aux 2 aux motors motor motor Allowed autochange area gt PID output 8119 AUTOCHNG LEVEL 100 96 Figure 51 Autochange level Autochange operation The purpose of the Autochange operation is to ensure equal duty time for all the motors Each motor in the system will in its turn be connected to the ACS 400 as well as direct on line T
110. g Ramp Function Generator output held 6 1 Normal operation Enter OPERATING 0 Force Ramp Function Generator input to zero 7 0 1 Fault reset Enter SWITCH ON INHIBITED 0 Continue normal operation 810 10 Unused 11 1 Select external control location 2 EXT2 0 Select external control location 1 EXT1 12 to 15 Unused ACS 400 User s Manual 1441 Example on Using the Control Word The following example shows how to use the Control Word to start the drive When the power is connected for the first time the state of the drive see the state machine in Figure 58 is NOT READY TO SWITCH ON Control Word is used to step through the state machine states until OPERATING state is reached meaning that the drive is running and follows the given reference Table 23 Using the Control Word Control Word Value Description Step 1 CW 0000 0000 0000 0110 When this value is written the drive state changes to READY TO SWITCH ON bit 15 bit 0 Step 2 Wait at least 100 ms before proceeding Step 3 CW 0000 0000 0000 0111 When this value is written the drive state changes to READY TO OPERATE Step 4 CW 0000 0000 0000 1111 When this value is written the drive starts but will not accelerate Drive state changes to OPERATION ENABLED Step 5 CW 0000 0000 0010 1111 When this value is written the ramp function generator RFG output is released Drive state changes to RFG ACC
111. guration The value of parameter 9902 is O FACTORY DI 4 is connected Input signals Output signals Jumper Setting Start stop and direction An output AO DI1 2 3 Frequency Al1 0 10 V Analog reference Al1 Relay output 1 Fault Ramp pair 1 2 selection DI5 Relay output 2 Running Al2 0 4 20 mA lt 1 SCR LI 2 A1 External Reference 1 0 10 V lt gt 0 50 Hz 5 3 AGND 4 10V Reference voltage 10 VDC 5 AI2 Not used 6 AGND 7 AO 1 Output frequency 0 20 mA 0 50 Hz 8 AGND 9 24V 24 VDC 10 DCOM1 RA V i 11 DIT Momentary activation with DI2 activated Start JA 2 DI2 Momentary deactivation Stop 13 DI3 Fwd Rev activate to reverse rotation direction 14 DI4 Has to be connected 15 DI 5 Ramp pair selection Activate to select ramp pair 2 16 DCOM2 17 ROTG Relay output 1 programmable 18 ROTA gt Default operation Fault gt 17 connected to 18 19 ROTB 20 RO2C Relay output 2 programmable 2 Roa Default operation Running gt 20 connected to 22 Note DI 4 is used to configure ACS 400 It is read only once when power is connected All parameters marked with are determined by the DI4 input Note Stop input DI2 deactivated panel START STOP button interlocked local Factory 1 parameter values
112. h the relay outputs 1 and 2 as well as the analog output from serial communication channel 1 Relay outputs can be controlled in the following way Step 1 Configure the ACS 400 to supervise the value of any of the parameters 131 133 using the parameters in group 32 SUPERVISION Step 2 Configure a relay output 1 or 2 to respond to the status of one of the supervised parameters The selected relay can now be turned on or off by writing to supervised parameter 131 133 some value that is either above or below the given supervision limits Refer to Table 16 for more information on required parameter settings With the given settings writing any value 100 255 to parameter 131 SER LINK DATA 1 causes the relay output 1 to activate Writing any value O 99 to parameter 131 causes the relay output 1 to deactivate Refer to Table 17 for information on analog output control Table 16 Relay output control Setting for Code Parameter Name SEN NO Standard Function Information 9 Modbus Group 01 OPERATING DATA 0131 SER LINK DATA 1 0 255 Controlling data for the relay outputs 0132 SER LINK DATA 2 O 255 ACS 400 User s Manual 135 Alternative zena Code Parameter Name Settings Standard Function Information g Modbus Group 14 RELAY OUTPUTS 1401 RELAY OUTPUT 1 0 NOT SEL e g 7 sUPERV1 Relay output 1 function ia OV
113. he DC bus voltage as measured by the ACS 400 The voltage is displayed in Volts DC 0109 OUTPUT VOLTAGE Displays the voltage applied to the motor 0110 ACS 400 TEMP Displays the temperature of the ACS 400 heatsink in degrees Fahrenheit 0111 EXTERNAL REF 1 The value of external reference 1 in Hz 0112 EXTERNAL REF 2 The value of external reference 2 in 0113 CTRL LOCATION Displays the active control location Alternatives are 0 LOCAL 1 ExT1 2 EXT2 See Appendix A on page 151 for description of different control locations 0114 RUN TIME R Shows the total running time of the ACS 400 in hours h Can be reset by pressing UP and DOWN buttons simultaneously when in parameter set mode 0115 kwh COUNTER R Shows the counted kilowatt hours of the ACS 400 in operation Can be reset by pressing UP and DOWN buttons simultaneously when in parameter set mode 0116 APPL BLK OUTPUT The reference value in percent received from the application block The value is from PID control or PFC control depending on the selected macro Otherwise the value is from 0112 EXT REF 2 0117 DI1 DI4 STATUS Status of the four digital inputs Status is displayed as a binary number If the input is activated the display will indicate 1 If the input is deactivated the display will be 0 ACS100 PAN oe ACS PAN 000001101BIN DI4 DI3 DI2 DI1 74
114. he minimum frequency reference This value is given as a percentage of the maximum frequency 1108 EXT REF2 MAX Sets the maximum reference in When the analog input signal is at maximum external reference 2 is equal to EXT REF2 MAX See Figure 27 on page 80 the PID Control or PFC macro is selected this parameter sets the maximum process reference any macro other than PID Control is selected this parameter sets the maximum frequency reference This value is given as a percentage of the maximum frequency EXT REF MAX EXT REF MIN EXT REF EXT REF EXT REF MIN EXT REF MAX P Analog input signal Analog input signal Al min Al max Figure 27 Setting EXT REF MINIMUM and EXT REF MAXIMUM The range of the analog input signal is set by parameters 1301 and 1302 or parameters 1304 and 1305 depending on the analog input used 80 ACS 400 User s Manual Group 12 Constant Speeds The ACS 400 has 7 programmable constant speeds ranging from 0 to 250 Hz Negative speed values cannot be given for constant speeds Constant speed selections are ignored if the process PID reference is followed the drive is in local control mode or PFC Pump Fan Control is active Note Parameter 1208 CONST SPEED 7 also acts as a so called fault speed which may be activated if the control signal is lost Refer to parameter 3001 Al lt MIN FUNCTION and parameter 3002 PANEL
115. he starting order of the motors is changed when Autochange is done To use the Autochange function an external alternation switchgear is needed Refer to Appendix B on page 157 for more information When Autochange is used the interlocks parameter 8120 must also be taken into use The Autochange is performed when the Autochange Interval parameter 8118 is elapsed from the previous autochange and the output from the PFC is below the level set by this parameter Autochange operation is as follows 1 The speed controlled motor stops The contactor of the speed controlled motor is switched off 2 The starting order is changed the starting order counter steps onward 3 The contactor of the motor that will be the new speed controlled motor is switched off if the motor is running If other motors are running they will not be interrupted 4 The contactor of the new speed controlled motor is switched on The autochange switchgear connects this motor to the ACS 400 5 Time set with parameter 8122 PFC START DELAY is waited 6 Speed controlled motor starts If a constant speed motor was stopped in Step 3 one more motor is connected direct on line by switching on the contactor of that motor After this step the same number of motors is running as before the Autochange 7 Normal PFC operation continues As an example the starting order in a three motor system is changed as follows First start Motor no 1 motor no 2 motor no
116. he statutory rules defines the essential requirements for emissions of electrical equipment used in Australia and New Zealand The standard AS NZS 2064 1997 Limits and methods of measurement of electronic disturbance characteristics of industrial scientific and medical ISM radiofrequency equipment covers the detailed requirements for three phase frequency converter The frequency converter ACS 400 comply with the AS NZS 2064 1997 limits for class A equipment Class A equipment is suitable for use in all establishments other than domestic and those directly connected to a low voltage network which supplies buildings used for domestic purposes The compliance is valid with the following provisions The frequency converter is equipped with RFI filter The motor and control cables are chosen as specified in this manual The installation rules of this manual are followed ACS 400 User s Manual 161 Cabling Instructions Keep individual unscreened wires between the cable clamps and the screw terminals as short as possible Route control cables away from power cables Mains Cable A four conductor cable three phase with protective earth is recommended for the mains cabling Shielding is not necessary Dimension the cables and fuses in accordance with the input current Always pay attention to local legislation when sizing the cables and fuses The mains input connectors are at the bottom of the converter unit Mains cable routing mu
117. ient in applications where the preprogrammed application macros of the ACS 400 can provide all desired functionality For a full description of the programmable features provided by the ACS 400 see ACS 400 Complete Parameter List on page 65 The following table lists the basic parameters S Parameters can be modified only when the drive is stopped Code Name User Group 99 START UP DATA 9901 LANGUAGE Language selection 0 ENGLISH 4 SPANISH 8 DANISH 12 reserved 1 ENGLISH AM 5 PORTUGUESE 9 FINNISH 2 GERMAN 6 DUTCH 10 SWEDISH 3 ITALIAN 7 FRENCH 11 RUSSIAN 9902 APPLIC MACRO Selects application macro Sets parameter values to their default values Refer to CROSSREF for a detailed description of each macro 0 FACTORY 1 ABB STANDARD 2 3 WIRE 3 ALTERNATE 4 MOTOR POT 5 HAND AUTO 6 PID CONTROL 7 PREMAGN 8 PFC CONTROL Default value 0 FACTORY MACRO 9905 MOTOR NOM VOLT Nominal motor voltage from motor name plate Range of this parameter depends on the type of the ACS 400 Default value 400 V unit 460 V 200 V unit 230 V 9906 MOTOR NOM CURR Nominal motor current from motor name plate Values for this parameter range from 0 5 In 1 5 In where ly is nominal current of the ACS 400 Default value In 9907 MOTOR NOM FREQ Nominal motor frequency from motor name plate Range 0 250 Hz Default value
