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Drive Low Power AC Drives User`s Manual for type ACS 400

1. Code Name Range Resolution Default User M Group 31 AUTOMATIC RESET 3101 NR OF TRIALS 0 5 1 0 3102 TRIAL TIME 1 600s 0 1 s 30 s 3103 DELAY TIME O 120s 0 1 s Os 3104 AR OVERCURRENT 0 1 1 O DISABLE 3105 AR OVERVOLTAGE 0 1 1 O DISABLE 3106 AR UNDERVOLTAGE 0 1 1 O DISABLE 3107 AR AI 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 81 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 81 1 3 Hz ACS 400 User s Manual 59 Code Name Range Resolution Default User S M Group 40 PID CONTROL 4001 PID GAIN 0 1 100 0 1 1 0 Y 4002 PID INTEG TIME O 600 s 0 1 s 60 s Y 4003 PID DERIV TIME 0 60s 0 1 s Os 4004 PID DERIV FILTER 0 10s 0 1
2. Figure 68 Termination for the RS485 link AS connections may only be made with the drive disconnected from the power source ACS 400 User s Manual 123 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 18 making parameter read and write possible Following sections describe how to configure the ACS 400 for more sophisticated communication and control Table 18 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 changed 124 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 Default communication settings for Channel 1 are listed in Table 18 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 infor
3. ACS 400 User s Manual 111 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 1401 RELAY OUTPUT 1 value is 29 PFC Relay output 2 is used for Pump and Fan motor control if 1402 RELAY OUTPUT 2 value is 29 PFC Table 17 depicts the use 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 17 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 number of auxiliary motors is 2 total of three relay outputs motors 1 2 and 3 are needed x Any other setting than 29 PFC Parameter NDIO module 1 NDIO module 2 n ACS 400 relays Module node number Module
4. f lsjejeje ooooocojo ol ma Rev BARSBIS OQO Warning Dangerous voltage Wait 5 minutes after lisconnecting supply A before proceeding ee User s Manual ro o OOD ooo X2 Panel connector ees Warning sticker T H X6 Connector for DDCS communication module A Do not connect olo Z OD 22 0 0 0 when unit is 9 powered 9 PE Cn GNO o z f U1 V1 W1 MAINS MOTOR Ule Mi U2 V2 W2 The contents of 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 above in section E Terminal Interface ACS 400 User s Manual G Type Designation Label and Code Key The Type Designation Label is attached on to the heat sink ABB industry Oy MADE IN FINLAND U
5. 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 D14 input Note Stop input DI2 deactivated panel START STOP button interlocked local Factory 1 parameter values 1001 EXT 1 COMMANDS DI1P 2P P 1503 AO CONTENT MAX 50 Hz 1002 EXT 2 COMMANDS NOT SEL 1601 RUN ENABLE O NOT SEL 1003 DIRECTION REQUEST 1604 FAULT RESET SEL 6 START STOP 1102 ExT1 EXT2 SEL 2008 MAXIMUM FREO 50 Hz 1103 EXT REF1 SELECT 2105 PREMAGN SEL O NOT SEL 1105 EXT REF1 MAX 2201 ACC DEC 1 2 SEL 5 DI5 1106 EXT REF2 SELECT O KEYPAD 4001 PID GAIN 1 0 1201 CONST SPEED SEL O NOT SEL 4002 PID INTEG TIME 60 s 1401 RELAY OUTPUT 1 3 FAULT 1 4101 PID GAIN 1 0 1402 RELAY OUTPUT 2 2 RUN 4102 PID INTEG TIME 60 s ACS 400 User s Manual 45 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 Start stop and direction DI1 2 Analogue reference Al1 Preset speed selection DI3 4 Output signals DIP switch An output AO Frequency c AI1 26 0 10 V Relay output 1 Fault Al2 9p 0 4 20mA Ramp pair 1 2 selection DI5 SCR Al1 AGND 10V AGND AO1 1 2
6. Ge 01 OPERATING DATA 9902 APPLIC MACRO 10 COMMAND INPUTS 9905 MOTOR NOM VOLT 8121 REG BYPASS 81 PFC CONTROL CTRL COPY TO DRIVE 8122 REG START DELAY COPY TO PANEL us LONG SHORT MENU 30 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 using UP DOWN buttons Modified value is stored by pressing ENTER Modifications can be cancelled and set mode inactivated by pressing MENU 9901 LANGUAGE 9901 LANGUAGE p accept and store It ENGLISH ENGLISH O value exit without saving e Note In the 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 ACS 400 User s Manual 31 Menu Functions Scroll the Menu for desired menu function then press and hold ENTER down until 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 Complete Parameter List on page 55 for a description of these parameters Copy Parameters from Drive to Panel upload Press 8 hold COPY TO PANEL ENTER COPYING Note Drive must be stopped and in local control Parameter 1602 PARAMETER LOCK must be setto
7. 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 3015 UNDERLOAD CURVE This parameter provides five selectable curves shown in Figure 49 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 ACS 400 User s Manual 87 Code Description 3022 AM FLT LIMIT Fault level for analogue input 1 supervision See parameter 3001 AI lt MIN FUNCTION 3023 AI2 FLT LIMIT Fault level for analogue input 2 supervision See parameter 3001 AI lt MIN FUNCTION lo In Trip time 3 5 3 0 60s 2 5 90 s 2 0 180 s 1 5 300 s 600 s 1 0 oo 0 5 0 fo fark 0 02 04 06 08 10 12 lo lt output current In nominal current of the motor fo output frequency fgnk break point frequency parameter 3008 BREAK POINT Figure 48 Thermal protection trip times when parameters 3005 MOT THERM TIME 3006 MOT LOAD CURVE and 3007 ZERO SPEED LOAD have default values 88 ACS 400 User s Manual Tuj 100 80 60 40 20 4 Figure 49 Underload curve types Ty nominal torque of the motor f y nominal frequency of the motor ACS 400 Use
8. ACS 400 User s Manual 161 Additional Instructions to Comply with EN61800 3 Second Environment Restricted Distribution Always follow the instructions for all cable screen connections The motor cable lengths have to be limited as specified in Table 37 and the minimum reguirement for motor cable screen according to Figure 77 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 37 Maximum motor cable lengths with switching frequency 4 kHz or 8 kHz Switching Frequency Converter Type 4 kHz 8 kHz ACS ACH 401 x004 3 x 100 m ACS ACH 401 x005 3 x 100 m ACS ACH 401 x006 3 x 100 m ACS ACH 401 x009 3 x 100 m 100 m ACS ACH 401 x011 3 x 100 m 100 m ACS ACH 401 x016 3 x 100 m 100 m ACS ACH 401 x020 3 x 100 m 100 m ACS ACH 401 x025 3 x 100 m 100 m ACS ACH 401 x030 3 x 100 m 100 m ACS ACH 401 x041 3 x 100 m 100 m Line Current Harmonics The current harmonic levels under rated load conditions are available on reguest Distribution Networks Isolated from Earth Refer to section Floating Network 162 ACS 400 User s Manual eonou Joud INOUJIM oDueuo 0 joefqns O gav 1002 LOOZ ZL S e d99J3 N3 O ASH SZLOH Z 69 0v9 AJVE Telephone 358 10 2211 00381 Helsinki Telefax ABB Oy AC Drives PO Box 184 FINLAND 358 10 222 2681
9. 5005 PROTOCOL SEL Defines what communication protocols are used Options 1 DDCS and 3 STD MDB DDCS should be selected only if DDCS communication module is installed 0 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 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 ACS 400 User s Manual 105 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 IO 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 to control the digital inputs and outputs of the extension module Note Value 2 IO EXTENSION should be used on
10. 80 Group 22 Accel Decel 82 Group 25 Critical Freg 83 Group 26 Motor Control 84 Group 30 Fault Functions 85 Group 31 Automatic Reset 90 Group 32 Supervision 91 Group 33 Information 94 Group 34 Process Variables 95 Group 40 PID Control 97 Group 41 PID Control 2 104 Group 50 Communication 105 Group 51 Ext Comm Module 107 Group 52 Standard Modbus 108 Group 81 PFC Control 110 Standard Serial Communication 121 Overview x s dint nali ued ha ede ne ae tees Me dee dps 121 Earthing and Termination 123 Activating Modbus Protocol 124 Communication settings 125 Control Locations 126 Output signal source selection 127 Diagnostic Counters 129 Communication 130 Introduction to Modbus 130 Register Read and Write 130 Register Mapp
11. AH Al2 Al1 2 D11 5 Remote DI3 4 Min freq Digital KEYPAD Picea Max freq inputs gear Const i Crit sp a bol speeds Acc Dec I I b Ih REF2 i j REF1 Hz Keypad Ref i Lo ReM A anaa Gaana GRRL FALRA SAATA Start Stop Direction i Local Start Stop a DH DIS EXT1 CA REQUEST K 7 Remote as Direction e KEYPAD _ NOT SEL FORWARD e DIH DI5 EXT2 REVERSE Enabled KEYPAD IDI DE ana EXTA iios DIRECTION RUN ENABLE 1001 1002 ue adi Figure 72 The control signal connections of the ABB Standard Alternate and Premagnetise macros ACS 400 User s Manual 151 EXT REF2 EXT REF1 EXT1 EXT2 CONST KEYPAD SELECT SELECT SEL SPEED SEL REF SEL 1106 1103 1102 1201 1101 Control IDI2 iDI3 i Terminals AM EXT Analogue KEYPAD inputs i EXT2 N Remote AH Min fr e 7 Remote If Max ea Digital KEYPAD PID l Local inputs Local c Crit sp DI1 DI5 AM o Acro APPlic E ONSE SI crt Speeds l Acc Dec AH AOT2 AI24 i l ACTUAL1 i o Mr t ia 4 ACTUAL i PA ACTUAL 2 VAL SEL REF1 Hz meurset i 4006 Keypad i Ref i Loc Rem ENS NOT SEL DIH EXT1 KEYPAB Rd NOTSEL EXT2 KEYPAD 1 EXT1 EXT2 COMMANDS COMMANDS 1001 1002 LN EE Remote WARD l Direction RE
12. 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 ACS PAN ae K PE 000001101BIN DI4 DIS DI2 DI1 64 ACS 400 User s Manual Code Description 0118 AH Relative value of analogue input 1 displayed in 0119 Al2 Relative value of analogue input 2 displayed in 0121 DI5 amp RELAYS Status of digital input 5 and relay outputs 1 indicates that the relay is energised and 0 indicates that the relay is de energised ACS100 PAN i F1 ACS PAN I LII 000000101BIN DI 5 Relay 2 status Relay 1 status 0122 AO Value of analogue output signal in milliamperes 0124 ACTUAL VALUE 1 PID PFC controller actual value 1 ACT1 displayed in per cent 0125 ACTUAL VALUE 2 PID PFC controller actual value 2 ACT2 displayed in per cent 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 02no fault See Diagnostics starting page 143 Can be cleared with the control panel by pressing UP and DOWN buttons simultaneously when in parameter set mode 0129 PRE
13. 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 104 ACS 400 User s Manual Group 50 Communication Parameters of this group define some general communication settings Parameters 5001 5002 and 5007 5009 are used only if 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 this parameter 5004 COMM FAULT FUNC Communication fault function This applies both to standard Modbus and DDCS link 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 the ACS 400 was last operating at 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
