Comp-AC User's Manual for type ACS 100 frequency converters
Contents
1. 19 Output Display een 20 Menu Structure 20 Setting Parameter Value 20 Menu Functions 21 Diagnostic Displays oooooocccnnncccccnnonocnnononanancnnnnnnnno 21 Resetting the Drive 22 ACS 100 Parameter Table 23 Group 01 Actual Values and Status 25 Group 02 Motor Values and Limits 25 Group 03 Drive Control 26 Group 04 Input Output ee eee 27 Group 05 Supervision 28 Diagnosties ernst 31 G n ralistes states es At 31 Alarm and Fault displays 31 Fault Resetting nn 31 ACS 100 EMC Instructions 35 Installation Study this manual carefully before proceeding Failure to observe the warnings and instructions given may cause a malfunction or personal hazard 1 4 CHECK the environment E See A 2 Ce INSTALL the ACS 100 3 a REMOVE the cover ATTACH a warning sticker in the language of your choice 5 _enniey power and control terminals See F G K 6 CHECK voltage supply CHECK the motor CHECK configuration switch S1 9 CONNECT power terminals CONNECT control wires 11 REPLACE the cover 12 TURN the power on See B C EI2. Standard series Nominal motor Py kw 0 75 1 1 1 5 2 2 1 Input ACS101 1K6 1 2K1 1 2K7 1 4K1 1 3 Input ACS103 1K6 1 2K1 1 2K7 1 4K1 1 Frame size B C D Nominal Ratings See H P Unit Input voltage U V 200 V 240 V 10 50 60 Hz ACS 101 1 ACS 103 3 Continuous output current Ip A 4 3 5 9 7 0 9 0 4 kHz Continuous output current Ip A 3 9 5 3 6 3 8 1 8 kHz Continuous output current Ip A 3 2 4 4 5 3 6 8 16 KHz Max output current lp max 4 kHz A 6 5 8 9 10 5 13 5 Max output current l gt max 8 KHz A 5 9 8 0 9 5 12 2 Max output current l2 max 16 kHz A 4 7 6 5 7 7 9 9 Output voltage U V 0 Uy 3 Input current l4 1 A 10 8 14 8 18 2 22 0 Input current l4 3 A 5 3 7 2 8 9 12 0 Switching frequency kHz 4 Standard 8 Low noise 16 Silent Protection limits See P Overcurrent peak A 13 8 19 0 23 5 34 5 Overvoltage Trip limit VDC 420 corresponds to 295 V input Undervoltage Trip limit VDC 200 corresponds to 142 V input Overtemperature C 90 95 heat heat sink sink Max wire sizes Max motor cable length m 75 75 75 75 Power terminals mm 4 single core Torque 0 8 Nm Control terminals mm 0 5 1 5 AWG22 AWG16 Torque 0 4 Nm Line fuse 1 A 16 16 20 25 ACS101 Line fuse 3 A 6 10 10 16 ACS103 Power losses Power circuit W 27 39 48 70 Control
3. 048A0001 heatsinkless series frame H Floating Network If the supply network is floating IT network remove the grounding screw GND Failure to do so may cause danger or damage the unit GND In floating networks do not use RFI filter The mains becomes connected to earth through the filter capacitors In floating networks this may cause danger or damage the unit Make sure that no excessive emission is propagated to neighbouring low voltage networks In some cases the natural suppression in transformers and cables is sufficient If in doubt a supply transformer with static screening between the primary and secondary windings can be used J Motor Check that the motor is compatible The motor must be a three phase induction motor with Uy from 200 to 240 V and fy either 50 Hz or 60 Hz If the motor values differ from these the group 02 parameter values must be changed The motor nominal current IN must be less than or equal to the nominal output current of the ACS 100 I See H and S K Control Terminals X1 Identification Description 1 SCR Terminal for signal cable screen Connected internally to frame earth 2 Al Analogue input 0 10 V lt gt O fnom output frequency Rj 190 kQ 0 10 V signal 500 Q 0 20 mA signal Resolution 0 1 accuracy 1 3 AGND Analogue input circuit common Connected internally to frame earth through 1 MQ 4 10V 10 V reference voltage
4. 1 30m 20m 10m ACS 101 H75 1 ACS 101 1K1 1 30 m 20 m 10m ACS 101 1H1 1 ACS 101 1K6 1 30 m 20 m 10m ACS 101 1H6 1 Converter type ACS100 140 IFCD 1 ACS 101 2K1 1 30 m 20 m 10m ACS 101 2K7 1 30m 20m 10m ACS 101 4K1 1 30m 20m 10m 38 Table 5 Maximum motor cable lengths with input filter ACS100 FLT C or ACS 140 FLT C and switching frequency 4 kHz or 8 kHz ACS100 FLT C Converter Type 4 kHz 8 kHz ACS 101 K75 1 100 m 100 m ACS 101 1K1 1 100 m 100 m ACS 101 1K6 1 100 m 100 m ACS 101 2K 1 100 m 100 m ACS 101 2K7 1 100 m 100 m ACS 101 4K1 1 100 m 100 m Converter Type ACS140 FLT C ACS 103 xKx 1 100 m 100 m Effective motor cable screen is required according to Figure 8 ACS 103 4K1 1 maximum continuous load 70 of nominal For ACS 101 4K1 1 and ACS 103 4K1 1 a cable shown in Figure 8 is required Always use output choke ACS CHK B if motor cable length exceeds 50 m With input filter ACS100 FLT C always use ouput choke ACS CHK A Chokes ACS CHK A and ACS CHK B are supplied in the same package with the input filter ACS100 FLT C With input filters ACS100 FLT C or ACS140 FLT C conducted emission complies with the limits for unrestricted distribution class in First Environment as specified in EN 61800 3 EN 50081 1 provided that the motor cable has effective screen see Figure 8 and maximum length is 30 m 39 Additional Instructions to Comply with EN61800 3