118. iliary voltage for these control connections must be taken from a single source which can either be one of the units or an external supply gt PP BP PP PE Warning The heat sink may reach a high temperature See Specifications on page 21 Note For more technical information contact the factory or your local ABB sales representative ACS 400 User s Manual iii ACS 400 User s Manual Table of Contents Salina Ae iii Installation is a aa sweeten 1 Reference Sections s 2 da A ed a eae C A cad a 3 Installation Environment 3 Dimensions iniMM 4 Mounting the ACS 400 on a Wall 6 Removing the Cover 7 Terminal Interface 9 Attaching a Warning Sticker 9 Type Code and Model Designation 10 Floating Network 11 Installation of ACS 400 Conduit Box 12 Cable Connections 14 Control Terminals 15 loo Lee en 16 Connection Examples 17 Replacing the Cover 18 Applying Power 18 Environmental nformation 18 Protection Features 19 Motor Over
119. in remote control REM the commands are given primarily through digital and analog inputs although commands can also be given through the control panel or serial communication Parameter 1102 EXT1 EXT2 SELECT selects between the two external control locations EXT1 and EXT2 For EXT1 the source of the Start Stop Direction commands is defined by parameter 1001 ExT1 COMMANDS and the reference source is defined by parameter 1103 EXT REF1 SELECT External reference 1 is always a frequency reference For EXT2 the source of the Start Stop Direction commands is defined by parameter 1002 ExT2 COMMANDS and the reference source is defined by parameter 1106 EXT REF2 SELECT External reference 2 can be a frequency reference or a process reference depending on the application macro selected In remote control constant speed operation can be programmed by parameter 1201 CONST SPEED SEL Digital inputs can be used to select between the external frequency reference and seven configurable constant speeds 1202 CONST SPEED 1 1208 CONST SPEED 7 152 ACS 400 User s Manual EXT REF2 EXT REF1 EXT1 EXT2 CONST SP KEYPAD SELECT SELECT SELECT SELECT REF SEL 1102 Control 1106 1103 0 1201 1101 Terminals 1 i AH 21Dl1 5 EXT1 Analogue KEYPAD EXT2 l inputs I Remote Al Al2 Al1 2 D f 5 DH DI5 Min freq Remote i e i f Max fre
120. inputs NDIO module 1 NDIO module 2 0 DI1 DI5 free DI1 Motor 1 Not used DI2 Unused 1 DI1 DI5 free DI1 Motor 1 Not used DI2 Motor 2 2 DI1 DI5 free DI1 Motor 1 DI1 Motor 3 DI2 Motor 2 DI2 Unused 3 DI1 DI5 free DI1 Motor 1 DI1 Motor 3 DI2 Motor 2 DI2 Motor 4 Interlock signals are active low i e an interlock is active when the corresponding interlock signal is absent If a start command is given when the interlock signal of the speed regulated motor is active the ACS 400 will not start and will show alarm 30 INTERLOCK on the control panel Each Interlock circuit should be wired as follows 1 A contact of the On Off switch of the motor must be wired to the Interlock circuit PFC logic detects if a motor is switched off The logic does not try to start the switched off motor the next available motor is started instead 2 A contact of the motor thermal relay or another protective device in the motor circuit must be wired to the Interlock input PFC logic detects if the thermal relay is activated The motor is stopped ACS 400 User s Manual 125 Code Description e a z 3 gt Orem Sag 56 Ox 2 a 229 900 lt Qoo coo tc C r ACS 400 230VAC esovac O ERM st On Off M1 M2 Figure 52 Wiring the interlocks of a PFC syst
121. ion D 9 SCR Al 1 AGND 10V Al2 AGND AO 1 el Ni oj cn AY oo ro AGND 9 24V 10 DCOM1 11 DI 1 12 DI2 13 DI 3 14 DI 4 15 DIS 16 DCOM2 Note 17 RO1C Output signals Jumper Setting An output AO Frequency AI 0 10 V Relay output 1 Fault AI2 0 4 20 mA Relay output 2 Running External Reference 1 0 10 V Reference voltage 10 VDC Not used Output frequency 0 20 mA lt gt 0 50 Hz 24 VDC Start Stop Activate to start Forward Reverse Activate to reverse rotation direction Reference up Activate to increase reference Reference down Activate to decrease reference Constant speed 1 Relay output 1 programmable 18 RO1A Default operation Fault gt 17 connected to 18 19 RO1B 20 RO2C Relay output 2 programmable 21 RO2A Default operation Running gt 20 connected to 22 22 RO2B f both DI 3 and DI 4 are active or inactive reference is kept stable Reference is stored during stop or power down condition Analog reference is not followed when motor potentiometer is selected Motor potentiometer parameter values 1001 ExT T 1 COMMANDS DI1 2 1402 RELAY OUTPUT 2 2 RUN 1002 ExT T 2 COMMANDS NOT SEL 1503 AO CONTENT MAX 60 Hz 1003 DIRECTION RE
122. ists and the gain is 1 Integration time 1 s denotes that a 100 change is achieved in 1 s Gain l I B l Gain 1 t PID integration time 4003 PID DERIV TIME PID controller derivation time If the process error value changes linearly D part adds a constant value into the PID controller output The derivative is filtered with a 1 pole filter The time constant of the filter is defined by parameter 4004 PID DERIV FILTER A Process Error Value 100 Gain m PID derivation time 106 ACS 400 User s Manual Code Description 4004 PID DERIV FILTER Time constant for the filter of D part By increasing the filter time constant it is possible to smooth the effect of the D part and suppress noise 4005 ERROR VALUE INV Process error value inversion Normally a decrease in feedback signal causes an increase in drive speed If a decrease in feedback signal is desired to cause a decrease in speed set ERROR VALUE INV to 1 YES 0 NO 1 YES 4006 ACTUAL VAL SEL PID controller feedback actual signal selection The feedback signal can be a combination of two actual values ACT1 and ACT2 The source for actual value 1 is selected by parameter 4007 and source for actual value 2 is selected by parameter 4008 1 ACTI Actual value 1 is used as the feedback signal 2 ACT1 ACT2 Difference of actual values 1 and 2 is used as the feedback signal 3 ACT1 ACT2 Sum of actual values 1 and 2 4 ACT ACT2 Prod
123. ital inputs are reserved for the interlock signals according to he following table Interlock signals No of aux motors ACS 400 digital param 8117 inputs NDIO module 1 NDIO module 2 0 DI1 DI3 free Not used Not used DI4 Motor 1 DI5 free 1 DI1 DI3 free DI4 Motor 1 DI5 Motor 2 2 DI1 DI3 free DI Motor 3 DI4 Motor 1 DI2 unused DI5 Motor 2 3 DI1 DI3 free DI1 Motor 3 Not used DI4 Motor 1 DI2 Motor 4 DI5 Motor 2 124 ACS 400 User s Manual Code Description 5 DI5 Interlocks function is in use Depending on the number of motors the digital inputs are reserved for the interloci k signals according to he following table Interlock signals No of aux motors ACS 400 digital param 8117 inputs NDIO module 1 NDIO module 2 0 DI1 DI4 free Not used Not used DI5 Motor 1 1 DI1 DI4 free DI1 Motor 2 Not used DI5 Motor 1 DI2 Unused 2 DI1 DI4 free DI1 Motor 2 Not used DI5 Motor 1 DI2 Motor 3 3 DI1 DI4 free DI1 Motor 2 DI1 Motor 4 DI5 Motor 1 DI2 Motor 3 DI2 Unused 6 EXTERNAL IO Interlocks function is in use All interlock signals are taken through external I O modules Depending on the number of motors the digital inputs are reserved for the interlock signals according to the following table Interlock signals No of aux Motors ACS 400 digital param 8117
124. ive motor will not run see page 41 motor stalls during acceleration see page 42 overvoltage fault indication see page 43 overcurrent fault indication see page 44 overload fault indication see page 45 Uundervoltage fault indication see page 46 external fault indication see page 47 no operator panel display see page 48 40 ACS 400 User s Manual Motor Will Not Run Is Operator Panel llluminated Wem YES Rated Voltage Across Terminals U1 V4 W1 NO YES Fault or Alarm Shown on Operator Panel Ves NO Green Run LED Illuminated on Operator Panel NO a YES Operator Panel in Local Control NO is YES Check circuit breaker magnetic contactor and input power Check circuit breaker magnetic contactor and input power See the rest of this section for specific fault or alarm Approximately 24VDC Present On Terminal X1 9 Place operator panel in local control and retry motor start Control power circuit is faulty replace the drive Does Operator Panel Display RUN NO YES Proper Reference Input Frequency NO g YES Voltage Present at Output Terminals NO U2 V2 W2 YES Voltage Present At Motor Terminals No YES Voltage Balanced Between Phases U2 V2 W2 NO YES Load Torque Too Large YES NO Motor is faul
125. larm and fault messages disappear when MENU ENTER or the arrow buttons on the control panel are pressed The message will reappear after a few seconds if the keypad is not touched and alarm or fault is still active 28 ACS 400 User s Manual Description DC OVERVOLTAGE FAULT 2 Figure 23 Fault and alarm messages Refer to the Programming on page 25 section for a complete list of alarms and faults Resetting the Drive from the Control Panel To reset a fault when the red LED is on press the RESET button Caution Resetting the fault may start the drive when in remote control To reset a fault when the red LED is blinking turn the power off Caution Turning the power on again may start the drive immediately Contrast Setting Display contrast can be adjusted any time Increase contrast by pressing and holding the ENTER and UP buttons Decrease contrast by pressing and holding the ENTER and DOWN buttons The buttons must be pressed simultaneously ACS 400 User s Manual 29 ACS100 PAN Control Panel The control panel can be connected to and detached from the converter at any time Control modes es N Units Active fault indicator SA AA pes Pot UB rea VENTYEWDBEV Shaft direction Display modes START STOP MENU REVERSE ENTER UP DOWN Control Modes The very first time the drive is powered up it is controlled from the Control Terminals remote control REM The ACS 400 is controlled from the control pa