14. 1 5 1 8 Nm Control terminals 0 5 1 5 AWG22 AWG16 Torque 0 4 Nm Line fuse 3 A 10 10 16 16 35 50 ACS401 Power losses at nominal point Power circuit Control circuit Power stages are designed for the continuous I5 gq current These values are valid when the altitude is less than 1000 m ASL See Q Low noise setting only available with optional control panel Derate Py and Ip to 80 26 ACS 400 User s Manual Follow local rules for cable cross sections see H Shielded motor cable is recommended Fuse type UL class CC or T For non UL installations IEC269 gG Note Use 60 C rated power cable 75 C if ambient temperature exceeds 45 C Note If an output isolator or contactor is used supply either stop signal or RUN ENABLE see parameter 1601 signal from an auxiliary contact of the isolator to the ACS 400 in order to make sure that the ACS 400 will coast to stop immediately when the isolator opens Improper use of the isolator may damage the ACS 400 and the isolator ACS 400 is suitable for use in a circuit capable of delivering not more than 65 kA rms symmetrical amperes 480 V maximum T Product Conformity CE Marking The ACS 400 complies with the requirements of the European e Low Voltage Directive 73 23 EEC with amendments e EMC Directive 89 336 EEC wi
15. 3 LAST SPEED A warning indication is displayed and the speed is set to the level the ACS 400 was last operating at 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 analogue 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 the ACS 400 was last operating at 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 panel is lost 3003 EXTERNAL FAULT External fault input selection 0 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 deactivated the ACS 400 is stopped and the motor coasts to stop and fault indication is displayed ACS 400 User s Manual 85 Code Description 3004 MOT THERM PROT Motor overtemperature function This parameter defines the operation of the motor thermal p
16. 3 4 s Al2 6 7 8 AGND 9 24V 10 DCOM1 11 DH 12 DI2 13 IDIS 14 DIA 15 DI5 16 IDCOM2 17 RO1C 18 RO1A 19 RO1B 20 RO2C 21 ROZA 22 RO2B Relay output 2 Running External Reference 1 0 10 V lt gt 0 50 Hz Reference voltage 10 VDC Not used Output frequency 0 20 mA lt gt 0 50 Hz 24 VDC Start Stop Activate to start Fwd Rev Activate to reverse rotation direction Constant speed selection Constant speed selection Ramp pair selection Activate to select ramp pair 2 Relay output 1 programmable Default operation Fault gt 17 connected to 18 Relay output 2 programmable 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 Const speed 1 1202 0 1 Const speed 2 1203 1 1 Const speed 3 1204 ABB Standard parameter values 1001 EXT 1 COMMANDS DIT 2 1503 AO CONTENT MAX 50 Hz 1002 EXT 2 COMMANDS NOT SEL 1601 RUN ENABLE O NOT SEL 1003 DIRECTION 1604 FAULT RESET SEL O KEYPAD 1102 EXT1 EXT2 SEL 2008 MAXIMUM FREQ 50 Hz 1103 EXT REF1 SELECT 2105 PREMAGN SEL O NOT SEL 1105 EXT REF1 MAX 2201 ACC DEC 1 2 SEL 5
17. 3201 3203 SUPERV 1 LIM HI First supervision limit high Display of this parameter depends on 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 selected supervised parameter 3204 3206 SUPERV 2 LIM HI Second supervision limit high Display of this parameter depends on selected supervised parameter 3204 ACS 400 User s Manual 91 Value of supervised parameter hi 3203 lo 3202 Energised 1 De energised 0 Energised 1 De energised 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 51 Operating data supervision using relay outputs when LOW x HIGH 92 ACS 400 User s Manual Value of supervised parameter LOW 3202 HI 3203 energised 1 de energised 0 energised 1 de energised 0 A Parameter 1401 RELAY OUTPUT 1 1402 RELAY OUTPUT 2 value is SUPRV1 OVER or SUPRV2 OVER B Parameter 1402 R
18. 50 Hz 2201 ACC DEC 1 2 SEL 0 NOT SEL 1106 EXT REF2 SELECT 1 A11 4001 PID GAIN 1 0 1201 CONST SPEED SEL 3 D13 4002 PID INTEG TIME 60 s 1401 RELAY OUTPUT 1 3 FAULT 1 4101 PID GAIN 1 0 1402 RELAY OUTPUT 2 2 RUN 4102 PID INTEG TIME 60 s ACS 400 User s Manual 51 Application Macro Premagnetise This macro is intended for those applications where the drive must start very guickly Building up the flux in the motor always takes time With the Premagnetise Macro this delay can be eliminated The value of parameter 9902 is 7 PREMAGN Input signals Output signals DIP switch Start stop and direction An output AO Frequency pal DI1 2 AM 9 5 0 10V Analogue reference Al1 Relay output 1 Fault Al2 9 0 4 20mA A SERE Preset speed selection DI3 4 Premagnetise DI5 Relay output 2 Running v4 SCR cHe JAO External Reference 1 0 10 V lt gt 0 50 H s AGND d mE x 4 10V Reference voltage 10 VDC s Al2 Not used ANa 7 AO1 Output freguency 0 20 mA lt gt 0 50 Hz s AGND o 24V 24 VDC Ra DCOM1 P DO Start Stop Active to start ACS 400 I v DI2 Fwd Rev Activate to reverse rotation DI3 Constant Speed selection 14 DI4 Constan
19. Connector X3 slim Modbus fieldbus RS485 4 l 515 CS100 PAN bese ACS PAN Connector for optional DDCS communication module DriveWindow Figure 66 Standard serial communication features of ACS 400 ACS 400 User s Manual 121 Data Flow A 4 Fieldbus 2 Master PLC o zT UA PE Ki 5 Fg 3 c o p Fieldbus D p sipaan bo o z SA S 9 o S g s c o 2 o 7 D 5 o 2 T 3 S 9 S g E o Tt 0 2 S ej E Figure 67 Structure of a fieldbus system 122 ACS 400 User s Manual Earthing and Termination RS485 Bus The RS485 network should not be directly earthed at any point All the devices on the network should be well earthed using their corresponding earthing terminals As always the earthing wires should not form any closed loops and all the devices should be earthed to a common earth The RS485 network must be terminated using 120 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 68 Terminated Terminated 00000 00000 00000 00000 mE CE NE
20. TA duty cycle t T lo lt T gt l T 10 min gt time Imax lo N 1 5 Constant torgue rating Ambient temperature 12 4p max is 40 C bs 50 C is permissible 12 Squared torque rating if lo and max are derated to 90 14 NZ Imax Maximum output current 1 0 gt Duty cycle in squared torque l2NSQmax and 0 1 0 2 0 3 0 4 0 5 constant torque l Nmax applications see Table 11 Figure 32 ACS 400 User s Manual 25 S Type Series and Technical Data Table 11 400 V series 3 Input U 380V 480V ACS401 410 48 63 Hz 006 009 3 X 3 X Frame size Nominal ratings See G Nominal motor Py Sguared torgue Input current linsa Continuous output current lonsq Max output current loNsQmax d Nominal motor Py Constant torque and power Input current liy Continuous output current lan Max output current loNmax Output voltage Up Switching 4 Standard frequency fsw 8 Low noise Protection limits Overcurrent peak 20 3 27 5 37 48 64 Overvoltage Trip limit 842 corresponds to 624 VAC input Undervoltage Trip limit 333 corresponds to 247 VAC input Overtemperature 95 heat sink Max cable length fsw 4 kHz 100 200 200 fsw 8 kHz 50 100 100 Max wire sizes and screw torgue of connectors Power terminals mm 10 AWG6 stranded 16 AWG4 35 AWG2 stranded Torque 1 3 1 5 Nm stranded Torque 3 2 3 7 Nm Torque
21. counters that can be used to debug the fieldbus system Refer to Standard Serial Communication on page 121 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 parity bit and 1 with even or odd parity O 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 hardly ever 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 Th
22. is selected Function Codes The ACS 400 supports the Modbus function codes given in Table 26 If any other function codes are used ACS 400 returns an exception response with error code 01 illegal function Table 26 Function codes Code Description 03 Read holding registers 06 Preset single register 16 10 Hex Preset multiple registers 132 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 It is effective when e 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 e 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 Table 27 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 page 139 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 29 Note Operation of Control Word and Status Word conforms to ABB Drives Profile with
23. is used to make the full parameter set visible OUTPUT display Parameter groups Parameters MEER gg z nD gige a 0 03 LiL E L G Setting Parameter Value Press ENTER to view the parameter value To set a new value press and hold ENTER until SET is displayed UC we 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 36 ACS 400 User s Manual 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 55 for a description of these parameters Select between basic and full menu Press and hold L LI inr ENU m Visible if Full menu is active Copy parameters from panel to drive upload Press amp hold ad EB TEA LIL ENTER ie MENU Note Drive must be stopped and in local control Parameter 1602 PARAMETER LOCK must be setto 1 OPEN Copy parameters from drive to panel download Press 8 hold LI mn CIL T Note Drive must be stopped and in local control Parameter 1602 PARAMETER LOCK mus
24. 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 chapter ACS 400 Complete Parameter List starting page 55 Table 20 Parameters for control command source selection 10 comm al1 Alternative UVE Code Parameter Name n Standard Function Information Settings Modbus Group 50 COMMUNICATION 5006 COMM COMMAND 0 NOT SEL 1 STD MODBUS Defines the serial communication channel 1 lt 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 m location 10 COMM 1002 EXT2 COMMANDS O NOT SEL 10 comM Enables the Control Word except bit 11 1 oDil when EXT2 is selected as control a 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 12D 8 COMM Enables external control location EXT1 ES 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 al1 9 ComM aAI1
25. 1203 Constant speed 3 1204 aj o o o Application macro Alternate parameter values 1001 EXT 1 COMMANDS 9 DI1F 2R 1503 AO CONTENT MAX 50 Hz 1002 EXT 2 COMMANDS O NOT SEL 1601 RUN ENABLE O NOT SEL 1003 DIRECTION 3 REQUEST 1604 FAULT RESET SEL O KEYPAD 1102 exT1 EXT2 SEL 6 ExT1 2008 MAXIMUM FREQ 50 Hz 1103 EXT REF1 SELECT 1 a11 2105 PREMAGN SEL O NOT SEL 1105 EXT REF1 MAX 50 Hz 2201 ACC DEC 1 2 SEL 5 DI5 1106 EXT REF2 SELECT O KEYPAD 4001 PID GAIN 1 0 1201 CONST SPEED SEL 7 DI3 4 4002 PID INTEG TIME 60s 1401 RELAY OUTPUT 1 3 FAULT 1 4101 PID GAIN 1 0 1402 RELAY OUTPUT 2 2 RUN 4102 PID INTEG TIME 60s 48 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 signals Output signals Start stop and direction An output AO Frequency DI1 2 Reference up DI3 Reference down DI4 Preset speed selection DI5 Relay output 1 Fault Relay output 2 Running 1 SCR 2 Alt 3 AGND 4 z10V Reference voltage 10 VDC s Al2 Not used e AGND nA 7 AO1 Output frequency 0 20 mA lt gt 0 50 Hz s A
26. DI5 1106 EXT REF2 SELECT O KEYPAD 4001 PID GAIN 1 0 1201 CONST SPEED SEL 4002 PID INTEG TIME 60 s 1401 RELAY OUTPUT 1 FAULT 1 4101 PID GAIN 1 0 1402 RELAY OUTPUT 2 RUN 4102 PID INTEG TIME 60 s 46 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 DI5 The value of parameter 9902 is 2 3 WIRE Input signals Output signals DIP switch Start stop and direction An output AO Frequency DI1 2 3 An Sp l 0 10V Analogue reference Al1 Preset speed selection DI4 5 Relay output 1 Fault Relay output 2 Running Al 9 0 4 20mA v SCR ch JAH External Reference 1 0 10 V lt gt 0 50 Hz 5 3 AGND 10V Reference voltage 10 VDC s AI2 Not used m 6 AGND NA 7 JAO1 Output freguency 0 20 mA lt gt 0 50 Hz s AGND 9 24V 24 VDC 10 DCOM1 AL DH Momentary activation with DI2 activated Start 12 DI2 Momentary deactivation Stop 13 DIS Activate to reverse rotation Fwd Rev PEN a pa Constant speed selection Constan