5. First Environment Unrestricted Distribution Always use optional RFI filter ACS100 FLT D or ACS100 FLT E 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 6 and the cable must have effective screen according to Figure 8 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 6 Maximum motor cable lengths with input filter ACS100 FLT D E or ACS140 FLT D and switching frequency 4 kHz ACS100 FLT D ACS100 FLT E Converter type 4 kHz 4 kHz ACS 101 K75 1 5m ACS 101 1K1 1 5m ACS 101 1K6 1 5m ACS 101 2K1 1 9 5m ACS 101 2K7 1 E 5m ACS 101 4K1 1 H 5m Two chokes ACS CHK A or ACS CHK C are supplied in the filter package The motor cable including the shield must be fed through the hole in the choke Also all control cables and the control panel cable if present must be fed through another choke The cable lengths between the converter and the chokes must be at maximum 50 cm For types ACS 101 2K1 1 ACS 101 2K7 1 and ACS 101 4K1 1 the control panel if present must be mounted on the converter front cover Line Current Harmonics The product standard EN 61800 3 refers to IEC 61000 3 2 which specifies limits for harmonic current emissions for equipment connected to low voltage public supply network The ACS 100 is a pro
6. N See H I See J See L See F G See G K M See N See O SEES ZB NM Re ed Reference Sections A Environmental Limits Ambient operating temperature 0 40 C 0 30 C if fgy 16 kHz Max ambient temperature 50 C if Py and I derated to 80 and few 4 kHz Installation altitude 0 1000 m if Py and Ip 100 Installation altitude 0 2000 m if Py and I derated 1 every 100 m above 1000 m Relative humidity less than 95 non condensing Storage temperature 40 C 70 C Transport temperature 40 C 70 C The ACS 100 should be installed in clean and dry air free from dripping water corrosive materials and electrically conductive dust pollution degree 2 The installation room must be locked or tool openable B Dimensions mm d2 di co Frame 200 V Series Weight kg Size IP 20 h1 h2 h3 di d2 di d2 1 3 A 126 136 146 117 32 149 0 9 0 8 B 126 136 146 117 69 186 12 11 C 198 208 218 117 52 169 1 6 1 5 D 225 235 245 124 52 176 1 9 1 8 H 126 136 146 119 0 119 0 8 C Installing the ACS 100 No Before installing the ACS 100 ensure that the mains supply to the installation is off Standard Series Frame sizes A B C
7. 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 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 9 Figure 9 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 It 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 100 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 custom
8. circuit W 17 18 19 20 Derate ambient temperature to 30 C or derate Py and Ip to 90 see Ip 8 kHz Derate ambient temperature to 30 C and derate Py and I to 75 see I 16 kHz Fuse type UL class CC or T For non UL installations IEC269 gG Use 60 C rated power cable 75 C if Tamp above 45 C 15 Heatsinkless series Nominal motor Py kw 0 12 0 18 0 25 0 37 0 55 0 75 1 Input ACS101 H18 1 H25 1 H37 1 H75 1 1H1 1 1H6 1 Frame size H Nominal ratings See H P Unit Input voltage U4 V 200V 240V 10 50 60 Hz ACS 101 1 Continuous output A 1 0 1 4 127 2 2 3 0 4 3 current Ip 4 kHz Continuous output A 0 9 1 3 1 5 2 0 2 7 3 9 current Ip 8 kHz Continuous output A 0 8 1 1 1 3 1 7 2 3 3 2 current Ip 16 kHz Max output current A 1 5 2 1 2 6 3 3 4 5 6 5 12 max 4 KHz Max output current A 1 4 2 0 2 3 3 0 4 1 5 9 12 max 8 KHz Max output current A 1 1 1 5 1 9 2 4 3 3 4 7 l2 max 16 kHz Output voltage U V 0 Uy 3 Input current I 1 A 2 7 4 4 5 4 6 9 9 0 10 8 Switching frequency kHz 4 Standard 8 Low noise 16 Silent Protection limits See P Overcurrent peak A 3 2 45 5 5 7 1 9 7 13 8 Overvoltage Trip limit V DC 420 corresponds to 295 V input Undervoltage Trip limit V DC 200 corresponds to 142 V inpu
9. output for analogue input potentiometer accuracy 2 10 mA 5 All Analogue input Al can be configured to accept 0 20 mA signal by shorting terminals 5 and 6 Then R 500 Q AGND Terminals for DI return wires AGND 8 12V Aux voltage output 12 V DC Imax 100 mA reference to AGND Short circuit protected 9 DCOM Digital input common To activate a digital input there must be 12 V or 12 V between that input and DCOM The 12 V may be provided by the ACS 100 X1 8 as in the connection examples see M or from an external 12 24 V source of either polarity DI Configuration ABB Standard 3 wire fnom 50 Hz fnom 60 Hz S1 0 1 2 3 4 See L S1 5 6 7 8 9 See L 10 DI1 Start Activate to start Motor will Start If DI 2 is activated momentary ramp up to frequency reference activation of DI 1 starts the ACS 100 Disconnect to stop Motor will coast to stop 11 DI2 Reverse Activate to reverse rotation Stop Momentary inactivation always direction stops the ACS 100 12 DI3 Jog Activate to set output frequency Reverse Activate to reverse rotation to constantspeed default 5 Hz see direction parameter 406 13 RO1 Fault relay output 14 RO2 Fault RO 1 and RO 2 connected 15 RO3 ANSE 12 V 250 V AC 30 V DC A 10mA 2A DI configuration can be modified with parameter 405 or ifthe control panel is not available with configuration switch S1 see L
10. when S1 0 AL 1 Parameter upload download failed AL2 Operation not allowed while start is active AL3 Operation not allowed in remote or local control AL 4 REVERSE button disabled Parameter 208 Dir Lock is active ALS Panel START button disabled DI configuration is 3 wire and DI2 is open AL6 Operation not allowed Parameter 503 Param Lock is active AL10 Overcurrent controller active AL11 Overvoltage controller active AL12 Undervoltage controller active AL13 Reserved Contact supplier AL14 Reverse command attempted in remote control REM while parameter 208 Dir Lock is active AL15 AL16 Reserved Contact supplier Note Alarms will be shown only if parameter 506 is set to 1 Yes 32 Table 3 Faults Code Description FL 1 Overcurrent e Possible mechanical problem Acc and or Dec times may be too small FL2 DC overvoltage Input voltage too high Dec time may be too small FL3 ACS 100 overtemperature Ambient temperature too high e Severe overload FL 4 Fault current output earth fault or short circuit FL5 Output overload FL 6 DC undervoltage FL 7 Analogue input fault See parameter 501 FL 8 Motor overtemperature See parameter 502 FES Panel disconnected from drive in local control Note If FL 9 is active when the power is turned off the ACS 100 will start in remote control REM when the power is turned back on FL10