126. le 22 is sent by the fieldbus master station to the drive The drive switches between its states according to the bit coded instructions of the Control Word See also state machine on CROSSREF The Status Word SW is a word containing status information sent by the drive to the master station The composition of the Status Word is explained in Table 24 Note Operation of Control Word and Status Word conforms to ABB Drives Profile with the exception of Control Word bit 10 REMOTE_CMD which is not used by the ACS 400 Table 22 The Control Word See also the state machine in Figure 58 on page 147 Bit Value Description 0 1 Enter READY TO OPERATE 0 Emergency OFF Ramp to stop according to parameter 2203 DECELER TIME 1 Enter OFF1 ACTIVE proceed to READY TO SWITCH ON unless other interlocks OFF2 OFF3 are active 1 1 Continue operation OFF2 inactive 0 Emergency OFF coast to stop Enter OFF2 ACTIVE proceed to SWITCH ON INHIBITED 2 1 Continue operation OFF3 inactive 0 Emergency stop Drive ramps to stop according to parameter 2205 DECELER TIME 2 Enter OFF3 ACTIVE proceed to SWITCH ON INHIBITED 3 0 1 Enter OPERATION ENABLED Note that also the Run enable signal must be present on a digital input see parameter 1601 RUN ENABLE 0 Inhibit operation Enter OPERATION INHIBITED Unused 1 Normal operation Enter RAMP FUNCTION GENERATOR ACCELERATOR ENABLED 0 Halt rampin
127. load Protection 20 Drive Overload Protection 20 Specifications 21 Product Conformity 23 Accessor S uu voe a ore DN qr e aia 24 Programming eia eh en a RUE este RR ene 25 ACS PAN A Control Panel 25 Control Modes 25 Output leben 26 Men Structure ase aa ee A ta ee Vi ould 26 Setting Parameter Value 27 ACS 400 User s Manual Menu FUNCIONS vee kaaa due ba lea i da dak ha 27 LED Indicators iii ni EN ENE ME Da teki 28 Diagnostic displays 28 Resetting the Drive from the Control Panel 29 Contrast Setting 29 ACS100 PAN Control Panel 30 Control MOdes ex aes Haak aa de Pd nega Pe vdani 30 Output Display axe dud A A ee ddr ees 31 Menu Giucture surse era a a A 31 Setting Parameter Value 31 Menu Functions 32 Diagnostic Displays 33 Resetting the Drive from the Control Panel 33 Diagnostics vsisi avokada rk n kan eke ee lada 35 General stni vsul zbali eea a ege d aues 35 Fault Resetting 35 Troubleshooting Guide 40
128. ned in the Machinery Directive and related harmonized standards The CDM BDM adjustable frequency drive can be considered as a part of safety device if the specific function of the CDM BDM adjustable frequency drive fulfills the requirements of the particular safety standard The specific function of the CDM BDM adjustable frequency drive and the related safety standard is mentioned in documentation of the equipment ACS 400 User s Manual 23 V Accessories ACS 100 140 400 EXT Extension cable kit for use with the control panel ACS400 IF11 3 through ACS400 IF41 3 RFI input filters RS485 232 Adapter DDCS Communication Module 24 ACS 400 User s Manual PROGRAMMING ACS PAN A Control Panel ACS PAN A is an alphanumeric control panel with LCD display and multiple languages The control panel can be connected to and detached from the converter at any time The panel can be used to copy parameters to other ACS 400 converters with the same software revision parameter 3301 Run indicator 0 0A 0 60 0 HZ mem Control modes 0 0 Hz aft direction UP DOWN Display modes UTPUT IMENU LOC REM RUNI MENA ENTER Green LED Red LED E lis RESET START STOP ESET KI e D LOC REM REVERSE Control Modes The very first time the drive is powered up it is controlled from the Control Terminal Block X1 remote control REM The ACS 400 is controlled from the control panel when the drive is in local c
129. nel when the drive is in local control LOC Switch to local control LOC by pressing and holding the MENU and ENTER buttons down simultaneously until first Loc or later LCr is displayed Ifthe buttons are released while Loc is displayed the panel frequency reference is set to the current external reference and the drive is stopped When LCr is displayed the current run stop status and the frequency reference are copied from the user I O Start and stop the drive by pressing the START STOP button Change the shaft direction by pressing the REVERSE button parameter 1003 must be set to REQUEST Switch back to remote control REM by pressing and holding the MENU and ENTER buttons down simultaneously until rE is displayed Shaft Direction FWD REV Visible Shaft direction is forward reverse Drive is running and at set point FWD REV Blinking rapidly Drive is accelerating decelerating FWD REV Blinking slowly Drive is stopped 30 ACS 400 User s Manual Output Display When the control panel is powered up the panel displays the actual output frequency Whenever the MENU button is pressed and held the control panel resumes this OUTPUT display To toggle between output frequency and output current press the UP or DOWN button To set the output frequency press ENTER Pressing the UP DOWN buttons changes the reference immediately Press ENTER again to return to OUTPUT display GQ 107 0
130. nged 132 ACS 400 User s Manual Communication settings Communication settings define the communication speed parity checking number of stop bits and fault functions These settings for Channel 1 are defined using parameters in groups 50 COMMUNICATION and 52 STANDARD MODBUS The default communication settings for Channel 1 are listed in Table 13 To be able to communicate with the master device the ACS 400 must use the same communication speed and parity settings as the master Further information on all the parameters and their alternative settings is given in ACS 400 Complete Parameter List on page 65 Table 14 Communication parameters Alternative A Code Parameter Name Settings Default Setting Function Information Group 52 STANDARD MODBUS 5201 STATION NUMBER 1 247 1 Slave number for ACS 400 in Modbus network 5202 COMM SPEED 3 300 bps 96 9600 bits s Communication speed 192 19200 bps 5203 PARITY O NONE O NONE Parity and stop bit setting 1 EVEN 2 ODD Group 50 COMMUNICATION 5003 COMM FAULT TIME 0 1 60 0 s 1 0 s Time limit for communication loss detection 5004 COMM FAULT FUNC O NOT SEL O NOT SEL Operation in case communication 1 FAULT with the master device is lost 2 CONST SP 7 3 LAST SPEED 5005 PROTOCOL SEL O NOT SEL O NOT SEL Communication protocol selection 1 DDCS Normally must be set to STD 2 STD MODBUS MODBUS 3 STD MDB
131. ntrol signal connections of the ABB Standard Alternate and Premagnetize macros 154 ACS 400 User s Manual EXT REF2 EXT REF1 EXT1 EXT2 CONST KEYPAD SELECT SELECT SEL SPEED SEL REF SEL 1106 1103 1102 1201 1101 Control I iDI2 Di i Terminal ks AM EXT Analogue KEYPAD inputs I EXT2 l Remote Al1 l i 1 Min freq Remote i d Digital KEYPAD Pb loa a Max freq inputs Local Apoli Const Crit sp DI1 DI5 AH ACTI pplic de Gods l i gt AIS i Sp l Acc Dec LAH AQT2 i AI2A i U I I ACTUAL i l Dor se REF2 1 ACTUAL l ACTUAL 2 VAL SEL REF1 Hz INSUESEL 4006 Keypad i Ref l Loc Rem O yO sacle a l Start Stop Direction NL NOT SEL V boca d Start Stop FN DI Ra EXTI e REQUEST A KEYPAD N emote Direction K AA o byes FORWARD e DISS REVERSE KEYPAD I i DI4 I i EXT1 EXT2 DIRECTION RUN ENABLE NDS COMMANDS 1003 1601 Figure 62 The control signal connections of the PID Control macro ACS 400 User s Manual 155 156 ACS 400 User s Manual Appendix B ACS 400 Pump and Fan Control PFC Macro Introduction The Pump and Fan Control PFC macro can operate a pump or fan or compressor station with one to four parallel pumps The control principle of a two pump station is as follows The motor of pum
132. ntroller falls below preset limit recovery when the process actual value falls below the preset limit Programmable sleep and wake up delays Sleep mode can also be activated through a digital input Two PID parameter sets selectable through a digital input PID controller parameters are in groups 40 and 41 ACS 400 User s Manual 159 Relay Outputs The ACS 400 has two programmable relay outputs Relay output 1 and 2 operation is configured by parameters 1401 RELAY OUTPUT 1 and 1402 RELAY OUTPUT 2 Value 29 PFC allocates the relay output for the Pump and Fan Control block This is the default setting for both relay outputs when the PFC macro is selected Adding More I O to ACS 400 When Pump and Fan control is used the ACS 400 is capable of using optional I O extension modules NDIO These modules provide additional relay outputs and digital inputs I O extensioning is needed When the standard relay outputs of the ACS 400 RO1 and RO2 are needed for other purposes and or number of auxiliary motors is large and When the standard digital inputs of the ACS 400 DI1 DI5 are needed for other purposes and or number of interlock signals auxiliary motors is large I O extension modules are connected to the ACS 400 via a DDCS fiber optic link An optional DDCS communication module is needed to use DDCS There can be either one or two NDIO modules on the DDCS link Each NDIO module contains two digital inputs and two
133. of relay outputs for different settings of parameters 1401 and 1402 If Autochange function is not used first relay output configured for PFC use controls the speed regulated motor If Autochange function is used the ACS 400 Autochange logic assigns the relay outputs to corresponding motors of which one is speed controlled Table 12 Usage of relay outputs Relay output configuration is set by parameters 1401 1402 and 8117 Number of relay outputs needed depends on the number of auxiliary motors For example if the number of auxiliary motors is 2 total of three relay outputs motors 1 2 and 3 are needed x Any setting other than 29 PFC NDIO module 1 NDIO module 2 Parameter ACS 400 relays Module node number Module node number setting 5 6 1401 1402 Relay Relay NDIO NDIO RELAY RELAY output output relay relay is di pe m OUTPUT OUTPUT RO1 RO2 output1 output2 Pinion funetion 1 2 function function function function 29 PFC 29 PFC Motor 1 Motor 2 Motor 3 Motor 4 Not used Not used start stop start stop start stop start stop 29 PFC x Motor 1 e g Fault Motor 2 Motor 3 Motor 4 Not used start stop start stop start stop start stop x 29 PFC e g Fault Motor 1 Motor 2 Motor 3 Motor 4 Not used start stop start stop start stop start stop x x e g Run e g Fault Motor 1 Motor 2 Motor 3 Motor 4 start stop start stop start stop start stop 8118 AUTOCHNG INTERV Sets the interval for the Autochange