27. 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 60s 0 1s 1s 5004 COMM FAULT FUNC 0 3 1 O NOT SEL 5005 PROTOCOL 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 Y 5009 DDCS HW CONFIG 0 1 1 1 STAR Y Group 51 EXT COMM MODULE 5101 FIELDBUSPAR1 15 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 O NONE 5206 BAD MESSAGES O FFFF 1 5207 GOOD MESSAGES O FFFF 1 5208 BUFFER OVERRUNS O FFFF 1 5209 FRAME ERRORS O FFFF 1 5210 PARITY ERRORS O FFFF 1 5211 cRC ERRORS O 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 96 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 50Hz 8110 START FREQ 2 0 0 250 Hz 0 1 Hz 50 Hz 8111 START FREQ 3 0 0 250 Hz 0 1 Hz 50 Hz 8112 LOW FREQ 1 0 0 250 Hz 0 1 Hz 25 Hz 8113 Low FREQ 2 0 0 250 Hz 0 1 Hz 25 Hz 8114 Low FREQ 3 0 0 250 Hz 0 1 Hz 25 Hz 8115 AUX MOT START D 0 0 3600 s 0 1s 1s 5s 8116 AUX MOT STOP D 0 0 3600 s 0
28. Interlocks function is in use Depending on the number of motors the digital inputs are reserved for the interlock signals according to 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 DI5 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 digital inputs are reserved for the interlock signals according to 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 DI1 Motor 3 DI4 Motor 1 Dl2 unused DI5 Motor 2 3 DI1 DI3 free DI1 Motor 3 Not used DI4 Motor 1 DI2 Motor 4 DI5 Motor 2 ACS 400 User s Manual 115 Code Description 5 DI5 Interlocks function is in use Depending on the number of motors the digital inputs are reserved for the interlock signals according to following table Interlock signals No of aux motors ACS 400 digital para
29. Manual Installation Study these installation instructions carefully before proceeding Failure to observe the warnings and instructions given 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 5 mm screws or nuts and bolts depending on the mounting surface drill At this point it is a good idea to check the motor parameters and write them down nominal voltage nominal current nominal frequency cos phi nominal power and nominal speed Unpacking the unit The ACS 400 comes in a box that in addition to the unit itself and this Users Manual contains Cable Gland Plates Warning Stickers and a separate Installation Guide The separate Installation Guide gives a summary of the installation instructions described here To help you marking the fixing points for installation of your ACS 400 a Wall Mounting Template is drawn on the lid of the box Remove the lid and save it Step by step instructions The installation of the ACS 400 has been broken down into a number of steps that are listed in Figure 1 on page 2 The steps must be carried out in the order shown To the right of each step reference is made to one or more Reference Sections on the following pages of this User s Manual These sections give detailed information needed for the correct installation of the unit A Warning Before you begin read Safet
30. OV 18 RO1A L 19 RO1B 19 ROIB 20 RO2C 20 RO2C 21 RO2A ne 21 RO2A 22 RO2B B 22 RO2B ACS 400 X3 SCR RS485 interf B Not termin A PH AGND EI SCR Figure 30 RS485 Multidrop application Signal termination is selected with DIP switch not terminated 22 ACS 400 User s Manual M Replacing the Cover Do not turn the power on before replacing the front cover IP 21 NEMA1 Units 1 First locate the bottom fixing clips 2 Click the retaining lever to its place 3 Replace the control panel Replacing the front cover to IP 21 NEMA1 units from size ACS401 x016 3 x and up 1 Hook the bottom end fingers of the lower part of the front cover 2 Click the retaining lever to its place 3 Hook the bottom end fingers 4 Click the retaining levers into place 5 Replace the control panel if available IP54 NEMA12 Units 1 Replace the control panel 2 Replace the front cover 3 Tighten the screws max torque 1 5 Nm N Power On When power is supplied to the ACS 400 the green LED comes on Note Only three power ups in five minutes are allowed Note Before increasing motor speed check that the motor is running in desired direction O Environmental Information The package is made of corrugated cardboard and can be recycled A product to be disposed of contains valuable raw material that should be recycled th
31. 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 42 ACS 400 User s Manual Application Macros Application Macros are preprogrammed parameter sets They minimise 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 depend on the digital input DI4 cannot be modified from the panel Parameter Values Select
32. SLIP COMP RATIO A sguirrel cage motor will slip under load The slip can be compensated by increasing the frequency as the motor torgue increases This parameter defines the gain for the slip 100 means full slip compensation 0 means no slip compensation Yoo compensation range C cv Ne H f Hz Field weakening point Figure 44 Operation of IR compensation 84 ACS 400 User s Manual Group 30 Fault Functions ACS 400 can be configured to respond as desired to certain abnormal external conditions analogue 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 freguency stall time and Current Code Description 3001 AI MIN FUNCTION Operation in case of Al signal drops below fault limit 3022 AI1 FLT LIMIT or 3023 AI2 FLT LIMIT 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
33. SPEED Y Nominal motor speed from motor name plate Range 0 3600 rpm Default 1440 rpm 9909 MOTOR NOM POWER v Nominal motor power from name plate Range 0 1 100 0 kW Default 2 0 30 0 kW depending on the type of the frequency converter 9910 MOTOR COS PHI Y 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 starting page 143 Can be cleared with the control panel by pressing UP and DOWN buttons simultaneously when in parameter set mode Group 10 COMMAND INPUTS 1003 DIRECTION v 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 50 Hz or 52 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 40 ACS 400 User s Manual Code Name User Group 13 ANALOGUE INPUTS 1301 MINIMUM Al1 Minimum value of Al1 in per cen
34. 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 h za Control modes Shaft direction UP DOWN Display modes UTPUT MENU LOC REM RUNI MENU ENTER Green LED Red LED RESET START STOP 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 control 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 e fthe button is released while LOCAL CONTROL is displayed the panel frequency reference is set to the current external reference and the drive is stopped e 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
35. User s Manual 157 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 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 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 77 Insulation jacket Copper wire screen Helix of copper tape Inner insulation Cable core Figure 77 Minimum requirement for motor cable screen e g MCMK NK Cables 158 ACS 400 User s Manual Recommended Symmetrical shielded cable thre
36. WAKE UP DELAY A parameter 4017 po Wake up level Time PID Output Output freguency ty SLEEP DELAY parameter 4013 SLEEP LEVEL parameter 4014 Time STOP START Figure 56 Sleep function operation ACS 400 User s Manual 101 4015 WAKE UP NON INVERTED ERROR VALUE LEVEL 100 6 1108 EXT REF2 MAX 75 96 SETPOINT APPLIED WAKE UP LEVEL 0 1107 EXT REF2 MIN gt Figure 57 Example of how the applied wake up level floats with the set point here parameter 4015 WAKE UP LEVEL eguals to 75 PID control non inverted case INVERTED ERROR VALUE A 4015 WAKE UP LEVEL 0 1108 EXT REF2 MAX 60 APPLIED WAKE UP LEVEL 100 SETPOINT 1107 EXT REF 2 MIN Y Figure 58 Example of how applied wake up level floats with the set point here parameter 4015 WAKE UP LEVEL equals to 60 96 PID control inverted case 102 ACS 400 User s Manual APPLIED WAKE AGT VALUE UP LEVEL p BS SLEEP DEACTIVATED ps TIME EXPIRES gt TIME Figure 59 Wake up level operation with non inverted error value A TIME EXPIRES a Te ge i i APPLIED WAKE Je gt Va ic UP LEVEL 7 N ACT VALUE Figure 60 Wake up level operation with inverted error value ACS 400 User s Manual 103 Group 41 PID Control 2 Parameters of this group belong to PID parameter set 2 The operation of parameters 4101 4112
37. 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 159 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 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 80 Figure 80 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 i
38. decrease the motor speed in order to keep the DC bus voltage above the lower limit By decreasing the output freguency 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 FREG Operating range minimum output freguency Note Keep MINIMUM FREQ lt MAXIMUM FREQ 2008 MAXIMUM FREQ Operating range maximum output frequency ACS 400 User s Manual 79 Group 21 Start Stop ACS 400 supports several start and stop modes including flying start and torgue boosting at start DC current can be injected either before the start command premagnetising or automatically right after the start command starting with DC hold DC hold can be used when stopping the drive with ramp If drive is stopping by coasting DC brake can be used Note Too long a DC injection time or premagn max time causes the motor 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
39. displayed Shaft Direction RUN gt Drive is running and at setpoint lt RUN e Shaft direction is forward gt or reverse lt RUN gt or lt RUN Arrow head blinking rapidly Drive is running but not at setpoint gt or lt Arrow head blinking slowly Drive is stopped ACS 400 User s Manual 29 Output Display When the control panel is powered up the panel displays a selection of actual values see Figure 33 Whenever the MENU button is pressed and held the control panel resumes this OUTPUT display Output current Torque Reference frequency 0 0A 0 50 0Hz Cursor is visible when reference can be modified Actual output frequency OUTPUT Figure 33 Output display variables The frequency reference can be modified using UP DOWN buttons when it is underlined Pressing 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 parameterised in such a way 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 32 for details on specifying the full parameter set The menu consists of parameter groups and menu functions OUTPUT display Menu Parameters 0 0A 0 50 0 Hz rev 99 START UP DATA 9901 LANGUAGE 0 0 Hz ENGLISH OUTPUT