11. 00 s 0 1 s 1 0s 5 0s 305 U f Ratio 1 2 1 Y 306 IR Comp ov 30 V 1V 10V 307 DC Inj Time 10 s 250 s 0 1 s 1 0s 0 0s 308 UCmax 0 1 1 Control Group 04 INPUT OUTPUT 401 JAI min 0 100 1 0 402 Al max 0 100 1 100 403 Ref min 0 Hz 300 Hz 1 Hz 0 Hz 404 Ref max 0 Hz 300 Hz 1 Hz 50 Hz 405 DI Config 1 3 1 Y 406 Const Speed 0 Hz 300 Hz 0 1 Hz 5 Hz Group 05 SUPERVISION 501 JAIFault 0 1 0 502 Freg Lim 0 Hz 300 Hz 1 Hz 35 Hz 503 Param Lock 0 2 1 504 Start Inhibit 10 1 1 23 Code Name Min Max Resolution Default User 505 Auto Reset 0s 3s 0 1s Os 506 Display 0 1 0 Alarms 24 Group 01 Actual Values and Status Code Description 101 Ref Freq Reference frequency 102 Last Fault Fault memory 0 no fault in memory Clear the fault memory by pressing the UP DOWN buttons simultaneously in parameter SET mode 103 Version Software version number 104 Temp Displays the temperature of the ACS 100 heatsink in degrees centigrade Group 02 Motor Values and Limits Code Description 201 Nom Volt Unom Nominal motor voltage from motor rating plate Nom Volt sets the maximum output voltage supplied to motor by ACS 100 Nom Freq sets the frequency at which output voltage is equal to the Nom Volt The ACS 100 cannot supply the motor with a
12. 31 Red LED off Green LED blinking ABNORMAL CONDITION e ACS 100 cannot fully follow control commands e Blinking lasts 15 seconds POSSIBLE CAUSES Acceleration or deceleration ramp is too fast in relation to load torque requirement A short voltage interruption e Give a stop signal to reset fault NOTE If the drive fails to start check that the input voltage is within the tolerance range 200 240 V 10 Give a start signal to restart the drive Red LED on Green LED on ACTION POSSIBLE CAUSES Transient overcurrent e Over undervoltage Overtemperature CHECK the supply line for phase loss or disturbances the drive for mechanical problems that might cause overcurrent that heat sink is clean Turn the power off Wait for the LEDs to turn off Turn the power back on Caution This action may start the drive Red LED blinking Green LED on ACTION POSSIBLE CAUSE Output earth fault Short circuit CHECK e the isolations in the motor circuit Note Whenever the ACS 100 detects a fault condition the fault relay activates The motor will coast to stop and the ACS 100 will wait to be reset If the fault still persists and no external cause has been identified contact your ACS 100 supplier 12 Q Motor Overload Protection If the motor current lout exceeds the nominal current lhom of the motor parameter 203 fo
13. Coast 2 Ramp See also parameter 307 DC Inj Time 302 Ramp Figure 2 Ramp shape 0 Linear Output frequency 1 Fast S curve 2 Medium S curve Img AAA 3 Slow S curve Linear Acc Time 303 Acc Acceleration time from zero to maximum frequency 0 fmax 304 Dec Deceleration time from maximum frequency to zero fmax 0 305 U f Ratio Figure 3 U f below weakening point Output voltage 1 Linear curves A and Unom 2 Square curves B and D Linear is preferred for constant torque applications and Square IR comp for centrifugal pump and 30 V fan applications ov 306 IR Comp Amount of IR compensation i e extra voltage applied to motor on frequency range 0 fnom Note IR compensation should be kept as low as possible 307 DC Inj Time DC injection time after modulation has stopped If stop mode is Coast ACS 100 uses DC Braking If stop mode is Ramp ACS 100 uses DC Hold after ramp 308 UC max Overvoltage regulator control Should be 0 if braking chopper is connected 0 No overvoltage control 1 Overvoltage control enabled 26 Group 04 Input Output Code Description 401 Al min Analogue input scaling 0 equals 0 mA or 0 V and 100 equals 20 mA or 10 V at input 402 Al max Analogue input scaling 0 equals 0 mA or 0 V and 100 equals 20 mA or 10 V at input Note Keep Al min l
14. Comp AC User s Manual for type ACS 100 frequency converters from 0 12 to 2 2 kW AA ED ED PA ID IP ACS 100 Frequency Converter User s Manual 3BFE 64307622 R0125 EN Effective 8 3 2000 2000 ABB Industry Oy Safety A Warning Only a competent electrician may install the ACS 100 IN iraina Dangerous voltages are present when mains supply 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 G SER Even when the motor is stopped there are dangerous voltages present at Power Circuit terminals U1 V1 W1 L N and U2 V2 W2 and U U Ne Even when the ACS 100 is powered down there may be dangerous external voltages at relay terminals RO1 RO2 ROS IN Warning The ACS 100 is not a field repairable unit Never attempt to repair a broken unit contact the supplier for replacement of the unit IN Warning The ACS 100 will start up automatically after an input voltage interruption if the external run command is on ee When the control terminals of two or more ACS100 140 400 units are connected in parallel the auxiliary voltage for these control connections must be taken from a single source which can either be one of the units or an external supply ER Altering the parameter settings or device configurations will affect the function and performance of the ACS 100 Check that these chan