134. ol location 12 DI3U 4D NC Speed reference is given through digital inputs as motor potentiometer control Digital input DI3 increases the speed the U stands for up and digital input DI4 decreases the speed the D stands for down NC indicates that the reference is not copied when switching control locations when switching back to a control location the reference returns to the last value used for that control location 12 DI3U 5D NC See description for 12 Digital input 5 decreases the speed 1104 EXT REF1 MIN Sets the minimum frequency reference for external reference 1 in Hz When the analog input signal is at minimum external reference 1 is equal to EXT REF1 MIN See Figure 27 on page 80 1105 EXT REF1 MAX Sets the maximum frequency reference for external reference 1 in Hz When the analog input signal is at maximum external reference 1 is equal to EXT REF1 MAX See Figure 27 on page 80 1106 EXT REF2 SELECT This parameter selects the signal source for external reference 2 The alternatives are the same as with external reference 1 see 1103 EXT REF1 SELECT 1107 EXT REF2 MIN Sets the minimum reference in When the analog input signal is at minimum external reference 2 is equal to EXT REF2 MIN See Figure 27 on page 80 If the PID Control or PFC macro is selected this parameter sets the minimum process reference If any other macro than PID is selected this parameter sets t
135. ol location selection DI3 Run enable DI2 An output AO Frequency Relay output 1 Speed regulated motor Relay output 2 Auxiliary motor o cy gt wn a 2 N Output signals Jumper Setting Al 0 10 V Al2 0 4 20 mA EXT1 Manual or EXT2 PID PFC reference 0 10 V Reference voltage 10 VDC Actual signal 0 20 mA PID Output frequency 0 20 mA lt gt 0 52 Hz 24 VDC Start Stop Activate to start ACS 400 Run enable Deactivation always stops ACS 400 EXT1 EXT2 Selection Activate to select PFC control Interlock Deactivation stops ACS 400 Interlock Deactivation stops constant speed motor Relay output 1 programmable Default operation Speed regulated motor switched on gt 17 connected to 19 Relay output 2 programmable Default operation Auxiliary motor switched on gt 20 connected to 22 Note Parameter 2107 START INHIBIT should be 0 OFF PFC parameter val 1001 ExT ues 1 COMMANDS 1402 RELAY OUTPUT 2 29 PFC 1002 ExT 2 COMMANDS 1503 AO CONTENT MAX 62 Hz 1003 DIRECTION 1601 RUN ENABLE 2 DI2 1102 EXT 1 EXT2 SEL 1604 FAULT RESET SEL O KEYPAD 1103 EXT REF1 SELECT 2008 MAXIMUM FREQ 62 Hz 1105 EXT REF1 MAX 2105 PREMAGN SEL 0 NOT SEL 1106 EXT REF2 SEL
136. omplete Parameter List on page 65 for a description of these parameters Copy Parameters from Drive to Panel upload Press amp hold Note The drive must be stopped and in local control Parameter 1602 PARAMETER LOCK must be set to 1 OPEN ACS 400 User s Manual 27 Copy Parameters from Panel to Drive download Press amp hold COPY TO DRIVE Note The drive must be stopped and in local control Parameter 1602 PARAMETER LOCK must be Set to 1 OPEN Selecting Full Parameter Set Initially only the basic parameters are visible When full Menu is active an asterisk appears on the second row of the panel display in Menu Activate this function again to resume the short Menu Press amp hold I Visible if full menu is active LED Indicators Red LED Green LED OFF ON Power ON and drive is operating normally OFF BLINKS Alarm is active ON ON Fault is active Drive can be reset from the control panel BLINKS ON Fault is active Turn power off to reset the drive Diagnostic displays When the red LED of the ACS PAN A is on or blinking a fault is active The relevant fault message flashes in the panel display When the green LED of the ACS PAN A is blinking an alarm is active The relevant alarm message is shown in the panel display Alarms 1 7 arise from button operation and the green LED does not blink for them The a
137. on section Last three exception response codes are stored into parameters 5213 5215 16 Al1 LOSS Analog input 1 loss Analog input 1 value is less than MINIMUM Al1 1301 See also parameter 3001 Al lt MIN FUNCTION 17 Al2 LOSS Analog input 2 loss Analog input 2 value is less than MINIMUM Al2 1306 See also parameter 3001 Al lt MIN FUNCTION 18 PANEL LOSS Panel communication loss Control panel is disconnected when Drive is in local control mode LOC is shown in the control panel display or Drive is in remote control mode REM and is parameterised to accept start stop direction or reference from the panel Refer to parameters in groups 10 COMMAND INPUTS and 11 REFERENCE SELECT See also parameter 3002 PANEL LOSS 19 ACS400 OVERTEMP ACS 400 overtemperature condition This alarm is given when the temperature reaches 95 of the trip limit 20 MOTOR OVERTEMP Motor overtemperature condition as estimated by the ACS 400 Refer to parameters 3004 3008 21 UNDERLOAD Motor load is too low Check for a problem in the driven equipment Refer to parameters 3013 3015 22 MOTOR STALL Motor is operating in the stall region This may be caused by excessive load or insufficient motor power Refer to parameters 3009 3012 36 ACS 400 User s Manual Display Description DDCS COMM LOSS DDCS communication loss has been detected Check the status of the fieldbus adapter Refer to the appropriate fieldbus adapter
138. onnected to the ACS 400 this parameter value must be set to 0 to ensure proper operation of the chopper O DISABLE 1 ENABLE 2006 JUNDERVOLT CTRL DC undervoltage controller enable If the DC bus voltage drops due to loss of input power the undervoltage controller will decrease the motor speed in order to keep the DC bus voltage above the lower limit By decreasing the output frequency the inertia of the load will cause regeneration back into the ACS 400 thus keeping the DC bus charged and preventing an undervoltage trip This will increase power loss ride through on systems with a high inertia such as a centrifuge or a fan O DISABLE 1 ENABLE TIME Enable with 500 ms time limit for operation 2 ENABLE Enable without time limit for operation 2007 MINIMUM FREQ Operating range minimum output frequency Note Keep MINIMUM FREQ lt MAXIMUM FREQ 2008 MAXIMUM FREQ Operating range maximum output frequency 88 ACS 400 User s Manual Group 21 Start Stop ACS 400 supports several start and stop modes including flying start and torque boosting at start DC current can be injected either before the start command premagnetizing or automatically right after the start command starting with DC hold DC hold can be used when stopping the drive with ramp If the drive is stopping by coasting DC brake can be used Note Too long a DC injection time or premagn max time causes the mo
139. ontrol LOC Switch to local control LOC by pressing and holding the LOC REM button until first LOCAL CONTROL or later LOCAL KEEP RUN is displayed Ifthe button is released while LOCAL CONTROL is displayed the panel frequency reference is set to the current external reference and the drive is stopped When LOCAL KEEP RUN is displayed the current run stop status and the frequency reference are copied from the user I O Start and stop the drive by pressing the START STOP button Change the shaft direction by pressing the REVERSE button parameter 1003 must be set to REQUEST Switch back to remote control REM by pressing and holding the LOC REM button until REMOTE CONTROL is displayed Run Indication and Shaft Direction RUN Drive is running and at setpoint RUN Shaft direction is forward gt or reverse lt RUN gt or lt RUN Arrow head blinking rapidly Drive is running but not at setpoint or Arrow head blinking slowly Drive is stopped ACS 400 User s Manual 25 Output Display When the control panel is powered up the panel displays a selection of actual values see Figure 22 Whenever the MENU button is pressed and held the control panel resumes this OUTPUT display Output current Torque Reference frequency Cursor is visible when reference can be modified Actual output frequency OUTPUT Figure 22 Output display variables The frequency refe
140. ounting screws or bolts and securely tighten in all four corners Note Lift the ACS 400 by its metal chassis Figure 6 IP 54 1 Remove the front cover see Figure 10 2 Remove the rubber plugs by pushing from outside 3 Screw in the screws Seis 4 Replace the rubber plugs T Figure 7 Removing the wall mounting template Marking and drilling the mounting holes Mounting type IP21 drives Mounting type IP54 drives ACS 400 User s Manual D Removing the Cover Opening frame size R1 and R2 units See Paragraph T for frame size assignments of type codes 1 Remove the control panel 2 Press the retaining lever inside the hole located at the top of the drive 3 Remove the cover Figure 8 Opening the frame size R1 and R2 drives of type IP 21 NEMA Type 1 Opening frame size R3 and R4 units See Paragraph T for frame size assignments of type codes Remove the control panel if needed Lift the retaining lever and simultaneously pull the upper front cover slightly Lift the other retaining lever with a screwdriver Open the upper part of the front cover and remove it Press the retaining lever and pull Remove the lower part of the front cover oahwn Figure 9 Opening the frame size R3 and R4 of type IP 21 NEMA Type 1 ACS 400 User s Manual IP 54 NEMA Type 12 amp 4 1 Take the screws off 2 Remove the front cover 3 Remove panel if needed 1 2 Figure 10 Opening t
141. p and digital input DI4 decreases the speed the D stands for down R indicates that the reference will be reset to zero when a Stop command is given The rate of change of the reference signal is controlled by parameter 2204 ACCELER TIME 2 6 DI3U 4D Same as above except that the speed reference is not reset to zero on a Stop command When the ACS 400 is started the motor will ramp up at the selected acceleration rate to the stored reference 7 DI4U 5D Same as above except that the digital inputs in use are DI4 and DI5 8 COMM The reference is given through serial communication 9 COMM Al1 10 COMM Al1 The reference is given through serial communication The analog input 1 signal is combined to the fieldbus reference sum or multiplication For more information Standard Serial Communication on page 129 Continued on next page ACS 400 User s Manual 79 Continued from previous page 11 DI3U 4D R NC Speed reference is given through digital inputs as motor potentiometer control Digital input DI3 increases the speed the U stands for up and digital input DI4 decreases the speed the D stands for down R indicates that the reference will be reset to zero when a Stop command is given NC indicates that the reference is not copied when switching control locations when switching back to a control location the reference returns to the last value used for that contr