40. 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 56 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 57 and Figure 59 Inverted error value parameter 4005 1 Applied wake up level is according to the following formula Limit parameter 1108 parameter 4015 parameter 1108 setpoint parameter 1108 parameter 1107 When the actual value is higher than or equal to this value the sleep function is de activated See Figure 58 and Figure 60 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 DI1 DI5 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 De
41. is clean Table 10 Red LED blinking Green LED on FAULT POSSIBLE CAUSE ACTION Output earth fault Turn the power off Short circuit Wait for the LEDs to turn off DC bus ripple too large Turn the power back on CHECK Caution This action may start the drive the insulation in the motor circuit Fuses and main phase 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 ACS 400 supplier 24 ACS 400 User s Manual Q 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 against overheating by tripping The trip time depends on the extent of the overload I In the output frequency and from Times given apply to a cold start ACS 400 provides overload protection in accordance with the National Electric Code US The default setting for motor thermal protection is ON For more information see Group 30 parameters page 85 in this manual lout In Trip time _ 300s 600 s oo 0 5 0 2 Output frequency 0 35 Hz Figure 31 R Loadability of ACS 400 In the event of an output overload the ACS 400 will first show an alarm and then trip l out t T
42. 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 than before the Autochange 7 Normal PFC operation continues As an example in a three motor system the starting order is changed as follows First start Motor no 1 motor no 2 motor no 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 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 ACS 400 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 ACS 400 User s Manual 113 Code Description 8120 INTERLOCKS Co
43. more information 156 ACS 400 User s Manual Appendix C ACS 400 EMC Instructions Mandatory Installation Instruction According to the EMC Directive for type ACS 400 freguency converters Follow the instructions given in the ACS 400 User s Manual and the instructions delivered with different accessories CE Marking A CE mark is attached to ACS 400 freguency 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 reguirements for immunity and emissions of electrical eguipment used in European Economic Area The EMC product standard EN 61800 3 covers the 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 b
44. of the group 1 OPERATING DATA 3202 SUPERV 1 LIM LO 0 255 e g 100 Lower supervision limit for supervised parameter 1 3203 SUPERV 1 LIM HI 0 255 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 0 255 e g 100 Lower supervision limit for supervised parameter 2 3206 SUPERV 2 LIM HI 0 255 e g 100 Upper supervision limit for supervised parameter 2 Table 22 Analogue output control R Setting for Code Parameter Name PASA Standard Function Information 9 Modbus Group 01 OPERATING DATA 0133 SER LINK DATA 3 0 255 Controlling data for the analogue output Group 15 ANALOGUE OUTPUT 1501 AO CONTENT 102 137 e g 133 Directs the contents of parameter 133 to the analogue output 1503 AO CONTENT MAX 255 Analogue output scaling upper limit 20 mA reached when value 255 written to parameter 133 128 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 the serial communication channel 1 Note Parameters 5206 52
45. 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 face H AL fH SLiH gt REF Hz 18 23 46 52 Figure 43 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 ACS 400 User s Manual 83 Group 26 Motor Control Code Description 2603 IR COMPENSATION Table 15 Typical IR compensation values IR compensation voltage at 0 Hz Note IR compensation should be 400 V Units kept as low as possible to prevent Pry kW 3 7 5 15 boo 37 overheating Refer to Table 15 IR comp V 21 18 15 12 10 2604 IR COMP RANGE IR compensation range Defines freguency after which IR compensation is 0 V 2605 LOW NOISE Motor acoustical noise option 0 OFF Standard switching frequency 4 kHz 1 ON 1 Low noise switching frequency 8 kHz Note When the low noise setting is used the maximum loadability of the ACS 400 is lp at 30 C ambient temperature 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
46. the exception of Control Word bit 10 REMOTE CMD which is not used by the ACS 400 Table 27 The Control Word See also the state machine on page 139 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 OFF 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 4 Unused 5 1 Normal operation Enter RAMP FUNCTION GENERATOR ACCELERATOR ENABLED 0 Halt ramping 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 8 to 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 133 Example on Using the Control Word The following ex
47. the limit 3205 See Group 32 Supervision starting page 91 11 AT SET POINT Relay energised when output freguency is egual to reference freguency 12 FAULT RST Relay energised 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 energised when fault or alarm occurs To see which alarms and faults cause the relay to energise refer to section Diagnostics on page 143 14 EXT CONTROL Relay is energised if external control is selected 15 REF 2 SEL Relay is energised if EXT2 is selected 16 CONST FREQ Relay is energised when a constant speed is selected 17 REF Loss Relay is energised when reference or active control place is lost 18 OVERCURRENT Relay is energised when overcurrent alarm or fault appears 19 OVERVOLTAGE Relay is energised when overvoltage alarm or fault appears 20 ACS400 TEMP Relay is energised when ACS 400 overtemperature alarm or fault exists 74 ACS 400 User s Manual Code Description 21 ACS OVERLOAD Relay is energised when ACS 400 overload alarm or fault exists 22 UNDERVOLTAGE Relay is energised when undervoltage alarm or fault exists 23 Al Loss Relay is energised when Al1 signal is lost 24 Al2 Loss Relays energised when Al2 signal is lost 25 MOT OVR TEMP Relay is energised when motor overtemperature alarm or fault exists 26 STALL Relay is energi
48. to IP classification Cooling air must be clean free from corrosive materials and electrically conduc tive dust In UL installations the ACS 400 should be installed in clean and dry air free from dripping water chemical gases Class 3C2 Storage solid particles Class 3S2 chemical gases Class 1C2 solid particles Class 1S3 Transportation chemical gases Class 2C2 solid particles Class 282 Atmospheric Pressure Sinusoidal Vibration 2 9 Hz 0 3 mm Storage IEC 60068 2 6 9 200 Hz 2 m s 2 9 Hz 1 5 mm 9 200 Hz 5 m s Transportation 2 9 Hz 3 5 mm 9 200 Hz 10 m s nee m not allowed max 100 m s 330 ft s 11 ms Free Fall not allowed 76 cm 30 in frame size R1 61 cm 24 in frame size R2 46 cm 18 in frame size R3 31 cm 12 in frame size R4 ACS 400 User s Manual 3 B Dimensions mm Units with IP 21 NEMA1 Enclosures A te 5 g e e TT k Figure2 IP 21 NEMA1 enclosures Table 2 Dimensions of units with IP 21 NEMA1 enclosures Frame Size IP 21 NEMA1 Dimension Reference mm R1 R2 R3 R4 w 125 125 203 203 w1 98 98 98 98 w2 98 98 w3 98 98 160 160 H 330 430 545 636 H1 318 417 528 619 H2 30
49. used as actual value 2 4009 ACT1 MINIMUM Minimum value for actual value 1 ACT1 Refer to Figure 55 and to Group 13 parameters for analogue input minimum and maximum settings 4010 ACT1 MAXIMUM Maximum value for actual value 1 ACT1 Refer to Figure 55 and to Group 13 parameters for analogue 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 Al min Al max p Analogue input signal ACT1 A ACT1 MINIMUM ACT1 MAXIMUM l r T p Analogue input signal Al min Al max Figure 55 Actual value scaling The range of the analogue input signal is set by parameters 1301 and 1302 or parameters 1304 and 1305 depending on the analogue input used ACS 400 User s Manual 99 Code Description 4013 PID SLEEP DELAY Time delay for the sleep function see Figure 56 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 56 When the ACS 400 output frequency falls below the sleep level the sleep delay counter is started When the ACS 400 output
50. 0 MOTOR COS PHI 0 50 0 99 0 01 0 83 Y Group 01 OPERATING DATA 0102 sPEED 0 9999 rpm 1 rpm 0103 OUTPUT FREQ O 250 Hz 0 1 Hz 0104 CURRENT 0 1A 0105 TORQUE 100 100 0 1 0106 POWER 0 1 kW 0107 DC BUS VOLTAGE O 999 9 V 0 1 V 0109 OUTPUT VOLTAGE 0 480 V 0 1 V 0110 ACs400 TEMP O 150 C 0 1 C 0111 EXTERNAL REF 1 O 250 Hz 0 1 Hz 0112 EXTERNAL REF 2 O 100 0 1 96 0113 CTRL LOCATION 0 2 1 0114 RUN TIME R 0 9999 h 1h 0115 kWh COUNTER R O 9999 kWh 1 kWh 0116 APPL BLK OUTPUT O 100 0 1 96 0117 Di1 DI4 STATUS 0000 1111 1 0 15 decimal 0118 JA O 100 0 1 0119 A2 O 100 0 1 0121 DI5 amp RELAYS 0000 0111 1 2 0 7 decimal 0122 jao 0 20 mA 0 1 mA 0124 ACTUAL VALUE 1 O 100 0 1 96 0125 ACTUAL VALUE 2 O 100 6 0 1 i 0126 CONTROL DEV 100 100 6 0 1 96 0127 PID ACT VALUE 100 100 0 1 96 ACS 400 User s Manual 55 Code Name Range Resolution Default User S M 0128 LAST FAULT 0 26 1 0129 PREVIOUS FAULT 0 26 1 0130 OLDEST FAULT 0 26 1 0131 SER LINK DATA 1 O 255 1 0132 SER LINK DATA 2 O 255 1 0133 SER LINK DATA 3 O 255 1 0134 PROCESS VAR 1 0135 PROCESS VAR 2 0136 RUN TIME 0 00 99 99 kh 0 01 kh 0137 MWh COUNTER 0 9999 MWh 1 MWh Group 10 COMMAND INPUTS 1001 EXT1 COMMA
51. 0 400 500 600 H3 373 473 586 686 D 209 221 248 282 D1 105 117 144 177 D2 147 159 200 233 a 5 5 5 5 6 5 6 5 b 10 10 13 13 c 5 5 6 0 8 0 8 0 d 5 5 5 5 6 5 6 5 Mass kg 5 5 8 5 19 0 28 6 See paragraph S for frame size assignments for type codes ACS 400 User s Manual Units with IP 54 NEMA12 Enclosures The IP 54 protection class has a different outer plastic cover compared to the IP 21 The IP 54 enclosure uses the same skeleton inner plastic part as the IP 21 enclosure but an internal fan is added to improve the cooling of the unit This kind of structure increases the dimensions compared to the IP 21 enclosure but the loadability of the units with IP 54 enclosure is the same as that of the IP 21 units W2 a 4 a qS ia n b Figure 3 IP 54 NEMA12 enclosures Table 3 Dimensions of units with IP 54 NEMA12 enclosures Frame Size IP 54 NEMA12 Dimension Reference mm R1 R2 R3 R4 Ww 215 215 257 257 w1 98 98 160 160 w2 98 98 H 453 551 642 742 H1 318 417 528 619 H2 330 430 545 636 D 240 253 280 312 D1 95 107 132 145 a 5 5 5 5 6 5 6 5 b 10 10 13 14 c 5 5