15. Digital input impedance 1 5 KQ Use multi strand 0 5 1 5 mm wire Note For fail safe reasons the fault relay signals a fault when the ACS 100 is powered down L Configuration Switch The ACS 100 can be configured by using a configuration switch or a control panel When the control panel is used S1 must be set to 0 The position of the configuration switch S1 determines the nominal frequency from set to motor fn e the acceleration and deceleration ramp time e he I O configuration of digital inputs See M Configuration Switch Position 0 is the factory default Note S1 must be set to 0 if the ACS 100 is configured using a control panel When setting the position of S1 first ascertain the motor nominal frequency fy and then select the desired ramp time The configuration of digital inputs DI is dependent on the nominal frequency from Ramp Time 0 fnom 5s fnom S1 position DI Configuration 1s 50 Hz 10s 30 s 60 s ABB standard 1s 5s 60 Hz 10s 30 s 60 s 3 wire oj CO NI o aya WO Ml O Note The ACS 100 reads the position of the configuration switch during power up Never set S1 when the ACS 100 is powered on 10 M Connection Examples ACS 100 1 SCR 1 1 0 ka A 2 3 AGND 4 Nov 5 JAI 6 7 8 AGND AGND 12V 9 DCOM Jo
16. Interface F Cable Connections Terminal Description Note L N 1 power supply input In figure below see G a 3 unit is shown U1 V1 W1 3 power supply input Do not use in 1 supply PE Protective Earth Min 4 mm Cu wire U2 V2 W2 Power output to motor Max cable length depends on the unit type see S Uc Uc DC bus voltage 325 V For optional ACS braking unit chopper BS Motor cable shield Follow local rules for cable cross sections Use shielded motor cable Route the motor cable away from control wires and the power supply cable to avoid electromagnetic interference A nore See EMC instructions on ACS 100 EMC Instructions on page 35 G Terminal Interface Power supply input Control Terminals see K ABB Industry Oy Configuration ACS103 1K6 1 Switch S1 Ui 37230 V U2 370 01 1 50 60 Hz 2 0 300 Hz H 5 3 A 12 S N 048A0001 Warning Sticker X1 Wait 5 minutes after disconnecting supply before proceeding See User s Manual Shield Power output to motor DC terminals for optional ACS braking unit chopper H Type Designation Label and Code Key Supply Serial number ACS 101 1 S N 048A0001 ACS 103 3 0 Year 2000 48 Week 48 Power ACS103 1K6 1 A0001 Internal 1K6 1 6 KVA standard 37 230V number series frames A B C 50 60 Hz and D 5 3 A 1H6 1 6 kVA S N
17. PE conductor or a four conductor cable with a concentric shield Minimum requirement for the motor cable screen is presented in Figure 7 Copper wire screen Helix of copper tape Insulation jacket Inner insulator Figure 7 Minimum requirement for motor cable screen e g MCMK NK Cables 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 8 L Braided metallic screen Inner insulator Insulation jacket L2 L1 PE optional jid Figure 8 Effective motor cable screen e g lflex Servo FD 780 CP Lappkabel or MCCMK NK Cables Twist the cable screen wires together into a bundle not longer than five times its width and connect to the bottom left hand corner of the converter heatsink terminal marked L 36 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 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 Route the control cables as far away as possible from the mains
18. Parameters inconsistent Check that Al min fmin is not greater than Al max fmax FL11 DC bus ripple too large Check supply FL12 Reserved Contact supplier FL13 FL14 Hardware error Contact supplier FL15 Analogue input out of range Check Al level FL16 FL19 Hardware error Contact supplier Full display Serial link failure blinking Bad connection between the control panel and the ACS 100 Note Faults with red blinking LED are reset by turning the power off and on Other faults are reset by pressing the START STOP button 33 34 ACS 100 EMC Instructions Mandatory Installation Instruction According to the EMC Directive for type ACS 100 frequency converters Follow the instructions given in the ACS 100 User s Manual and the instructions delivered with different accessories CE Marking ACE mark is attached to ACS 100 frequency converters to verify that the unit follows the provisions of the European 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 the requirements stated for frequency converters ACS 100 frequency converters comply with the requirements stated in EN 61800 3 for Second Environment and First Environment Product standard EN 61800 3 Adjus
19. V 10 50 60 Hz ACS 101 1 ACS 103 3 Continuous output current l gt A 1 0 1 4 1 7 2 2 2 0 4 kHz Continuous output current Ip A 0 9 1 3 1 5 2 0 2 7 8 kHz Continuous output current Ip A 0 8 1 1 1 3 1 7 2 3 16 KHz Max output current lo max A 1 5 2 1 2 6 3 3 4 5 4 kHz Max output current lo max A 1 4 2 0 2 3 3 0 4 1 8 kHz Max output current l2 max A 1 1 1 5 1 9 2 4 3 3 16 kHz Output voltage Us V 0 Uy 3 Input current I 1 A 2 7 4 4 5 4 6 9 9 0 Input current I 3 A 3 2 4 2 Switching frequency kHz 4 Standard 8 Low noise 16 Silent Protection limits See P Overcurrent peak A 3 2 45 5 5 7 1 9 7 Overvoltage Trip limit VDC 420 corresponds to 295 V input Undervoltage Trip limit VDC 200 corresponds to 142 V input Overtemperature C 90 heat sink Max wire sizes Max motor cable length m 50 50 50 75 75 Power terminals mm 4 single core Torque 0 8 Nm Control terminals mm 0 5 1 5 AWG22 AWG16 Torque 0 4 Nm Line fuse 1 ACS101 A 6 6 10 10 10 Line fuse 3 ACS103 A 6 6 Power losses Power circuit W 10 12 13 19 Control circuit W 10 12 14 16 Derate ambient temperature to 30 C or derate Py and Ip Derate ambient temperature to 30 C and derate Py and I to 75 see I 16 kHz Fuse type UL class CC or T For non UL installations IEC269 gG Use 60 C rated power cable 75 C if Tamp above 45 C 14 o 90 see I 8 kHz