142. p Function Generator Figure 58 The state machine for evaluation of start and stop signals ACS 400 User s Manual 147 Fault and Alarm Status The ACS 400 provides fault and alarm status words for the external control system These data words are accessible only through the serial communication link but not from the control panel Fault and alarm status words are located in parameter group 3 The group also contains copies of the Control Word and Status Word Group 3 parameters are of read only type however both alarm words can be reset by writing a zero to them Table 26 Fault and alarm status words MAIN COMMAND WORD Description Read only copy of the Control Word See page 141 MAIN STATUS WORD Read only copy of the Status Word See page 143 FAULT WORD 1 Fault information When a fault is active the corresponding bit is set Bit descriptions are given in Table 27 FAULT WORD 2 Fault information When a fault is active the corresponding bit is set Bit descriptions are given in Table 27 ALARM WORD 1 Alarm information When an alarm is active the corresponding bit is set Bits remain set until the whole alarm word is reset by writing O to it See Table 28 ALARM WORD 2 Alarm information When an alarm is active the corresponding bit is set Bits remain set until the whole alarm word is reset by writing O to it See Table 28 Table 27 Bit descriptions for fault wo
143. p no 1 is connected to the ACS 400 The capacity of the pump is controlled by varying the motor speed The motor of pump no 2 is connected direct on line The pump can be switched on and off by the ACS 400 when necessary The process reference and actual value are fed to the ACS 400 PID controller The PID controller adjusts the speed frequency of the first pump such that the process actual value follows the reference When the frequency reference of the process PID controller exceeds the limit set by the user the PFC macro automatically starts the second pump When the frequency falls below the limit set by the user the PFC macro automatically stops the second pump Using the digital inputs of the ACS 400 an interlocking function can be implemented the PFC macro detects if a pump is switched off and starts the other pump instead The PFC macro makes automatic pump alternation possible Thus each pump can be run with an equal duty time For more information on the alternation system and the other useful features such as Sleep function Constant reference value Reference steps and Regulator by pass see parameter group 40 41 and 81 parameter descriptions As default when PFC macro is selected the ACS 400 receives the process reference setpoint through analog input 1 process actual value through analog input 2 and Start Stop commands through digital input 1 The interlocks are connected to digital input 4 speed regulated motor and digital
144. parameter 9902 is 2 3 WIRE Input signals Start stop and direction DI1 2 3 Analog reference Al1 Preset speed selection DI4 5 o NJ on BY co po N Output signals An output AO Frequency Relay output 1 Fault Relay output 2 Running Jumper Setting Al 0 10 V Al2 0 4 20 mA External Reference 1 0 10 V lt gt 0 50 Hz Reference voltage 10 VDC Not used Output frequency 0 20 mA 0 50 Hz 24 VDC Momentary activation with DI2 activated Start Momentary deactivation Stop Activate to reverse rotation Fwd Rev Constant speed selection Constant speed selection Relay output 1 programmable Default operation fault gt 17 connected to 18 Relay output 2 programmable Default operation running gt 20 connected to 22 Constant speed selection 0 open 1 connected DI4 DI5 Output Reference through Al1 Constant speed 1 1202 Constant speed 2 1203 O O o Constant speed 3 1204 Note Stop input D12 deactivated panel START STOP button interlocked local Application Macro 3 wire parameter values 1001 EXT 1 COMMANDS 4 DITP 2P 3 1402 RELAY OUTPUT 2 2 RUN 1002 EXT 2 COMMANDS O NOT SEL 1503 AO CONTENT MAX 60 Hz
145. possible Also the cable routing must be done so that the distance from the sides of the converter is at least 20 cm to avoid excessive radiation to the cable A double shielded twisted pair cable is recommended for the analogue signals Employ one individually shielded pair for each signal Do not use common return for different analogue signals A double shielded cable is the best alternative for low voltage digital signals but single shielded twisted multipair cable is also usable see Figure 69 Figure 69 A double shielded twisted pair cable on the left and a single shielded twisted multipair cable on the right The analogue and digital input signals should be run in separate screened cables Relay controlled signals providing their voltage does not exceed 48 V can be run in the same cables as digital input signals lt is recommended that the relay controlled signals be run as twisted pairs Never mix 24 VDC and 115 230 VAC signals in the same cable Note When the overriding control equipment and the ACS 400 are installed inside the same cabinet these recommendations might be overly cautious If the customer plans to test the entire installation there is an opportunity to save some costs by relaxing these recommendations for example by using unshielded cable for the digital inputs But the customer must verify this Control Panel Cable If the control panel is connected to the converter with a cable use only the p
146. pplied wake up level floats with the set point here parameter 4015 WAKE UP LEVEL equals to 60 PID control inverted case ACS 400 User s Manual 111 ACT VALUE APPLIED WAKE o S j UP LEVEL RH ES SLEEP DEACTIVATED md mE TIME EXPIRES gt TIME Figure 48 Wake up level operation with non inverted error value A TIME EXPIRES APPLIED WAKE JOA N UP LEVEL J Na pA Ed SLEEP DEACTIVATED ACT VALUE gt Figure 49 Wake up level operation with inverted error value 112 ACS 400 User s Manual Group 41 PID Control 2 Parameters of this group belong to PID parameter set 2 The operation of parameters 4101 4112 4119 4120 is analogous with set 1 parameters 4001 4012 4019 4020 PID parameter set 2 can be selected by parameter 4016 PID PARAM SET ACS 400 User s Manual 113 Group 50 Communication Parameters of this group define some general communication settings Parameters 5001 5002 and 5007 5009 are used only if the DDCS option module is installed Code Description 5001 DDCS BIT RATE DDCS link baud rate in Mbits s 5002 DDCS NODE NR DDCS link node number 5003 COMM FAULT TIME Communication time out delay This applies both to standard Modbus and DDCS link When communication loss supervision is activated by parameter 5004 COMM FAULT FUNC the bus master must write Control Word Reference 1 or Reference 2 periodically The maximum period is set by
147. q Digital KEYPAD Applic Loca inputs Local ep O Const Crit speed Din DIS Speed c SRE Acc Dec I I i i 1 I I i i i REF2 i i REF1 Hz Ca U Keypad i i Ref Loc Rem L 4 l Se p i d I e Start Stop NOT SEL Local i DIM DIB N EXT1 N BaS Remot Direction KEYPAD NOT SEL o emete FORWARD 1 DId DI5 5 EXT2 REVERSE Een Enabled i i E i DI1 DI5 EXT1 EXT2 DIRECTION RUN ENABLE COMMANDS COMMANDS 1003 1601 1001 1002 Figure 60 Selecting control location and control source ACS 400 User s Manual 153 Internal Signal Connections for the Macros EXT REF2 EXT REF1 EXT1 EXT2 CONST SP KEYPAD SELECT SELECT SELECT SELECT REF SEL E 1106 1103 1102 1201 1101 Maui tU l ExT DI3 4 y An EXT1i Analogue KEYPAD inputs i EXT2 ATA AA t DI3 4 Min freg Digital KEYPAD i Max freq inputs E Const Crit sp SS E Pena Acc Dec i REF2 REF1 Hz Keypad Ref Coc Rem eec eoe aa maraka Ed sena AP d Start Stop Direction l ZDA i i FH i NY NOT SEL Local H EE Y Start Stop EOR DI1 DI5 EXT A Direction Nasta Jt KEYPAD NOT SEL FORWARD e Ne PA I I Ka DH DI5 EXT2 REVERSE l l I Enabled am DI1 DI5 AMES ANOS DIRECTION RUN ENABLE 1001 1002 1003 aU Figure 61 The co
148. r 1 DI3 DI5 free Not used Not used DI1 free DI2 Motor 1 DI3 Motor 2 DI4 DI5 free DI1 free DI2 Motor 1 DI3 Motor 2 DI4 Motor 3 DI5 free DI DI2 DI3 DI4 DIS free Motor 1 Motor 2 Motor 3 Motor 4 Warning If the Autochange function is used the Interlocks must also be taken into use see parameter 8118 AUTOCHNG INTERV 0 NOT SEL No Interlocks function is in use All digital inputs are available for other purposes Interlocks function is in use Depending on the number of motors the digital inputs are reserved for the interlock signals according to epending on the number of motors the digital inputs are reserved for the ACS 400 User s Manual 123 Code Description 3 DI3 Interlocks function is in use Depending on the number of motors the digital inputs are reserved for the interlock signals according to the following table Interlock signals No of aux motors param 8117 ACS 400 digital inputs NDIO module 1 NDIO module 2 DI1 DI2 free DI3 Motor 1 DI4 DI5 free Not used Not used DI1 DI2 free DI3 Motor 1 DI4 Motor 2 DIS free DI1 DI2 free DI3 Motor 1 DI4 Motor 2 DI5 Motor 3 DI1 DI2 free DI3 Motor 1 DI4 Motor 2 DI5 Motor 3 DI1 Motor 4 DI2 Unused Not used 4 DIA Interlocks function is in use Depending on the number of motors the dig
149. r cable size U2 V2 W2 Power output to motor See T Uc Uc DC bus For optional ACS BRK braking unit X11to16 Control Wiring Low voltage control use shielded cable X1 17 to 22 Control Wiring Low voltage or 115VAC X3 RS485 Communications Use shielded cable Follow local codes for cable size To avoid electromagnetic interference use separate conduits for input power wiring motor wiring control and communications wiring and braking unit wiring Keep these four classes of wiring separated in situations where the wiring is not enclosed in conduit Also keep 115VAC control wiring separated from low voltage control wiring and power wiring Use shielded cable for control wiring Use 60 C rated power cable 75 C if over 100 amps Refer to Section T Specifications on page 21 for current ratings fuse recommendations and the maximum wire size capacities and tightening torques for the terminals The ACS 400 is suitable for use on a circuit capable of delivering not more than 65 000 RMS symmetrical amperes 480 V maximum The ACS 400 has an electronic motor protection feature that complies with the requirements of the National Electric Code USA When this feature is selected and properly adjusted additional overload protection is not required unless more than one motor is connected to the drive or unless additional protection is required by applicable safety regulations See parameters 3004 3005 and 3006 For C