52. 00 kQ J1 AI1 open lt gt 0 50 Hz frequency reference 0 20 mA R 500 Q J1 Al1 closed lt gt 0 50 Hz frequency reference Resolution 0 1 accuracy 1 AGND Analogue input circuit common Connected internally to frame earth through 1 MQ 10V 10 V 10 mA reference voltage output for analogue input potentiometer accuracy 2 Al2 Analogue input channel 2 programmable Default 0 20 mA R 500 Q J1 AI2 closed 0 10 V Rj 200 kQ J1 Al2 open Resolution 0 1 accuracy 1 AGND Analogue input circuit common Connected internally to frame earth through 1 M AO1 Analogue output programmable Default 0 20 mA load lt 500 Q lt gt 0 50 Hz output frequency Accuracy 3 typically AGND Common for DI return signals Connected internally to frame earth through 1 MQ 24 V Auxiliary voltage output 24 V DC 20 10 250 mA reference to AGND Short circuit protected 10 DCOM1 Digital input common 1 for DI1 DI2 and DIS To activate a digital input there must be 2 10 V or s 10 V between that input and DCOM1 The 24 V may be provided by the ACS 400 X1 9 as in the connection examples see L or by an external 12 24 V source of either polarity DI Configuration Factory 0 Factory 1 11 DI 1 Start Activate to start Motor will ramp up to Start If DI 2 is activated momentary frequency reference Disconnect to stop activation of DI
53. 01 EXT 1 COMMANDS 2 DI1 2 1503 AO CONTENT MAX AP 9 0 4 20mA External Reference 1 0 10 V lt gt 0 50 Hz Hand Control 50 Hz 1002 EXT 2 COMMANDS 7 DI5 4 1601 RUN ENABLE O NOT SEL 1003 DIRECTION 3 REOUEST 1604 FAULT RESET SEL O KEYPAD 1102 EXT1 EXT2 SEL 3 DI3 2008 MAXIMUM FREQ 50 Hz 1103 EXT REF1 SELECT T ait 2105 PREMAGN SEL O NOT SEL 1105 EXT REF1 MAX 50 Hz 2201 ACC DEC 1 2 SEL O NOT SEL 1106 EXT REF2 SELECT 2 az 4001 PID GAIN 1 0 1201 CONST SPEED SEL 0 NOT SEL 4002 PID INTEG TIME 60 s 1401 RELAY OUTPUT 1 3 FAULT 1 4101 PID GAIN 1 0 1402 RELAY OUTPUT 2 2 RUN 4102 PID INTEG TIME 60s 50 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 Start stop DI1 5 Analogue reference Al1 Actual value Al2 Output signals DIP switch An output AO Frequency F Relay output 1 Fault An 2 0 10V e Relay output 2 Running Al2 2 0 4 20mA Control location selection DI2 Constant speed DI3 Run enable DI4 SCR Ali AGND 10V Al2 AO1 e N Jo a a o
54. 1 14 ACS 400 User s Manual The gland plate for control cables B see Figure 17 type IP 21 NEMA1 frequency converters Figure 21 Fixing the gland plate for control cables B Control cables Figure 22 Control cable connections IP 21 NEMA1 Note See ACS 400 EMC Instructions on page 157 15 ACS 400 User s Manual IP 54 Units A package containing five screws and two gland plates is included with the type IP 54 NEMA12 ACS 400 freguency converters Figure 23 Gland plate for power cables A and for control cables B type IP 54 NEMA 12 freguency converters To open the front cover see Removing the Cover on page 7 Figure 24 Fixing the gland plate for power cables A type IP 54 NEMA12 frequency converters 16 ACS 400 User s Manual Connect the power cables before installing the gland plate for control cables IP 54 NEMA12 Different diameters are marked on the grommet surface Cut the grommets after checking the correct cable size Table 5 Terminal Description Note U1 V1 W1 3 power supply input Do not use in 1 supply PE Protective Earth Follow local rules for cable cross sections U2 V2 W2 Power output to motor See R Uc Uc DC bus For optional ACS BRK braking unit l Motor cable shield Follow local rules for cable type and cross section
55. 1 OPEN Copy Parameters from Panel to Drive download Press 8 hold COPY TO DRIVE COPYING ENTER Note Drive must be stopped and in local control Parameter 1602 PARAMETER LOCK must be setto 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 8 hold Pi FULL SHORT MENU FULL SHORT MENU Visible if full menu is active 32 ACS 400 User s Manual 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 ACS 400 User s Manual 33 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 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 f
56. 1 3 380 480 V For more information see ACS400 User s Manual U2 0 0 Type ACS401000432 zadka aii Hn Mnsq 47 6 2A C US Code 63996611 I2n I2nsg 4 9 6 6A IND CONT EQ MELI mmm C CE N713 Serno 1982800001 f2 0 250Hz Figure 12 ACS 400 type designation label The figure below shows the key for the type designation ACS 40 1 x004 3 2 AC Drive Product Type S lt Standard product x OEM ACS 400 Product Family Input Bridge 0 6 pulse rectifier Enclosure Type 1 Wall mounted Accessories 0 Standard unit x Filter panel and manual options Rated Output Power in kVA See ACS 400 rating tables section S Table 11 Voltage Rating 1 200 240 V AC 3 380 480 V AC Enclosure Class 2 IP 21 NEMA1 5 IP 54 NEMA12 Figure 13 The key to the type designation code Serial number label is attached on the upper part of the back plate of the unit between fixing holes Type ACS401000432 Code 63996611 Ser no 1982800001 Figure 14 Serial number label 10 ACS 400 User s Manual H Motor Check the compatibility of the motor By default the motor must be a three phase induction motor with Uy 400 V and fy 50 Hz If the motor values differ from these the group 99 parameter values must be changed The motor nominal current ly must not exceed the nominal output current of the ACS 400 low in constant torque applications or
57. 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 lt 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 lt DISABLE 1 ENABLE If 1 is selected the fault analogue input signal under minimum level is reset automatically after the delay set by parameter 3103 DELAY TIME Trial time REN a A X X lime Now x Automatic reset Figure 50 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 90 ACS 400 User s Manual 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 energised when the values of 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 selected supervised parameter
58. 1 starts the ACS 400 Motor will coast to stop 12 DI2 Reverse Activate to reverse rotation Stop Momentary inactivation always stops direction the ACS 400 18 DI 3 Jog Activate to set output frequency to Reverse Activate to reverse rotation jogging frequency default 5 Hz direction 14 DI 4 Must be deactivated for Factory 0 Must to be activated for Factory 1 15 DI 5 Ramp pair selection ACC1 DEC1 or ACC2 DEC2 16 DCOM2 DCOWM2 digital input common 2 for DI4 DI5 17 RO1C Relay output 1 programmable default operation fault gt 17 connected to 18 18 ROTA 12 250 V AC 30 V DC 10 mA 2A a 19 RO1B a 20 RO2C Relay output 2 programmable default operation running gt 20 21 RO2A connected to 22 12 250 V AC 30 V DC 10 mA 2A 22 RO2B ee Digital input impedance 1 5 ko Use multi strand 0 5 1 5 mm wire Note DI 4 is read only when powered up Factory macro 0 and 1 Note For fail safe reasons the fault relay signals a fault when the ACS 400 is powered down 20 ACS 400 User s Manual Note Terminals 3 6 and 8 are at the same potential Note DI4 and DI5 are galvanically isolated from DI1 DI3 To utilise DI4 and DI5 a jumper wire must be connected See section L for details Note If control panel is available also other macros can be selected The digital input depends on the macro selected Analogue input configuration The analogue input signal is selected with DI
59. 10 V 20 mA EXT REF 1 MAX Hysteresis 4 of Full Scale 2V 4mA EXT REF 1 MIN 0V 0mA 2 96 2 96 EXT REF 1 MIN Figure 37 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 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 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 AI The reference is given through serial communication The analogue input 1 signal is combined to the fieldbus reference sum or multiplication For more information see chapter Standard Serial Communication on page 121 ACS 400 User s Manual 69 11 DI3U 4D R NC 12 DI3U 4D NC 13 DI4U 5D NC Selections 11 12 13 are the same as selections 5 6 7 respectively with the exception that the referenc
60. 12 are displayed in hexadecimal format by the control panel Table 23 Code Name Range User Group 52 STANDARD MODBUS 5206 BAD MESSAGES 0 65535 5207 GOOD MESSAGES O 65535 5208 BUFFER OVERRUNS O 65535 5209 FRAME ERRORS O 65535 5210 PARITY ERRORS 0 65535 5211 CRC ERRORS O 65535 5212 BUSY ERRORS 0 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 129 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 required contact your ABB supplier for a copy of 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 corres
61. 1s 1s 3s 8117 NR OF AUX MOT 0 3 1 1 Y ACS 400 User s Manual 61 Code Name Range Resolution Default User S M 8118 AUTOCHNG INTERV 0 0 336 h 0 1h 0 0 h NOT SEL 8119 AUTOCHNG LEVEL 0 0 100 0 0 1 50 8120 INTERLOCKS 0 6 1 4 D14 Y 8121 REG BYPASS CTRL 0 1 1 O NO 8122 PFC START DELAY 0 10s 0 01 s 0 5 s The maximum factor depending on the type of the frequency converter at 4 kHz switching frequency Range and default value depend on drive type and parameter 2605 LOW NOISE setting 62 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 O 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 starting page 43 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 v
62. 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 ANALOGUE OUTPUT 1501 JAO CONTENT 102 137 1 103 1502 AO CONTENT MIN H 0 0 Hz 1503 AO CONTENT MAX T 50 Hz Y 1504 MINIMUM 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 1 s Group 16 SYSTEM CONTROLS 1601 RUN ENABLE 0 6 1 0 Y 1602 PARAMETER LOCK 0 2 1 1 OPEN 1604 FAULT RESET SEL 0 7 1 6 Y 1605 LOCAL LOCK 0 1 1 O OPEN 1607 PARAM SAVE 0 1 1 O DONE 1608 DISPLAY ALARMS 0 1 1 O NO Group 20 LIMITS 2003 MAX CURRENT 0 5 ly 1 5 1 7y 01A 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 1 Hz 0 Hz 2008 MAXIMUM FREQ 0 250Hz 1Hz 50 Hz Y Group 21 START STOP 2101 START FUNCTION 1 4 1 1 RAMP 2102 STOP FUNCTION 1 2 1 1 COAST 2103 TORQ BOOST CURR O 5 Iy 1 5 1 7 Iy O 1A 1 2 ly 2104 STOP DC INJ TIME 0 250s 0 1s Os 2105 PREMAGN SEL 0 6 1 0 Y 2106 PREMAGN MAX TIME 0 0 130 0 s 0 1s 2 0s 2107 START INHIBIT 0 1 1 1 ON ACS 400 User s Manual 57 Code Name Range Resolution Default User S M Group 22 ACCEL DECEL 2201 ACC DEC 1 2 SEL 0 5 1 5 viv 2202 ACCELER TIME 1 0 1 1800s 0 1 1s 5s 2203 DECELER T
63. 2 MAXIMUM Al Maximum value of Al1 Value corresponds to maximum reference set by parameter 1105 EXT REF1 MAX or 1108 EXT REF2 MAX See Figure 38 on page 71 1303 FILTER Al1 Filter time constant for analogue input Al1 As the analogue 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 i A Unfiltered signal 100 T 63 a Filtered signal gt t Time constant Figure 39 Filter time constant for analogue input Al1 1304 MINIMUM Al2 Minimum value of Al2 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 Value corresponds to maximum reference set by parameter 1105 EXT REF1 MAX or 1108 EXT REF2 MAX 1306 FILTER Al2 Filter time constant for Al2 Refer to parameter 1303 FILTER AI Example To set the minimum allowed analogue input value to 4 mA value for parameter 1301 MINIMUM Al1 1304 MINIMUM Al2 is calculated as follows Value Desired minimum value Full range of the analogue input 100 4 mA 20 mA 100 20 Note In addition to this parameter setting the anal