20. and D Install the ACS 100 vertically Leave 25 mm free space above and below the unit Ensure that there is sufficient cool air in the cabinet to compensate for the power losses power and control circuits listed at the end of sections Technical Data Wall mounting Use M4 screws DIN rail 35 mm Press the lever on top of the unit while installing on removing from DIN rail Flange mounting The ACS 100 can be installed so that the heat sink is in an air duct The power circuit losses will then be dissipated outside leaving only the control circuit losses to be dissipated inside see S Heatsinkless series Frame size H A note The frame size H does not include the heatsink The heatsinkless ACS 100 is intended for applications where an external heatsink is available Ensure that the area of installation fulfils the heat dissipation requirements Mounting Surface Requirements Install the heatsinkless ACS 100 on an uncoated clean metallic surface that fulfils the following requirements A minimum thickness of 3 mm The surface must be stiff and flat max flatness error 0 1 and max roughness R 3 2 um a Ea L E W 58 8 5 or M4 Po holes Heat Dissipation Requirements Ensure that the mounting surface is capable of conducting power losses into the environment The maximum temperature of the mounting plate may not exceed 80 C under
21. any circumstances The table below gives the power losses and minimum surface area requirements when a 3 mm steel plate capable of dissipating heat from both sides is used as a heatsink max ambient temperature 40 C The 3 mm steel plate is only one example any kind of external heatsink can be used if it meets the mounting surface and heat dissipation requirements Converter Type Power Loss W Gao Da ACS 101 H18 1 ri 150 x 150 ACS 101 H25 1 10 180 x 180 ACS 101 H37 1 12 200 x 200 ACS 101 H75 1 13 210x210 ACS 101 1H1 1 19 250 x 250 ACS 101 1H6 1 27 300 x 300 Mechanical Installation Clean the mounting surface Apply thermal grease between the ACS 100 and the mounting surface Use M4 screws mounting torque 1 1 5 Nm After installation verify the thermal design by monitoring the temperature parameter 104 of the ACS 100 The thermal design is successful if the ACS 100 temperature does not exceed 85 C under full load and maximum ambient temperature D Removing the Cover 1 Press the four snap on buttons on the top and bottom corners of the unit simultaneously 2 Remove the cover ce E Attaching a Warning Sticker The packing box includes warning stickers in different languages Attach a warning sticker in the language of your choice to the place on the inside plastic skeleton as indicated in section G Terminal
22. ault is reset automatically after the delay set by this parameter If O s is selected the fault is not reset automatically Trial time x x gt Time A Now x Automatic reset Figure 6 Operation of automatic reset function The number of trials is constant 5 and the trial time is constant 30 s By moment Now three faults has occurred making the next fault fourth the system is reset automatically because the number of trials is less than 5 28 506 Display Alarms Controls the visibility of some of the alarms see Diagnostics on page 31 0 No Some of the alarms are suppressed 1 Yes All of the alarms are enabled 29 30 Diagnostics General This chapter describes the various diagnostic displays of the control panel and lists the most common causes for the particular display If the fault cannot be resolved by the given instructions contact an ABB service representative Caution Do not attempt any measurement parts replacement or other service procedures not described in this manual Such actions will void guarantee endanger correct operation and increase downtime and expense Alarm and Fault displays The seven segment display unit of control panel indicates alarms and faults using codes ALxx or FLxx where xx is the corresponding alarm or fault code Alarms 1 6 arise from button operation Green LED blinks for AL10 16 meaning that the ACS 100 can
23. cs flashes in the panel display until the fault is reset or the display is cleared You can clear the display without resetting the fault by pressing any button The word FAULT will be visible in the display Note If no other button is pressed within 15 seconds and the fault is still active the fault code will be displayed again After a power failure the drive will be in the same control mode LOC or REM as before the power failure 22 ACS 100 Parameter Table S Value can be modified only when Configuration switch S1 0 N Not changeable when start is active Code Name Min Max Resolution Default User N Group 01 ACTUAL VALUES AND STATUS 101 Ref Freq 0 Hz 300 Hz 0 1 Hz z 102 Last Fault a 0 103 Version 0 0 0 0 99 9 F 104 Temp D C 150 C 0 1 C Group 02 MOTOR VALUES AND LIMITS 201 Nom Volt 200 V 240 V 200 208 230 V Y 220 230 240 V 202 Nom Freq 50 Hz 1200 Hz 1 HZ 50 Hz Y 203 Nom Curr 0 5xl gt 1 5xl2 10 1 A Ip v 204 Nom Speed 0 rpm 13600 rpm 1 rpm 1440 rpm Y 205 Max Curr 0 5xlp 1 5xl2 10 1 A 1 5 206 Max Freq 0 Hz 300 Hz LH2 50 Hz Y 207 Min Freq O Hz 300 Hz 1 Hz 0 Hz 208 Dir Lock 1 2 1 209 Motor Noise 0 2 0 Y Group 03 DRIVE CONTROL 301 Stop 1 2 1 302 Ramp 0 3 0 303 Acc 0 1s 1800 s 0 1 s 1 0s 5 0s 304 Dec 0 1s 18