150. rds 1 and 2 See also the Diagnostics section for more information about faults and fault codes Bit Fault Word 1 Fault Word 2 Overcurrent Underload DC overvoltage Reserved ACS 400 overtemperature DDCS link Fault current Reserved Output overload DC undervoltage Analog input 1 fault Analog input 2 fault COIN OO a A N oO Motor overtemperature Hardware error o Panel loss o Parameters inconsistent E A DC bus ripple too large E N Motor stall ET e Serial communication loss E A External fault a Output ground fault 148 ACS 400 User s Manual Table 28 Bit descriptions for ALARM WORD 1 and ALARM WORD 2 See also the Diagnostics section for more information about alarms and alarm codes Bit Alarm Word 1 Alarm Word 2 Overcurrent controller alarm Overload alarm Overvoltage controller alarm Autoreset alarm Undervoltage controller alarm PID sleep alarm Direction lock alarm PFC autochange alarm Serial communication loss PFC interlock alarm Modbus exception Analog input 1 loss Analog input 2 loss Panel loss ACS 400 overtemperature o 0 J O OI Boni Motor overtemperature Underload Motor stall alarm DDCS link Reserved Reserved Reserved ACS
151. relay outputs Setting up NDIO modules Refer to the Installation and Start up Guide of the NDIO module for installation instructions After installation the communication between the ACS 400 and NDIO modules is set up as follows Set the module node numbers using the DIP switches located inside the modules Refer to NDIO module manual for details Module node number must be 5 if only one NDIO module is used Node numbers must be 5 and 6 if two NDIO modules are used Connect power to NDIO modules Activate DDCS protocol by setting parameter 5005 PROTOCOL SEL to 1 DDCS Tell the ACS 400 that extended I O is used by setting parameter 5007 DDCS BUS MODE to 2 EXTENDED IO Communication between the ACS 400 and the NDIO module s is now operating Alternation Switchgear PFC autochange operation set by parameters 8118 AUTOCHNG INTERV and 8119 AUTOCHNG LEVEL requires dedicated alternation switchgear which is controlled through the relay outputs of the ACS 400 Contact your nearest ABB supplier for more information 160 ACS 400 User s Manual Appendix C ACS 400 EMC Instructions Mandatory Installation Instruction According to the EMC Directive for type ACS 400 frequency converters Follow the instructions given in the ACS 400 User s Manual and the instructions delivered with different accessories CE Marking A CE mak is attached to ACS 400 frequency converters to verify that the unit follows the provisions of the Europe
152. rence can be modified using the UP DOWN buttons when the reference display is underlined Pressing the UP or DOWN buttons changes the reference immediately The reference can be modified in local control mode but also in remote control mode if the ACS 400 is programmed for that type of operation Menu Structure ACS 400 has a large number of parameters Of these only the so called basic parameters are initially visible See Selecting Full Parameter Set on page 28 for details on specifying the full parameter set The menu consists of parameter groups and menu functions 26 ACS 400 User s Manual Setting Parameter Value Parameter set mode is entered by pressing ENTER In set mode value is underlined Value is altered by pressing the UP DOWN buttons The modified value is stored by pressing ENTER Modifications can be cancelled and set mode inactivated by pressing MENU accept and store Q Gra exit without saving e Note In parameter set mode the cursor blinks when the parameter value is altered Note To view the parameter default value in the parameter set mode press the UP DOWN buttons simultaneously Menu Functions Scroll the Menu for desired menu function then press and hold ENTER down until the display blinks to start the operation Note Parameter copying does not affect all parameters The excluded parameters are 9901 9905 9910 1605 1607 5002 5201 and all Group 51 parameters See ACS 400 C
153. ritical frequency lock out will happen 2503 CRIT FREQ 1 HI Critical frequency 1 end 2504 CRIT FREQ 2 LO Critical frequency 2 start 2505 CRIT FREQ 2 HI Critical frequency 2 end Note If LOW gt HI no critical frequency lock out will happen Example A fan system vibrates badly from 18 Hz to 23 Hz and from 46 Hz to 52 Hz Set the parameters as follows CRIT FREQ 1 LO 18 Hz and CRIT FREQ 1 HI 23 Hz CRIT FREQ 2 LO 46 Hz and CRIT FREQ 2 HI 52 Hz foutput frer H HL fiH RL fen gt frer Hz 18 23 46 52 Figure 32 Example of critical frequencies setting in a fan system with bad vibrations at frequency ranges 18 Hz to 23 Hz and 46 Hz to 52 Hz 92 ACS 400 User s Manual Group 26 Motor Control Code Description 2603 IR COMPENSATION Table 10 Typical IR compensation values IR compensation voltage at O Hz Note IR compensation should be 400 V Units kept as low as possible to prevent Py kW 3 75 15 22 37 overheating Refer to Table 10 IRcomp V 21 18 15 12 10 2604 IR COMP RANGE IR compensation range Defines frequency after which IR compensation is 0 V 2605 LOW NOISE Motor acoustical noise option 0 OFF Standard switching frequency 4 kHz 1 0N 1 Low noise switching frequency 8 kHz Note When the low noise setting is used the maximum loadability of the ACS 400 is Io at 30 C ambient temperatur
154. s and cables is sufficient If in doubt the supply transformer with static screening between the primary and secondary windings can be used Note Remove both grounding screws otherwise you may cause danger or damage the unit Location of the grounding screws is shown in Figure 15 and Figure 16 Note In IT networks do NOT use an RFI filter The input power becomes connected to ground through the filter capacitors In floating networks this may cause danger or damage the unit GND 1 GND 2 GND 1 GND 2 Figure 16 Removing the grounding screws from frame size R3 and R4 frequency converters ACS 400 User s Manual 11 I Installation of ACS 400 Conduit Box A package containing one USA conduit box installation kit is included with the ACS 400 Figures show conduit box installation IEC conduit plate installation is not covered in the US manual for the ACS 400 please contact your local ABB representative for additional information regarding IEC installations For CE installation requirements see ABB publication CE US 02 CE Council Directives and Variable Speed Drives Contact your local ABB representative for specific IEC installation instructions Figure 17 US conduit box installation kit Your ACS 400 should include the parts shown above the two 2 halves of the conduit box four 4 screws with captive washers and two 2 self tapping screws A different conduit arrangement containing five screws and two cable clamp
155. s below fault limit 3022 Al1 FLT LIMIT or 3023 AG FLT LIMIT O NOT SEL No operation 1 FAULT A fault indication is displayed and the ACS 400 coasts to stop 2 CONST SP 7 A warning indication is displayed and the speed is set according to parameter 1208 CONST SPEED7 3 LAST SPEED A warning indication is displayed and the speed is set to the level at which the ACS 400 was last operating This value is determined by the average speed over the last 10 seconds Caution If you select CONST SPEED 7 or LAST SPEED make sure that it is safe to continue operation in case the analog input signal is lost 3002 PANEL LOSS Operation in case of control panel loss fault 1 FAULT A fault indication is displayed and the ACS 400 coasts to stop 2 CONST SP 7 A warning indication is displayed and the speed is set according to parameter 1208 CONST SPEED7 3 LAST SPEED A warning indication is displayed and the speed is set to the level at which the ACS 400 was last operating This value is determined by the average speed over the last 10 seconds Caution If you select CONST SPEED 7 or LAST SPEED make sure that it is safe to continue operation in case the panel is lost 3003 EXTERNAL FAULT External fault input selection O NOT SEL External fault signal is not used 1 5 DI1 DI5 This selection defines the digital input used for an external fault signal If an external fault occurs i e digital input is d
156. se 120013 Constant Speed selection E ate Constant Speed selection 18 DCOMZ Ramp pair selection Activate to select ramp pair 2 a STE m Relay output 1 programmable Cer Default operation Fault gt 17 connected to 18 2 d Relay output 2 programmable SRO LL Default operation Running gt 20 connected to 22 Constant speed selection 0 open 1 connected DI3 DI4 Output 0 0 Reference through Al1 1 0 Constant speed 1 1202 0 1 Constant speed 2 1203 1 1 Constant speed 3 1204 Application macro Alternate parameter values 1001 EXT 1 COMMANDS 9 DI1F 2R 1402 RELAY OUTPUT 2 2 RUN 1002 EXT 2 COMMANDS O NOT SEL 1503 AO CONTENT MAX 60 Hz 1003 DIRECTION 3 REQUEST 1601 RUN ENABLE O NOT SEL 1102 EXT1 EXT2 SEL 6 EXT1 1604 FAULT RESET SEL O KEYPAD 1103 EXT REF1 SELECT 1 Ai 2008 MAXIMUM FREQ 60 Hz 1105 EXT REF1 MAX 60 Hz 2105 PREMAGN SEL 0 NOT SEL 1106 EXT REF2 SELECT 0 KEYPAD 2201 ACC DEC 1 2 SEL 5 DI5 1201 CONST SPEED SEL 7 DI3 4 4001 PID GAIN 1 0 1401 RELAY OUTPUT 1 3 FAULT 1 4002 PID INTEG TIME 60s 58 ACS 400 User s Manual Application Macro Motor Potentiometer This macro provides a cost effective interface for PLCs that vary the speed of the drive using only digital signals The value of parameter 9902 is 4 MOTOR POT Input signa Is Start stop and direction DI1 2 Reference up DI3 Reference down DI4 Preset speed select
157. selection parameter 1103 EXT REF1 SELECT or 1106 EXT REF2 SELECT to COMM COMM Al1 or COMM Al1 The latter two enable correction of the fieldbus reference using analog input Al1 The following table explains these selections Note that the analog input value is a percentage value 0 100 which can be seen in parameter 0118 Al1 When the analog input is 50 the correction is 0 When the input is lt 50 gt 50 the correction reduces respectively increases the reference used Table 25 Correcting the fieldbus reference through analog input Parameter Setting Effect of Al1 Value on Fieldbus Reference COMM None COMM AI1 Corrected fieldbus reference given fieldbus reference analog input Al1 value COMM AI Corrected fieldbus reference given fieldbus reference analog input Al1 value 50 96 144 ACS 400 User s Manual Example of the effect of Al1 value on fieldbus reference Assume that 2008 MAXIMUM FREQ 50 Hz Assume that fieldbus reference 1 is 5000 corresponding to 25 of full scale and voltage at Al1 is 3 V corresponding to 30 of full scale 1 If setting COMM AI1 is used then the corrected fieldbus reference is 25 30 50 5 or 2 5 Hz 2 If setting COMM AI1 is used then the corrected fieldbus reference is 25 30 50 15 or 7 5 Hz REF A 100 50 FIELDBUS REFERENCE gt AM 50 95 100 96 ACS 400 User s Manual 145 Actual V