64. 5 5 8 0 8 0 d 5 5 5 5 6 5 6 5 Mass kg 7 2 11 2 22 3 32 3 See paragraph S for frame size assignments for type codes ACS 400 User s Manual 5 C Mounting the ACS 400 on the Wall A Warning Before installing the ACS 400 ensure the mains supply to the installation is off Note ACS 400 can be mounted onto an air duct when flange mounting option set is used 1 The lid of the packing box shows the Wall Mounting Template Remove the lid from the box Figure 4 Removing the wall mounting template 2 The ACS 400 should only be mounted vertically on a smooth solid surface free T from heat damp and condensation Ensure minimum air flow gaps of 200 mm 1 above and below and 30 mm on the sides of the unit e 1 Using the mounting template mark the position of the fixing holes 2 Drill the holes 3 Screw in four screws or affix nuts and bolts depending on the mounting surface px ox a Figure 5 Marking and drilling the fixing holes 3 IP 21 NEMA1 Position the ACS 400 onto the fixings and securely tighten in all four corners Note Only lift the ACS 400 by its metal chassis IP 54 NEMA12 1 Remove the front cover see Figure 10 2 Remove the rubber plugs by pushing from outside 3 Screw in the screws 4 Replace the rubber plugs es oro 0j VR Figure 7 Affixing type IP 54 NEMA12 freguency converters 6 ACS 400 User s Manual D Removing the Cove
65. DDCS channels altered values are not automatically saved to permanent memory Instead this parameter must be used O 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 143 1 NO Some of the alarms are suppressed 2 YES All of the alarms are enabled 78 ACS 400 User s Manual 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 connected to the ACS 400 this parameter value must be set to 0 to ensure proper operation of the chopper O DISABLE 1 ENABLE 2006 UNDERVOLT CTRL DC undervoltage controller enable If the DC bus voltage drops due to loss of input power the undervoltage controller will
66. DS 1601 RUN ENABLE 2 DI2 1003 DIRECTION 1604 FAULT RESET SEL O KEYPAD 1102 EXT1 EXT2 SEL 2008 MAXIMUM FREQ 52 Hz 1103 EXT REF1 SELECT 2105 PREMAGN SEL 0 NOT SEL 1105 EXT REF1 MAX 2201 ACC DEC 1 2 SEL 0 NOT SEL 1106 EXT REF2 SELECT 4001 PID GAIN 2 5 1201 CONST SPEED SEL 0 3s NOT SEL 4002 PID INTEG TIME 1401 RELAY OUTPUT 1 29 PFC 4101 PID GAIN 2 5 1402 RELAY OUTPUT 2 29 PFC 4102 PID INTEG TIME 3s ACS 400 User s Manual 53 54 ACS 400 User s Manual ACS 400 Complete Parameter List lnitially only the so called basic parameters shaded grey in Table 12 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 12 Full parameter set Code Name Range Resolution Default User S M Group 99 START UP DATA 9901 LANGUAGE 0 11 1 O ENGLISH 9902 APPLIC MACRO 0 8 1 O FACTORY Y 9905 MOTOR NOM VOLT 380 400 415 440 460 400 V Y 480 V 9906 MOTOR NOM CURR 0 5 lu 1 5 lu 0 1A 1 0 IN Y 9907 MOTOR NOM FREQ O 250 Hz 1 Hz 50 Hz Y 9908 MOTOR NOM SPEED 0 3600 rpm 1 rpm 1440 rpm Y 9909 MOTOR NOM POWER 0 1 100 kW 0 1 kW ki Y 991
67. Drive User s Manual Low Power for type ACS 400 freguency AC Drives converters from 2 2 to 37 kW File Name ABB ACDrives ACS400 user D501 AA EP ED PA ID ID ACS 400 Freguency Converter User s Manual 3AFY 64036947 R0125 REV C EN Effective 5 12 2001 copyright O 2001 ABB Oy Safety p P PPP Pe o Warning Only a competent electrician may install the ACS 400 Warning 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 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 the ACS 400 is powered down there may be dangerous external voltages at relay terminals RO1A RO1B RO1C RO2A RO2B RO2C Warning Never attempt to repair a broken unit contact the supplier Warning The ACS 400 will start up automatically after an input voltage interruption if the external run command is on Warning 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 Warning The heat sink may reach a high temperature see S Table 11 Note For more technical information contac
68. ELAY 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 energised B Initially the relay is energised Figure 52 Operating data supervision using relay outputs when LOW gt HIGH ACS 400 User s Manual 93 Group 33 Information Code Description 3301 SW VERSION Software version 3302 TEST DATE Displays the test date of the ACS 400 yy ww 94 ACS 400 User s Manual 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 1 STANDARD P
69. GND 9 24V 424 VDC i DCOMI Start Stop Activate to start LLL 13 DI2 Forward Reverse Activate to reverse rotation direction I 7 DB Reference up Activate to increase reference 7 DIA Reference down Activate to decrease reference L DI5 Constant speed 1 16 DCOM2 17 ROTC Relay output 1 programmable 18 RO1A Default operation Fault gt 17 connected to 18 19 RO1B 20 RO2C Relay output 2 programmable z OLA Default operation Running gt 20 connected to 22 22 d Note e If both DI 3 and DI 4 are active or inactive reference is kept stable e Reference is stored during stop or power down condition e Analogue reference is not followed when motor potentiometer is selected Motor potentiometer parameter values 1503 AO CONTENT MAX 50 Hz 1601 RUN ENABLE O NOT SEL 1001 EXT 1 COMMANDS DI1 2 NOT SEL 1002 EXT 2 COMMANDS 1003 DIRECTION 1604 FAULT RESET SEL O KEYPAD 1102 ExT1 EXT2 SEL 2008 MAXIMUM FREQ 50 Hz 1103 EXT REF1 SELECT 2105 PREMAGN SEL O NOT SEL 1105 EXT REF1 MAX 2201 ACC DEC 1 2 SEL O NOT SEL 1106 EXT REF2 SELECT 4001 PID GAIN 1 0 1201 CONST SPEED SEL 4002 PID INTEG TIME 60s 1401 RELAY OUTPUT 1 4101 PID GAIN 1 0 1402 RELAY OUTPUT 2 4102 PID INTEG TIME 60s ACS 400 User s Manual 49 Application Macro Hand Auto This mac
70. IME 1 0 1 1800 s 0 1 1s 5s 2204 ACCELER TIME 2 0 1 1800 s 0 1 1s 60 s 2205 DECELER TIME 2 0 1 1800s 0 1 1s 60 s 2206 RAMP SHAPE 0 3 1 O LINEAR Group 25 CRITICAL FREQ 2501 CRIT FREQ SEL 0 1 1 O OFF 2502 CRIT FREQ 1 LO 0 250 Hz 1Hz 0 Hz 2503 CRIT FREQ 1 HI 0 250 Hz 1Hz 0 Hz 2504 CRIT FREQ 2 LO 0 250 Hz 1Hz 0 Hz 2505 CRIT FREQ 2 HI O 250 Hz 1Hz 0 Hz Group 26 MOTOR CONTROL 2603 IR COMPENSATION 0 60V 1V 10V 2604 IR COMP RANGE O 250 Hz 1 Hz 50 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 1 250 Hz 1 Hz 35 Hz 3009 STALL FUNCTION 0 2 1 O NOT SEL 3010 STALL CURRENT 0 5 ly 1 5 1 7y 0 1A 1 2 ly 3011 STALL FREQ HI 0 5 50 Hz 0 1 Hz 20 Hz 3012 STALL TIME 10 400 s 1s 20 s 3013 UNDERLOAD FUNC 0 2 1 O NOT SEL 3014 UNDERLOAD TIME 10 400 s 1s 20 s 3015 UNDERLOAD CURVE 1 5 1 1 3022 JAI1 FLT LIMIT O 100 1 0 3023 AI2 FLT LIMIT O 100 1 0 58 ACS 400 User s Manual
71. IP 21 NEMA1 freguency converters To open the front cover see Removing the Cover on page 7 Connect the gland plate for power cables with one screw The threaded hole for the screw is located in the middle of the heat sink at the bottom end Figure 18 Fixing the gland plate for power cables A type IP 21 NEMA1 frequency converters 12 ACS 400 User s Manual Table 4 Cable connections Terminal Description Note U1 V1 W1 3 power supply input Do not use in 1 supply PE Protective Earth Follow local rules for cable cross sections U2 V2 W2 Power output to motor See R Uc Uc DC bus For optional ACS BRK braking unit l Motor cable shield Follow local rules for cable type and cross sections Use screened motor cable Route the motor cable away from control wires and the power supply cable to avoid electromagnetic interference MAINS Goo o Be ae amp GM EUR 89 oj Figure 19 Motor cable connection for frame sizes R1 and R2 IP 21 NEMA1 Note See ACS 400 EMC Instructions on page 157 A note The output contactor can be used only as a safety device Do not close the contactor when the ACS 400 is running ACS 400 User s Manual 13 PELU V1 Wi Ue Uc uz V2 W2 Gi Figure 20 Motor cable connection for frame sizes R3 and R4 IP 21 NEMA
72. Jis selected as control location See T or section References below for information 8 COMM 10 comm al1 jon the alternative settings 9 coMM4A11 126 ACS 400 User s Manual Alternative peau usd Code Parameter Name A Standard Function Information Settings Modbus 1106 EXT REF2 SELECT O lt KEYPAD 8 COMM Fieldbus reference 2 is used when EXT2 12An 9 COMM AI1 is selected as control location See A or section References below for information 8 COMM 10 comM Al1 jon the alternative settings 9 coMM4A11 10 comm al1 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 DIT DI5 communication Control Word bit 7 6 START STOP 7 COMM Output signal source selection It is possible to control both the relay outputs 1 and 2 as well as the analogue output from the 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 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 paramet
73. LOCAL LOCK denies local control mode ra 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 OVERVOLTAGE Overvoltage controller is active i 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 e Check connections between external control system and the ACS 400 e 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 Communication section Last three exception response codes are stored into parameters 5213 5215 16 AI1 LOSS Analogue input 1 loss Analogue input 1 value is less than MINIMUM Al1 3022 See also parameter 3001 AI lt MIN FUNCTION 17 AI2 LOSS Analogue input 2 loss Analogue input 2 value is less than MINIMUM AI2 3023 See also parameter 3001 AI 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 parameteris
74. NDS o 10 1 2 4 viv 1002 EXT2 COMMANDS 0 10 1 0 viv 1003 DIRECTION 1 3 1 3 viv Group 11 REFERENCE SELECT 1101 KEYPAD REF SEL 1 2 1 1 REF1 Hz 1102 ExT1 EXT2 SEL 1 8 1 6 viv 1103 EXTREF1 SELECT 0 13 1 1 viv 1104 EXT REF1 MIN 0 250 Hz 1 Hz 0 Hz 1105 EXTREF1 MAX 0 250 Hz 1 Hz 50 Hz Y 1106 ExT REF2 SELECT 0 13 1 0 viv 1107 EXT REF2 MIN O 100 1 0 1108 EXT REF2 MAX 0 500 1 100 Group 12 CONSTANT SPEEDS 1201 CONST SPEED SEL o 10 1 3 0 viv 1202 CONST SPEED 1 0 250 Hz 0 1 Hz 5 Hz 1203 CONST SPEED 2 0 250 Hz 0 1 Hz 10 Hz 1204 CONST SPEED 3 0 250 Hz 0 1 Hz 15 Hz 1205 CONST SPEED 4 0 250 Hz 0 1 Hz 20 Hz 1206 CONST SPEED 5 0 250 Hz 0 1 Hz 25 Hz 1207 CONST SPEED 6 0 250 Hz 0 1 Hz 40 Hz 1208 CONST SPEED 7 0 250 Hz 0 1 Hz 50 Hz Group 13 ANALOGUE INPUTS 1301 MINIMUM Al1 0 100 1 0 1302 MAXIMUM Al1 O 100 1 100 1303 FILTER Alt 0 10s O 1s 0 1s 1304 MINIMUM Al2 0 100 1 0 1305 MAXIMUM Al2 0 100 1 100 1306 FILTER Al2 0 10s O 1s 0 1s 56 ACS 400 User s Manual Code Name Range Resolution Default User M Group 14 RELAY OUTPUTS 1401 RELAY OUTPUT 1 0 31 1 3 Y 1402 RELAY OUTPUT 2 0 31 1 2 Y 1403 RELAY 1 ON DELAY O 3600 s 0 1s 1s Os 1404 RELAY 1 OFF DELAY O 3600 s 0
75. P switch Al open voltage input U and Al connected current input I Examples on selecting the analogue input signal 1 Al1 U 0 10V Alt 2 Al2 0 4 20 mA Al2 S 2 Ali U 0 10V Al1 op Al2 U 0 10V Al2 9 3 AH 0 4 20 mA AH gy Al2 0 4 20 mA Al2 gt RS485 terminal X3 Table 7 prsi Signal termination is selected x3 Description RS485 interf with DIP switch 1 Screen Termin 2 B tog gt 3 A 2 4 AGND 5 Screen ACS 400 User s Manual 21 L Connection Examples 0 20 mA M Ground the cable screen on the sourcing end V DI configuration NPN connected sink Figure 29 I O examples Other Modbus devices ACS 400 ACS 400 x1 x1 1 SCR Analogue 1 SCR Analogue 2 JAH inputs 2 AM inputs AIT 2 10 10V A 2 10 10 V UD Et rtm ag emet 5 Al2 5 Al2 6 AGND 6 AGND 7 AO1 7 AO1 8 AGND 8 AGND 9 424V 9 24V 10 DCOM1 10 DCOM1 11 DI 11 DH 12 DI2 12 DI2 13 DI3 r 13 DIS 14 DIA DI configuration 14 DIA 45 DI5 PNP connected 15 DI5 16 DCOM2 source 16 DCOM2 with external es 17 RO1C power supply 17 RO1C 18 RO1A