24. er must verify this Control Panel Cable If the control panel is connected to the converter with a cable use only the cable provided with the option package ACS100 EXT or 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 37 Additional Instructions to Comply with EN61800 3 First Environment Restricted Distribution and AS NZS 2064 1997 Class A Always use optional RFI filter as specified in Tables 4 and 5 and follow the instructions in the filter package for all cable screen connections The filters with regular cable lengths are shown in Table 4 and the filters with extra long cable lengths in Table 5 The motor cable lengths have to be limited as specified in Tables 4 and 5 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 4 Maximum motor cable lengths with input filter ACS 100 140 IFAB 1 or IFCD 1 and switching frequency 4 kHz 8 kHz or 16 kHz ACS100 140 IFAB 1 Converter type 4 kHz 8 kHz 16 kHz ACS 101 K18 1 30 m 20 m 10m ACS 101 H18 1 ACS 101 K25 1 30m 20m 10m ACS 101 H25 1 ACS 101 K37 1 30m 20m 10m ACS 101 H37 1 ACS 101 K75
25. fessional equipment to be used in trades professions or industries and which is not intended for sale to the general public The supply authorities shall be notified as authorisation may be required before connection The current harmonic levels under rated load conditions are available on request 40 Distribution Networks Isolated from Earth Input filters cannot be used in floating supply networks or high impedance earthed industrial distribution networks Make sure that no excessive emission is propagated to neighbouring low voltage networks In some cases the natural suppression in transformers and cables is sufficient If in doubt a supply transformer with static screening between the primary and secondary windings can be used 41 42 AA ED ED PA ID ED Effective 8 3 2000 2000 ABB Industry Oy EN Subject to change without prior notice 3BFE 64307622 R0125 ABB Industry Oy P O Box 184 00381 Helsinki FINLAND Telephone 358 10 22 2000 Telefax 358 10 22 22681
26. g Reverse Start 10 IDI Stop 11 Di 12 DI3 DI configuration ABB Standard 13 RO 1 14 RO2 15 JRO 3 ACS 100 SCR Al AGND 10 V All AGND AGND 12V A DCOM Reverse Stop Start 10 DI 1 11 DI 2 12 DI 3 13 IRO 1 1 10kQ qx L DI configuration 3 Wire o NJ of o NH d np x 14 RO 2 A 15 RO 3 Frequency Reference from a Current Source ACS 100 1 SCR 0 20 mA ui Al 2 3 AGND SCR 4 10V 5 6 N Replacing the Cover Do not turn the power on before replacing the cover back on 11 O Power On When power is supplied to the ACS 100 the green LED comes on P Protection Features The ACS 100 has a number of protective features Overcurrent Overvoltage Undervoltage Overtemperature Output earth fault Output short circuit Input phase loss 3 Power loss ride through 500 ms 1 0 terminal short circuit protection Long term overcurrent limit trip 110 Short term current limit 150 Motor overload protection see Q The ACS 100 has the following LED alarm and fault indicators for location of LED alarm indicators see section G Ifthe ACS 100 PAN control panel is connected see Diagnostics on page
27. ges do not cause any risk to persons or property Ne The heat sink may reach a high temperature see S Note For more technical information contact the supplier Table of Contents Safety PE EEA EP RI i Installation nee nenn 1 Reference Sections 2 Environmental Limits nennen 2 Dimensions mm 2 Installing the ACS 100 3 REMOVING the Cover 6 Attaching a Warning Sticker 6 Cable Connections 6 Terminal Interface 7 Type Designation Label and Code Key 8 Floating Network 8 MOLOV osa A M ere er 8 Control Terminals 9 Configuration Switch 10 Connection Examples sese eser ereer ee eee eee 11 Replacing the Cover 11 POWE ON antenne aero alle 12 Protection Features 12 Motor Overload Protection 13 Loadability of ACS 100 13 Type Series and Technical Data 14 Product Conformity anive 17 Environmental Information 17 Leea 18 Programming soriana cds 19 Control Panel isis 19 Control Modes
28. is below the level given by parameter 401 Al min a fault indication is displayed and the ACS 100 coasts to stop 502 Freq Lim fiim Figure 5 Frequency limit for thermal lout Inom protection Together with Trip time parameter 203 Nom Curr determines the continuous 60s safe operation area for the 3 0 motor 25 4 0 Hz Thermal protection 2 0 i 300s disabled Wh hes oe 1 0 7 R ee Ve 0 0 fout fiim 0 0 0 2 0 4 0 6 0 8 1 0 503 Param Lock Parameter lock 0 STAR STOP and REVERSE buttons and parameter modification disabled Parameter value viewing is allowed 1 Not locked 2 Modified values not stored in permanent memory 504 Start Inhibit Start inhibit control Start inhibit means that a pending start command is ignored when ault is reset or mode change from local to remote takes place 0 Off Start inhibit control disabled Drive will start after fault is reset or mode is changed while there is a pending start command 1 On Start inhibit control is enabled Drive will not start after fault is reset or mode is changed In order to start the drive again give start command anew 505 Auto Reset The automatic reset system can be used for resetting undervoltage faults automatically Auto reset sets the number of allowed auto resets 5 within a certain time 30 s O s Disable If a value greater than 0 s is selected the undervoltage f