158. simultaneously when in parameter set mode 0131 SER LINK DATA 1 Free data location that can be written from serial link 0132 SER LINK DATA 2 Free data location that can be written from serial link 0133 GER LINK DATA 3 Free data location that can be written from serial link 0134 PROCESS VAR 1 Process variable 1 as selected by the parameters in group 34 0135 PROCESS VAR 2 Process variable 2 as selected by the parameters in group 34 0136 RUN TIME Shows the total running time of ACS 400 in thousands of hours kh 0137 MWh COUNTER Counts the megawatt hours of ACS 400 in operation ACS 400 User s Manual 75 Group 10 Command Inputs Start Stop and Direction commands can be given from the control panel or from two external locations EXT1 EXT2 The selection between the two external locations is made with parameter 1102 EXT1 EXT2 SEL For more information on control locations refer to Appendix A on page 151 Code Description 1001 EXT1 COMMANDS Defines the connections and the source of Start Stop Direction commands for External control location 1 EXT1 0 NOT SEL No Start Stop Direction command source for ExT1 is selected i Dl1 Two wire Start Stop connected to digital input DI DI1 deactivated Stop DU activated Start 2 DI1 2 Two wire Start Stop Direction Start Stop is connected to digital input DI1 as above Direction is connected to digital input DI2 DI2 deactivated Forw
159. st be done so that the distance from the sides of the converter is at least 20 cm to avoid excessive radiation to the mains cable In the case of shielded cable twist the cable screen wires together into a bundle not longer than five times its width and connect to the PE terminal of the converter Or PE terminal of input filter if present Motor Cable The motor cable must be a symmetrical three conductor cable with a concentric PE conductor or a four conductor cable with a concentric shield however a symmetrical constructed PE conductor is always recommended Minimum requirement for the motor cable screen is presented in Figure 66 Insulation jacket Copper wire screen Helix of copper tape Inner insulation Cable core Figure 66 Minimum requirement for motor cable screen e g MCMK NK Cables 162 ACS 400 User s Manual Recommended Symmetrical shielded cable three phase conductors and a concentric or otherwise symmetrically constructed PE conductor Allowed A separate PE conductor is required if the conductivity of the cable shield is lt 50 of the conductivity of the phase conductor and a shield PE hield conductor and shield Shield PE ePE Allowed for motor cables with phase conductor cross section up to 10 mm Not allowed for motor cables Shield A four conductor system three phase conductors and a protective conductor Figure 67 Cable recommendations and restrictions
160. t parameter 1108 parameter 1107 When the actual value is higher than or equal to this value the sleep function is de activated See Figure 47 and Figure 49 4016 PID PARAM SET PID parameter set selection When set 1 is selected parameters 4001 4012 and 4019 4020 are used When set 2 is selected parameters 4101 4112 and 4119 4120 are used 1 5 DI DIS PID parameter set is selected through a digital input DI1 DI5 Parameter set 1 is used when the digital input is not active Parameter set 2 is used when the digital input is active 6 SET 1 PID parameter set 1 is active 7 SET2 PID parameter set 2 is active 4017 WAKE UP DELAY Delay for deactivation of PID sleep function Refer to parameter 4015 WAKE UP LEVEL and Figure 45 4018 SLEEP SELECTION PID sleep function control 0 INTERNAL When INTERNAL is selected the sleep state is controlled by the output frequency process reference and process actual value Refer to parameters 4015 WAKE UP LEVEL and 4014 PID SLEEP LEVEL 1 5 Dl1 DI5 Sleep state is activated and deactivated using a digital input ACS 400 User s Manual 109 Code Description 4019 SET POINT SEL Set point selection Defines the reference signal source for the PID controller Note When PID regulator is by passed parameter 8121 REG BYPASS CTRL this parameter has no significance 1 INTERNAL Process reference is a constant value set with parameter 4020 INTERNAL SET
161. t used 6 AGND eA 7 AO 1 Output frequency 0 20 mA lt gt 0 50 Hz 8 AGND 9 24V 24 VDC 10 DCOM1 c MD Start Stop Activate to start ACS400 12 DI2 Fwd Rev Activate to reverse rotation direction 13 DI 3 Constant Speed 1 Default 5 Hz 14 DI4 Leave unconnected PS Ramp pair selection Activate to select ramp pair 2 16 DCOM2 17 RO1C Relay output 1 programmable 18 RO1A Default operation Fault gt 17 connected to 18 19 ROTB 20 RO2C Relay output 2 programmable a wis Default operation Running gt 20 connected to 22 Note DI 4 is used to configure ACS 400 It is read only once when power is connected All parameters marked with are determined by the DIA input Factory 0 parameter values 1001 EXT 1 COMMANDS 1402 RELAY OUTPUT 2 2 RUN 1002 EXT 2 COMMANDS 1503 AO CONTENT MAX 60 Hz 1003 DIRECTION 1601 RUN ENABLE 0 NOT SEL 1102 EXT1 EXT2 SEL 1604 FAULT RESET SEL 6 START STOP 1103 EXT REF1 SELECT 2008 MAXIMUM FREQ 60 Hz 1105 EXT REF1 MAX 2105 PREMAGN SEL O NOT SEL 1106 EXT REF2 SELECT O KEYPAD 2201 ACC DEC 1 2 SEL 5 DI5 1201 CONST SPEED SEL 3 DI3 4001 PID GAIN 1 0 1401 RELAY OUTPUT 1 3 FAULT 1 4002 PID INTEG TIME 60 s ACS 400 User s Manual Application Macro Factory 1 This macro is intended for applications where there is NO control panel available It provides a general purpose 3 wire I O confi
162. tart 12 DI 2 Fwd Rev Activate to reverse rotation direction 13 DI 3 Constant speed selection 14 DI 4 Constant speed selection 15 DI 5 Ramp pair selection Activate to select ramp pair 2 16 DCOM2 TT ROTC Relay output 1 programmable 18 ROTA gt Default operation Fault gt 17 connected to 18 19 ROB 20 RO2C Relay output 2 programmable 21 ROZA Default operation Running gt 20 connected to 22 22 RO2B Constant speed selection 0 open 1 connected DI3 DIA Output Reference through Al1 Const speed 1 1202 Const speed 2 1203 Const speed 3 1204 el e ABB Standard parameter values 1001 EXT 1 COMMANDS DI1 2 1402 RELAY OUTPUT 2 2 RUN 1002 EXT 2 COMMANDS NOT SEL 1503 AO CONTENT MAX 60 Hz 1003 DIRECTION REQUEST 1601 RUN ENABLE O NOT SEL 1102 EXT1 EXT2 SEL EXT1 1604 FAULT RESET SEL O KEYPAD 1103 EXT REF1 SELECT AH 2008 MAXIMUM FREQ 60 Hz 1105 EXT REF1 MAX 60 Hz 2105 PREMAGN SEL O NOT SEL 1106 EXT REF2 SELECT KEYPAD 2201 ACC DEC 1 2 SEL 5 DI5 1201 CONST SPEED SEL DI3 4 4001 PID GAIN 1 0 1401 RELAY OUTPUT 1 FAULT 1 4002 PID INTEG TIME 60s 56 ACS 400 User s Manual Application Macro 3 wire This macro is intended for those applications where the drive is controlled using momentary push buttons It gives two more preset speeds compared to Factory Macro 1 by using DI4 and DIS The value of
163. th DC hold O NOT SEL Premagnetizing not used 1 5 DI DIS Premagnetizing command is received through a digital input 6 CONST Constant premagnetizing time after start command Time is defined by parameter 2106 PREMAGN MAX TIME 2106 PREMAGN MAX TIME Maximum premagnetizing time ACS 400 User s Manual 89 Code Description 2107 START INHIBIT Start inhibit control Start inhibit means that a pending start command is ignored when fault is reset or Run Enable activates while start command is active or mode change from local to remote takes place or mode change from remote to local takes place or when switching from EXT1 to EXT2 takes place or when switching from EXT2 to EXT1 takes place 0 OFF Start inhibit control disabled Drive will start after fault is reset Run Enable is activated or mode is changed while there is a pending start command 1 0N Start inhibit control enabled Drive will not start after fault is reset Run Enable is activated or mode is changed In order to start the drive again give start command anew 90 ACS 400 User s Manual Group 22 Accel Decel Two acceleration deceleration ramp pairs can be used If both ramp pairs are used the selection can be made between these in run time through a digital input The S curve of the ramps is adjustable Code Description 2201 ACC DEC 1 2 SEL Selects the source for the ramp pair s
164. the first auxiliary motor is stopped After the auxiliary motor is stopped the ACS 400 s output frequency is increased by the value 8109 START FREQ 1 8112 LOW FREQ 1 Note Low Frequency 1 should be within limits 2007 MINIMUM FREQ 1 and 8109 START FREQ 1 8113 LOW FREQ2 Sets a frequency limit see Figure 50 When the ACS 400 s output frequency falls below the value 8113 LOW FREQ 2 1 Hz and two auxiliary motors are running the Stop Delay counter is started When the time set with parameter 8116 AUX MOT STOP D is elapsed and if the output frequency is still below value 8113 LOW FREQ 2 1 Hz the second auxiliary motor is stopped After the auxiliary motor is stopped the ACS 400 s output frequency is increased by a value 8110 START FREQ 2 8113 Low FREQ 2 Note Low Frequency 2 should be within limits 2007 MINIMUM FREQ 1 and 8109 START FREQ 2 8114 LOW FREQ 3 Sets a frequency limit see Figure 50 When the ACS 400 s output frequency falls below a value 8114 Low FREQ 3 1 Hz and three auxiliary motors are running a Stop Delay counter is started When the time set with parameter 8116 AUX MOT STOP D is elapsed and if the output frequency is still below the value 8114 LOW FREQ 3 1 Hz the third auxiliary motor is stopped After the auxiliary motor is stopped ACS 400 output frequency is increased by value 8111 START FREQ 3 8114 Low FREQ 3 Note Low Frequency 3 should be within limits 2007 MINIMUM FREQ 1 and 8109 START FREQ 3
165. the frequency of the controlled motor in a three motor system ACS 400 User s Manual 127 Code Description 8122 PFC START DELAY Sets the start delay for all the motors in the system The delay works as follows 1 The contactor that connects the speed regulated motor to the ACS 400 is switched on by a ACS 400 relay output 2 PFC Start Delay is waited 3 Speed regulated motor is energized and normal PFC operation starts Auxiliary motors are started Caution There should always be PFC Start Delay set if the motors are equipped with star delta starters The PFC Start Delay must be set longer than the time setting of the star delta starter After the motor is switched on by the relay output of the ACS 400 there must be enough time for the star delta starter to first switch to star connection and then back to delta connection before the ACS 400 inverter starts switching 128 ACS 400 User s Manual Standard Serial Communication Overview The ACS 400 can be connected to an external control system using the standard Modbus fieldbus connection The ACS 400 can receive all of its control information either from the Modbus fieldbus or the control can be distributed between the fieldbus and other available control locations e g digital analog inputs and the drive control panel The ACS 400 has two serial communication channels or ports Channel 0 and Channel 1 Channel 1 is the standard Mod