76. PUT 2 2 RUN 4102 PID INTEG TIME 60s 44 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 configuration The value of parameter 9902 is 0 FACTORY DI 4 is connected Input signals Output signals DIP switch Start stop and direction An output AO x DI1 2 3 Frequency AM 9 0 10V e Analogue reference Al1 e Relay output 1 Fault Al2 9 0 4 20mA e Ramp pair 1 2 selection DI5 e Relay output 2 Running vv SCR 2 TAN External Reference 1 0 10 V lt gt 0 50 Hz z AGND LH 10V Reference voltage 10 VDC s Al2 Not used AGND AO1 Output frequency 0 20 mA lt gt 0 50 Hz m s AGND o 24V 424 VDC i DEOMI Momentary activation with DI2 activated Start A DI2 Momentary deactivation Stop DI3 Fwd Rev activate to reverse rotation direction 14 IDi4 Has to be connected 15 DIS Ramp pair selection Activate to select ramp pair 2 16 IDCOM2 47 ROTC Relay output 1 programmable 18 ROTA Default operation Fault gt 17 connected to 18 1 RO1B j 2n Roze Relay output 2 programmable A RO2B Default operation Running gt 20 connected to 22
77. Pipe 1 Pipe f mm 1 3 j Outlet Sewage Pipe 2 Tank 3 Outlet Pipe 3 2 i 3 Contactors rU 1 U ru ACS 400 Mains 3 73 ojoj Figure 64 Regulator bypass control The capacity of the pumping station outlet flow follows the measured inlet flow Output Freguency A Maximum freguency Start freg 2 Start freg 1 Low freq2 Low freq 1 Minimum p Control Signal freguency a b C a No auxiliary motors running b One auxiliary motor running c Two auxiliary motors running Figure 65 The relation between the control signal and the frequency of the controlled motor in a three motor system 118 ACS 400 User s Manual 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 ACS 400 is switched on by a ACS 400 relay output 2 PFC Start Delay is waited 3 Speed regulated motor is energised and normal PFC operation starts Auxiliary motors are started Caution There should always be PFC Start Delay set if the motors are eguipped 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 fir
78. 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 131 Exception Codes The ACS 400 supports the standard Modbus exception codes These are shown in Table 25 Table 25 Exception codes Code Name Meaning 01 ILLEGAL The function code received in the guery is not an allowable FUNCTION action for the slave ACS 400 Unsupported Command 02 ILLEGAL DATA The data 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
79. T 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 61 When ACS 400 output frequency falls below 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 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 8115 AUX MOT START D Sets the Start Delay for the auxiliary motors See parameter 8112 Low FREQ 1 and Figure 61 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 gt lt f max 8109 START FREQ 1 41 Hz 22 tone ee tee cee BSS Be pRrequency in ce crease during 8112 LOW FREQ 1 1 Hz s tes Ese nece ea c4 CARO elec S the Start Delay crease during the Stop Delay poke tM frin r 5 Time lt 8116 AUX MOT STOP D Increasing flow Start Aux Motor 1 Decreasing Stop Start Y flow Stop Figure 61 Start Frequency Low Frequency Start Delay and Stop Delay
80. VERSE DIA DIRECTION RUN ENABLE 1003 1601 Figure 73 The control signal connections of the PID Control macro 152 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 e The motor of the pump no 1 is connected to the ACS 400 The capacity of the pump is controlled by varying the motor speed e The motor of the pump no 2 is connected direct on line The pump can be switched on and off by the ACS 400 when necessary e 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 e 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 e 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 othe
81. VIOUS FAULT Previous recorded fault See Diagnostics starting page 143 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 starting page 143 Can be cleared with the control panel by pressing UP and DOWN buttons 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 SER 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 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 starting page 149 Code Description 1001 EXT1 COMMANDS Defines the connections and the source of Start Stop Directi
82. a Res a eee ar eee x 23 Environmental Information 23 Protection Features 24 Motor Overload Protection 25 Loadability of ACS 400 25 Type Series and Technical Data 26 Product Conformity 27 ACCESSONES nba z ale perde ba oad Se ae ae Ree OR nn 28 Programming 5262290 tre REAL PERS cd a 29 ACS PAN A Control Panel 29 Controli MOde S 4 403 au eee ge p ela shee ya hago E d 29 Output Display 30 Menu Structure 30 Setting Parameter Value 31 ACS 400 User s Manual Men Functions eee aenea leni I Ru Maen A No sees 32 LED Indicators eine as ate ett E e Ears 33 Diagnostic displays 34 Resetting the Drive from the Control Panel 34 Contrast Setting 34 ACS100 PAN Control Panel 35 Control Modes 35 Output Display iii sine kee e uum ES 36 Menu Structures i3 ero Li ecce E E E iue 36 Setting Parameter Value 36 Menu Functions 37 Diagnostic Displays 38 Resetting the Dr
83. able 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 116 ACS 400 User s Manual Code Description N Q gt O lt m O lt m 6 822 z odo 888 2 SEB S cee cee ACS 400 IL O vacd movae en SE D ae Ratio On Off On Off 3 M1 M2 Figure 63 Wiring the interlocks of a PFC system with two motors There is a thermal relay in the supply circuit of M2 ACS 400 User s Manual 117 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 Example is given in Figure 64 and Figure 65 O 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 i 3 7 i i Outlet Pla Inlet
84. al 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 PID PFC control block exceeds the level set by this parameter Autochange operation is not possible Output freguency A f MAX No aux 1 aux 2 aux motors motor motor Allowed autochange area gt PID output 8119 AUTOCHNG LEVEL 100 Figure 62 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 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 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 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
85. ample 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 69 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 28 Using the Control Word Control Word Value Description Step 1 CW z 0000 0000 0000 0110 When this value is written drive state changes to READY TO SWITCH ON bit 15 bit O Step 2 Wait at least 100 ms before proceeding Step 3 CW 0000 0000 0000 0111 When this value is written 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 ACCELERATOR ENABLED Step 6 CW 0000 0000 0110 1111 When this value is written the ramp function generator RFG input is released Drive state changes to OPERATING 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 ar
86. 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 143 Table 34 Alarms Alarm k TES Code Display Description ds 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 2 START ACTIVE Control panel function is not allowed while start is active 3 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 BUTTON DISABLED Control panel function is denied for any of the following reasons e START STOP button is interlocked from digital input This can happen with certain digital input configurations Refer to chapter Application Macros e REVERSE button is locked because shaft direction is fixed by parameter 1003 DIRECTION e 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 e Parameter 1602 PARAMETER LOCK denies parameter editing e Parameter 1605
87. anel displays standard variables 2 PROCESS VAR Panel displays process variables See Figure 53 Process variable 1 OUTPUT Freguency reference Process variable 2 Figure 53 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 when displayed Refer to Figure 54 Value Display 0 125 1 12 5 2 1 25 3 0 125 Figure 54 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 1 lt A 5 s 9 C 13 kW 2 V 6 h 10 lIbft 14 W 3 Hz 7 lt rpm 11 mA 15 kWh 16 F 20 m h 17 hp 21 dm s 18 MWh 22 bar 19 2 m s 23 kPa 24 GPM 28 MGD 25 PSI 29 inHg 26 CFM 30 FPM 27 ft 31 Cst ACS 400 User s Manual 95 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 Pr
88. anual From any state From any state Emergency Stop OFF3 CW Bit2 0 T OFF3 SW Bit5 0 ACHV Emergency Off OFF2 CW Bit1 0 OFF2 ka CE SW Bit4 0 f 0 1 0 L2 From any state OFF1 CW Bit0 0 MAINS OFF f20 1 0 Power ON L2 A CD CW Bit3 0 SENO OPERATION SW Bit2 0 INHIBITED gt C D CW Bit5 0 L2 D CW Bit6 0 A i gt G This state transition occurs also if the fault is reset b from any other source e g digital input State meum CW Control Word SW Status Word Output current f Output frequency RFG Ramp Function Generator From any state Fault FAULT SW Bit3 1 E CW Bit7 1 E j SWITCH ON INHIBITED SW Bit6 1 CW Bit0 0 NOT READY SW Bito 0 TO SWITCH ON CW xxxx xxxx xxxx x110 READY TO SW Bit0 1 SWITCH ON CW xxxx xxxx xxxx x111 READY TO OPERATE SW Biti 1 CW Bit3 1 and za SW Bit12 1 OPERATION ENABLED SW Bit2 1 Et S CW Bit5 1 RFG ACCELERATOR ENABLED l CW Bit6 1 OPERATING SW Bit8 1 i Figure 69 The state machine for evaluation of start and stop signals ACS 400 User s Manual 139 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 contai
89. ault is still active Description DC OVERVOLTAGE FAULT 2 Figure 34 Fault and alarm messages Refer to Diagnostics section for 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 ENTER and UP buttons Decrease contrast by pressing and holding ENTER and DOWN buttons The buttons must be pressed down simultaneously 34 ACS 400 User s Manual ACS100 PAN Control Panel The control panel can be connected to and detached from the converter at any time Units Control modes E fi AVS Z Active fault indicator Crp a mm z S VENO EWDREV 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 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 e If the buttons are released while Loc is display
90. below preset limit Alternatively sleep function can be activated and deactivated through a digital input Figure 73 on page 152 Appendix A 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 exists and the gain is 1 Integration time 1 s denotes that a 100 change is achieved in 1 s Gain Gain 1 m t PID integration time 0 NOT SEL Integrator is off the controller is P or PD controller 0 1 600 s Integrator is on the controller is PI or PID controller ACS 400 User s Manual 97 Code Description 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 _ __ z PID derivation time 4004 PID DERIV FILTER Time constant for the filter of D part By increasing the filter time constant it is possible to smooth t
91. ction 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 ACS 400 User s Manual 67 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 starting page 149 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 DI 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 a