29. n switch S1 must be set to 0 Parameter 503 Param Lock must be set to 1 Restore factory defaults Press amp hold Ego um MENU Parameter 503 Param Lock can also be set to 2 Copy parameters from panel to drive download Press amp hold gt Copy parameters from drive to panel upload Press amp hold Diagnostic Displays When the red LED of the ACS 100 is on or blinking a fault is active The relevant fault message flashes in the panel display When the green LED of the ACS 100 is blinking an alarm is active The relevant alarm message is shown in the panel display Alarms 1 6 arise from button operation and green LED does not blink for them The alarm and fault messages disappear by pressing MENU ENTER or the arrow buttons of the control panel The message will reappear after a few seconds if the keypad is not touched and alarm or fault is still active fault code alarm code Refer to Diagnostics section for complete list of alarms and faults 21 Resetting the Drive When the red LED of the ACS 100 is on or blinking there is an active fault To reset a fault when the red LED is on press the START STOP button Caution When in remote control this may start the drive 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 The relevant fault code see Diagnosti
30. not fully follow the control commands The faults are indicated by red LED The alarm and fault messages disappear by pressing MENU ENTER or the arrow buttons of the control panel The message will reappear after a few seconds if the keypad is not touched and the alarm or fault is still active Last fault code is stored into parameter 102 This fault memory can be cleared from the control panel by pressing UP and DOWN buttons simultaneously 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 100 can be configured to automatically reset certain faults Refer to parameter 505 AUTO RESET Warning If an external source for start command is selected and is still active the ACS 100 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 31 Table 2 Alarms Code Description CE 0 CE9 Position of configuration switch S1 Certain parameters can be modified only
31. played for one second e g CF 0 when S1 0 Control Modes The very first time the drive is powered up it is controlled from terminal X1 remote control REM The ACS 100 is controlled from the control panel 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 If the 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 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 e 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 19 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 se
32. r a prolonged period of time the ACS 100 automatically protects the motor from overheating by tripping Trip time depends on the extent of the overload lout Inom the output frequency and nominal motor frequency fhom Times given apply to a cold start ACS 100 provides overload protection in accordance with the National Electric Code US The default setting of motor thermal protection is ON For more information see parameter 502 on page 28 lout Inom Trip time 15 300s 600s 1 0 05 Het re oS le es ee ere ee ae 0 0 lt N lo Output frequency from 50 Hz S Output frequency from 60 Hz R Loadability of ACS 100 In the event of an output overload the ACS 100 will trip lout t duty cycle UT Imax T lt 10 min l2 7 time Imax l2 15 Ambient temperature Oamb Max is 40 C 1 4 13 50 C is permissible if lp is derated to 80 1 2 1 1 1 9 duty cycle 01 0 2 0 3 04 0 5 13 S Type Series and Technical Data Standard series Nominal motor Py kW 0 12 0 18 0 25 0 37 0 55 1 Input ACS101 K18 1 K25 1 K37 1 K75 1 1K1 1 3 Input ACS103 K75 1 1K1 1 Frame size A Nominal Ratings See H P Unit Input voltage U4 V 200 V 240
33. requency converter and the related safety standard is mentioned in the documentation of the equipment UL ULc and C Tick Markings Frame size UL ULc C Tick ACS 100 A pending pending pending ACS 100 B pending pending pending ACS 100 C pending pending pending ACS 100 D pending pending pending ACS 100 H pending pending pending The ACS 100 is designed for use on a circuit capable of delivering no more than 65 kA U Environmental Information A product to be disposed of contains valuable raw material that should be recycled thus preserving energy and natural resources Instructions for disposal are available from ABB sales and service companies 17 V Accessories PEC 98 0008 Panel Extension Cable kit for use with the ACS 100 ACS 140 ACS 400 ACS 100 140 IFxx 1 ACS 100 FLT RFI input filters ACS CHK Input output chokes ACS BRK Braking units ACS BRC Braking choppers 18 Programming Control Panel This section of the manual provides information on how to use the ACS 100 PAN control panel with an ACS 100 frequency converter 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 100 with the same software revision parameter 103 When the control panel is powered up the LCD display illuminates for one second Immediately afterwards the position of the configuration switch S1 is dis
34. s 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 for use in public low voltage network The installation rules of this manual are followed 35 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 three conductor cable single phase and neutral with protective earth or four conductor cable three phase with protective earth are 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 top of the converter unit Mains 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 mains cable In the case of screened 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