166. tor to heat up Code Description 2101 START FUNCTION Conditions during motor acceleration 1 RAMP Ramp acceleration as set 2 FLYING Flying start Use this setting if the motor is already rotating and the drive will start smoothly at the current frequency The drive will automatically search the correct output frequency 3 TORQUE BOOST Automatic torque boost might be necessary in drives with high starting torque Torque boost is only applied at start Boosting is stopped when output frequency exceeds 20 Hz or when output frequency is equal to reference See also parameter 2103 TORQ BOOST CURR 4 FLY BOOST Activates both the flying start and torque boost Note If torque boost is used the switching frequency is always 4 kHz In this case parameter 2605 Low NOISE is ignored 2102 STOP FUNCTION Conditions during motor deceleration 1 COAST Motor coasts to stop 2 RAMP Ramp deceleration as defined by the active deceleration time 2203 DECELER TIME 1 or 2205 DECELER TIME 2 2103 TORQ BOOST CURR Maximum supplied current during torque boost See also parameter 2101 START FUNCTION 2104 STOP DC INJ TIME DC injection time after modulation has stopped If 2102 STOP FUNCTION is 1 COAST the ACS 400 uses DC braking If 2102 STOP FUNCTION is 2 RAMP ACS 400 uses DC hold after ramp 2105 PREMAGN SEL Options 1 5 select source for premagnetizing command Option 6 selects start wi
167. ty Press start button Check for Enable signal DI 2 Depress Up button Hand Mode until motor rotates Drive is faulty relpace the drive Check wiring between motor and drive Drive is faulty replace the drive Reduce load troque or disconnect load Replace drive with one of larger capacity Change start function 2102 to torque boost and set torque boost 2103 to higher value ACS 400 User s Manual 41 Motor Stalls during Acceleration With drive in stopped Acceleration Time condition extend Too Short YES gt acceleration time by changing parameter 2202 or 2204 Load Inertia Too Large Load Torque Check if special motor is Too High No used YES YES V f Profile Correct With drive in stopped condition change parameter 2606 NO YES Use larger wire between YES drive and motor Shorten distance between drive and motor Large Motor Terminal Voltage Drop NO Decrease load inertia Extend acceleration time Decrease load torque Replace drive with larger rated drive 42 ACS 400 User s Manual Overvoltage Fault Indication Remove noise sources Connect surge suppressors across relay and magnetic contactor coils Provide line filter to remove noise on input line Is Input AC Supply Voltage Correct NO YES Does Overvoltage Trip Occur Only During Acceleration YES gt NO
168. ty bit and 1 with even or odd parity 0 NONE 1 EVEN 2 ODD 5206 BAD MESSAGES This diagnostics counter increases by one every time the ACS 400 finds any kind of communication error During normal operation this counter rarely increases 5207 GOOD MESSAGES This diagnostics counter increases by one every time a valid Modbus message has been received by the ACS 400 During normal operation this counter is increasing constantly 5208 BUFFER OVERRUNS Longest possible message length for the ACS 400 is 32 bytes If a message exceeding 32 bytes is received this diagnostic counter increases by one every time a character which cannot be placed in the buffer is received 5209 FRAME ERRORS This diagnostic counter increases by one every time a character with a framing error is received from the bus Communication speed settings of the devices connected in the bus differ Ambient noise levels may be too high 5210 PARITY ERRORS This diagnostic counter increases by one every time a character with a parity error is received from the bus Parity settings of the devices connected on the bus differ Ambient noise levels may be too high ACS 400 User s Manual 117 Code Description 5211 CRC ERRORS This diagnostic counter increases by one every time a message with a CRC error is received Ambient noise levels may be too high CRC calculation is not performed correctly 5212 BUSY ERRORS This diagnostic
169. ual These sections give detailed information needed for the correct installation of the unit A Warning Before you begin read all of the Safety instructions ACS 400 User s Manual 1 See A 1 C CHECK the environment 2 C MOUNT the ACS 400 to the wall 3 4 REMOVE the cover 4 C ATTACH a warning sticker in the language of your choice 5 C IDENTIFY power and control terminals 6 C CHECK voltage supply 7 C CHECK the motor C CHECK I O jumpers J1 and J2 ER C CONNECT power terminals C CONNECT control wires in C REPLACE the cover 12 C TURN the power on Figure 1 Step by step instructions for installing the ACS 400 The references after each step refer to one or more of the Reference Sections on the following pages in this manual See E F See E I J Co O oO o 4 Wa D D m A CD o o Wa D D O NE E S ZO EIA 2 ACS 400 User s Manual Reference Sections A Installation Environment Stationary Use Ambient temperature 32 104 F 0 40 C Max ambient temperature 122 F 50 C if Py and Ip derated to 90 Installation altitude 0 3300 ft 1000 m if Py and l 100 Installation altitude 3300 6600 ft 1000 2000 m if P and l derated 1 every 330 ft 100 m above 3300 ft 1000 m Relative humidity less than 95 non condensing The ACS 400 must be installed in a heated indoor controlled
170. uct of actual values 1 and 2 5 ACT1 ACT2 Quotient of actual values 1 and 2 6 MIN A1 A2 Smaller of actual values 1 and 2 7 MAX A1 A2 Greater of actual values 1 and 2 8 sqrt A1 A2 Square root of difference of actual values 1 and 2 9 sgA1 sqA2 Sum of square roots of actual values 1 and 2 4007 ACT1 INPUT SEL Source for actual value 1 ACT1 1 Al1 Analogue input 1 is used as actual value 1 2 Al2 Analogue input 2 is used as actual value 1 4008 ACT2 INPUT SEL Source for actual value 2 ACT2 1 Al1 Analog input 1 is used as actual value 2 2 Al2 Analog input 2 is used as actual value 2 ACS 400 User s Manual 107 Code Description 4009 ACT1 MINIMUM Minimum value for actual value 1 ACT1 Refer to Figure 44 and to Group 13 parameters for analog input minimum and maximum settings 4010 ACT1 MAXIMUM Maximum value for actual value 1 ACT1 Refer to Figure 44 and to Group 13 parameters for analog input minimum and maximum settings 4011 ACT2 MINIMUM Minimum value for actual value 2 ACT2 Refer to parameter 4009 4012 ACT2 MAXIMUM Maximum value for actual value 2 ACT2 Refer to parameter 4010 ACT1 96 A ACT1 MAXIMUM ACT1 MINIMUM p Analog input signal Al min Al max AcT1 A ACT1 MINIMUM ACTI MAXIMUM4 r r Analog input signal Al min Al max Figure
171. uration To activate a digital input there must be gt 10 V or lt 10 V between that input and DCOM1 The 24 V may be provided by the ACS 400 X1 9 using the connection examples see Section M or by an external 12 24 V source of either polarity HVAC Hand Auto Macro 8 default 11 DI 1 AUTO mode Start Stop Close to start Motor will ramp up to frequency reference Open to stop Motor will coast to stop 12 DI2 Run Enable Close to enable 13 DI3 Select constant speeds 1 to 7 14 DI 4 Select constant speeds 1 to 7 15 DI5 Select constant speeds 1 to 7 16 DCOM2 DCOM2 digital input common for DI4 DI5 17 R01 Relay output 1 programmable default fault gt 17 connected to 18 12 250 VAC 30 V DC 10 mA 2A 18 RO1 Red 19 RO1 20 RO2 Relay output 2 programmable default running 2 20 connected to 22 12 250 V AC 30 V DC 10 mA 2A 21 RO2 22 RO2 nobe Digital input impedance 1 5 ko Use multi strand 0 5 1 5 mm 20 16 AWG wire Note For safety reasons the fault relay signals a fault when the ACS 400 is powered down Note DI 4 and 5 are electrically isolated from DI1 2 and 3 To utilize DI4 and 5 a jumper must be connected See section M for details Note Terminals 3 6 and 8 are at the same potential ACS 400 User s Manual 15 RS485 terminal X3 X3 Description Screen B A AGND Screen aj Eloi N
172. usly while in parameter set mode Fault Resetting Faults that are indicated by a red blinking LED are reset by turning the power off for a while Other faults indicated by red static LED can be reset either from the control panel by digital input or serial communication or switching the supply voltage off for a while When the fault has been removed the motor can be started The ACS 400 can be configured to automatically reset certain faults Refer to parameter group 31 AUTOMATIC RESET Warning If an external source for start command is selected and it is active the ACS 400 may start immediately after fault reset Warning All electrical installation and maintenance work described in this chapter should only be undertaken by a qualified electrician The Safety Instructions on the first pages of this manual must be followed ACS 400 User s Manual 35 Table 5 Alarms Alarm A SAA Code Display Description 4 OPERATION FAILED Parameter upload or download failed The software versions of the drives may not be compatible Software version can be seen from parameter 3301 SOFTWARE VERSION p START ACTIVE Control panel function is not allowed while start is active 36 LOCAL REMOTE Control panel function is not allowed in current control mode local or remote Control mode is local when LOC is displayed and remote mode when REM is displayed on the control panel 5
173. ype IP 54 NEMA Type 12 amp 4 drives ACS 400 User s Manual E Terminal Interface A 1 Green LED o O Red LED X3 RS485 connector LI Termination jumper J2 IT dba A SES 8 d X2 Panel connector Sr m X1 I O connection see OU 1 Moo Analog input 2 Olle DIP switch J1 On 7 5 O 6 O 7 O 8 O 9 O 19 S Warning sticker i2 o all 13 8 Warning Dangerous voltage 14 O Wait 5 minutes after 15 O alsvonnecting Supp 164 NS VT 19 20 e 21 el 22 Uol o E X6 Connector for DDCS poe AAA communication module o o O Pe Ou GND ES o ES i Additional PE ground terminals provided on RE o vi M Uer v2 v2 W2 PE frame sizes R3 and R4 Figure 11 Terminal Interface F Attaching a Warning Sticker The contents of the packing box include warning stickers in different languages Attach a warning

User`s Manual ACS 400 AC Drives for Speed Control of 3 to 40 Hp

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