35. t Overtemperature C 90 heat sink Max wire sizes Max motor cable m 50 50 50 75 75 75 length Power terminals mm 4 single core torque 0 8 Nm Control terminals mm 0 5 1 5 AWG22 AWG16 torque 0 4 Nm Line fuse 1 A 6 6 10 10 10 16 ACS101 Power losses Power circuit W 10 12 13 19 27 Control circuit W 10 12 14 16 17 Derate ambient temperature to 30 C or derate Py and Ip to 90 see Ip 8 kHz Derate ambient temperature to 30 C and derate Py and I to 75 see I 16 kHz Fuse type UL class CC or T For non UL installations IEC269 gG Use 60 C rated power cable 75 C if Tamp above 45 C 16 T Product Conformity CE Marking The ACS 100 complies with the requirements of the European e 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 A note See ACS 100 EMC Instructions on page 35 A frequency converter 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 mentioned in the Machinery Directive and related harmonised standards The CDM BDM frequency converter can be considered as a part of safety device if the specific function of the CDM BDM frequency converter fulfils the requirements of the particular safety standard The specific function of the CDM BDM f
36. t Al max Figure 4a Ref max Ref min Al max Analogue input signal 403 Ref min Reference value for analogue input scaling 404 Ref max Reference value for analogue input scaling Figure 4b fref Ref min Ref max Almax Analogue input signal Al min 405 DI Config Digital input configuration 1 ABB Standard 2 3 wire 3 Alternate Note After modifications turn the power off and then on again to validate changes 406 Const speed Constant speed Can be actuated from digital input See Table 1 Table 1 DI configurations ABB Function Standard activated deactivated DI 1 start stop DI 2 reverse forward DI3 parameter analogue input is 406 Const fref speed is fref 3 Wire Function DI 1 Momentary activation with DI2 activated start DI 2 Momentary deactivation stop DI 3 When activated reverse direction When deactivated forward direction Alternate Function activated deactivated DI 1 start stop if DI2 is also forward deactivated DI2 start stop if DI1 is also reverse deactivated DI 3 parameter analogue input is 406 Const fref speed is fref Note When Alternate is selected the drive stops if DI1 and DI2 are activated at the same time 27 Group 05 Supervision Code Description 501 Al Fault Analogue input supervision 0 not in use 1 If analogue input
37. t the output frequency in local control mode LOC press ENTER Pressing the UP DOWN buttons changes the output immediately Press ENTER again to return to OUTPUT display LOC OUTPUT LOC U LOC OUTPUT I ZI IL SET a Hz O ke ED na OUTPUT Menu Structure OUTPUT display Parameter groups Parameters Loc 171 7 loc PT 1 Loc Wit IZ k ee LI IT Enea IL OUTPUT J D PAR Q2 ma e ji 103 at 20 E na BR cue Setting Parameter Value Press ENTER to view the parameter value To set a new value press and hold ENTER until SET is displayed J TON s 394 IE ig PAR H y fo V CANCEL STORE 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 UP DOWN buttons simultaneously 20 Menu Functions Scroll the Parameter groups for the desired Menu Function Press and hold ENTER until the display blinks to start the function Note Factory default settings and parameter copying does not affect all parameters The excluded parameters are 201 Nom Volt 202 Nom Freq 203 Nom Curr 204 Nom Speed and 503 Param Lock See ACS 100 Parameter Table for a description of these parameters Note Drive must be stopped and in local control The configuratio
38. table 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 100 no RFI filter is needed in Second Environment C Tick Marking pending A C tick mark is attached to 1 phase ACS 100 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 The 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 a frequency converter The frequency converter ACS 100 complies with the AS NZS 2064 1997 limits for class A equipment Class A equipment is suitable for use in all establishment
39. voltage greater than the mains voltage See figure 3 202 Nom Freq from Nominal motor frequency from motor rating plate field weakening point See Figure 3 203 Nom Curr Inom Nominal motor current from the motor rating plate Note This parameter is used only when motor thermal protection function is used Refer to parameter 502 Freq Lim See Figure 5 204 Nom Speed Nominal motor speed from motor rating plate 205 Max Curr Maximum output current the ACS 100 will supply to motor 206 Max Freq fmax Figure 1 Usage of fmin and fmax to limit output Maximum frequency the freguency ACS 100 will supply to motor Output frequency 207 Min Freq fmin Minimum frequency the f ACS 100 will supply to max motor fmin Note Keep fmin lt fmax fmin max fref 208 Dir Lock Direction lock Reverse can be disabled 1 FWD REV 2 FWD only 209 Motor Noise Motor noise control 0 standard switching frequency 4 kHz 1 low noise switching frequency 8 kHz 2 silent switching frequency 16 kHz Note When the low noise 8 kHz setting is used the maximum loadability of the ACS 100 is Ip at 30 C ambient temperature or 0 9 Ip at 40 C When the silent 16 kHz setting is used the maximum loadability is 0 75 l at 30 C ambient temperature 25 Group 03 Drive Control Code Description 301 Stop Stop mode 1
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