92. d by the ACS 400 Also shown in OUTPUT display 0105 TORQUE Output torque Calculated value of torque on 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 the 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 Centigrade 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 O LOCAL 1 ExT1 2 EXT2 See Appendix A starting page 149 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 per cent 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
93. 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 lt 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 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 premagnetising command Option 6 selects start with DC hold O NOT SEL Premagnetising not used 1 5 Dh Dis Premagnetising command is received through a digital input 6 CONST Constant premagnetising time after start command Time is defined by parameter 2106 PREMAGN MAX TIME 2106 PREMAGN MAX TIME Maximum
94. e Direction A DIS EXT2 KEYPAD REVERSE i Di4 EE ans EI AGE DIRECTION RUN ENABLE 1001 1002 1003 1601 Figure 76 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 PFC control macro is selected Key features of the PID controller are e PID sleep function to stop the regulation when the output of PID controller falls below preset limit recovery when the process actual value falls below preset limit e Programmable sleep and wake up delays Sleep mode can also be activated through a digital input e Two PID parameter sets selectable through a digital input e PID controller parameters are in groups 40 and 41 ACS 400 User s Manual 155 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 Pump and Fan Control block This is the default setting for both relay outputs when 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 e When the standard relay outputs of the ACS 400 RO1 and RO2 are needed for other purposes and or number of a
95. e value is not copied when moving from EXT1 to EXT 2 or moving from EXT2 to EXT1 or moving from local to remote 1104 EXT REF1 MIN Sets the minimum frequency reference for external reference 1 in Hz When analogue input signal is at minimum external reference 1 equals to EXT REF1 MIN See Figure 38 on page 71 1105 EXT REF1 MAX Sets the maximum frequency reference for external reference 1 in Hz When analogue input signal is at maximum external reference 1 equals to EXT REF1 MAX See Figure 38 on page 71 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 analogue input signal is at minimum external reference 2 equals to EXT REF2 MIN See Figure 38 If the PID Control or PFC macro is selected this parameter sets the minimum process reference f any other macro than PID is selected this parameter sets the minimum frequency reference This value is given as a percentage of the maximum frequency 1108 EXT REF2 MAX Sets the maximum reference in When analogue input signal is at maximum external reference 2 equals to EXT REF2 MAX See Figure 38 If the PID Control or PFC macro is selected this parameter sets the maximum process reference If any other macro than PID Control is selected this parameter sets the maximum frequency re
96. e error e Panel loss a o Parameters inconsistent a Em DC bus ripple too large a N Motor stall wo Serial communication loss a A External fault oa Output earth fault 140 ACS 400 User s Manual Table 33 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 0 Overcurrent controller alarm Overload alarm 1 Overvoltage controller alarm Autoreset alarm 2 Undervoltage controller alarm PID sleep alarm 3 Direction lock alarm PFC autochange alarm 4 Serial communication loss PFC interlock alarm 5 Modbus exception Reserved 6 Analogue input 1 loss 7 Analogue input 2 loss 8 Panel loss 9 ACS 400 overtemperature 10 Motor overtemperature 11 Underload 12 Motor stall alarm 13 DDCS link 14 Reserved 15 Reserved ACS 400 User s Manual 141 142 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 cured by the given instructions contact an ABB service representative Caution Do not attempt any measurement parts replacement or other service procedure not described in this manual Suc
97. e 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 PE 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 78 Cable recommendations and restrictions 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 79 Braided metallic screen Inner insulator Insulation jacket Y L2 TREE a ile Ji We L1 4 ug v Niva L3 Figure 79 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 J 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
98. e received through serial communication parameter 1001 134 ACS 400 User s Manual Table 29 The Status Word Bit Value Description 0 1 READY TO SWITCH ON O NOT READY TO SWITCH ON 1 1 READY TO OPERATE O oFF1 ACTIVE 2 1 OPERATION ENABLED 0 Not ready OPERATION INHIBITED 3 0 1 FAULT 0 No fault 4 1 OFF2 inactive O OFF2 ACTIVE 5 1 OFFS inactive O 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 O The value of first supervised parameter is 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 135 References References are 16 bit words comprising 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 corresp
99. earthed 360 degrees with an EMC cable gland e g Zemrex SCG screened cable glands Table 36 Maximum motor cable lengths with input filters ACS400 IF 11 3 ACS400 IF41 3 and switching frequency 4 kHz or 8 kHz Switching Freguency Converter Type Filter 4 kHz 8 kHz ACS ACH 401 x004 3 x ACS400 IF 11 3 100 m ACS400 IF22 3 10m 10m ACS ACH 401 x005 3 x ACS400 IF 11 3 100 m ACS400 IF22 3 10m 10m ACS ACH 401 x006 3 x ACS400 IF 11 3 100m ACS400 IF22 3 10m 10m ACS ACH 401 x009 3 x ACS400 IF21 3 100m 100 m ACS400 IF22 3 10m 10m ACS ACH 401 x011 3 x ACS400 IF21 3 100 m 100 m ACS400 IF22 3 10m 10m ACS ACH 401 x016 3 x ACS400 IF31 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 IF 41 3 100 m 100 m ACS ACH 401 x030 3 x ACS400 IF 41 3 100 m 100 m ACS ACH 401 x041 3 x ACS400 IF 41 3 100 m 100 m Conducted emission with input filters ACS400 IF 11 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
100. ed 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 DI1 DI5 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 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 ACS 400 User s Manual 77 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
101. ed the panel frequency reference is set to the current external reference and the drive is stopped e 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 ACS 400 User s Manual 35 Output Display When the control panel is powered up the panel displays the actual output freguency Whenever the MENU button is pressed and held the control panel resumes this OUTPUT display To toggle between output freguency and output current press the UP or DOWN button To set the output freguency press ENTER Pressing the UP DOWN buttons changes the reference immediately Press ENTER again to return to OUTPUT display p LIJ B Z Hz B Z Hz OUTPUT OUTPUT Aa V O dije OUTPUT LIJ 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
102. ed 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 144 ACS 400 User s Manual Display Description DDCS COMM LOSS DDCS communication loss has been detected e Check the status of the fieldbus adapter Refer to appropriate fieldbus adapter manual e Check the DDCS option module and optical fibres e Check connections between external control system and fieldbus adapter Refer to DDCS Option module manual and parameters 5003 5006 Reserved Reserved 26 OUTPUT OVERLOAD Inverter overload condition The ACS 400 output current exceeds the ratings given on page 25 of this manual 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 functio
103. en alternating the direction of rotation of the drive The value of parameter 9902 is 3 ALTERNATE Input signals Output signals DIP switch Start stop and direction An output AO Frequency DI1 2 Ali 2h 0 10V Analogue reference Al1 Relay output 1 Fault Al2 1 2 0 4 20mA e Preset speed selection DI3 4 Relay output 2 Running Ramp pair 1 2 selection DI5 vna SCR c HH oe AH External Reference 1 0 10 V lt gt 0 50 Hz mag AGND s 4 eH0V Reference voltage 10 VDC s Al2 Not used 6 AGND 7 AO1 Output frequency 0 20 mA lt gt 0 50 Hz s AGND 9 24V 24 VDC 10 DCOM1 3 11 DH art fwd state is the same as drive stops Start fwd If DI1 state is th DI2 d t lt 12 DI2 Start reverse r DI3 Constant Speed selection a DA Constant Speed selection es DIS Ramp pair selection Activate to select ramp pair 2 46 IDCOM2 17 RO1C Relay output 1 programmable 18 ROTA Default operation Fault gt 17 connected to 18 19 ROIB j 20 RO2C Relay output 2 programmable FI AN Default operation Running gt 20 connected to 22 22 RO2B Constant speed selection 0 open 1 connected DI3 DI4 Output Reference through Al1 Constant speed 1 1202 Constant speed 2
104. equency is still above value 8111 START FREQ 3 1 Hz the third auxiliary motor is started After the third auxiliary motor is started 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 8112 LOW FREQ 1 Sets a frequency limit see Figure 61 When ACS 400 output frequency falls below 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 value 8112 Low FREQ 1 1 Hz the first auxiliary motor is stopped After the auxiliary motor is stopped ACS 400 output frequency is increased by 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 1 110 ACS 400 User s Manual Code Description 8113 LOW FREQ 2 Sets a frequency limit see Figure 61 When ACS 400 output frequency falls below 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 ACS 400 output frequency is increased by a value 8110 STAR
105. er 131 133 some value that is either above or below the given supervision limits Refer to Table 21 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 0 99 to parameter 131 causes the relay output 1 to deactivate Refer to Table 22 for information on analogue output control Table 21 Relay output control Alternative So Nhe Code Parameter Name Setti Standard Function Information eng 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 127 Alternative Zohn Code Parameter Name Settings Standard Function Information 9 Modbus Group 14 RELAY OUTPUTS 1401 RELAY OUTPUT 1 O NOT SEL e g 7 SUPERV1 Relay output 1 function Na OVER 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
106. er 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 149 Remote Control When the ACS 400 is in remote control REM the commands are given primarily through digital and analogue inputs although commands can be given also 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 freguency 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 inpu
107. escription 3008 BREAK POINT Break point of motor load curve Refer to Figure 46 for an example of a motor load curve See Figure 48 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 output frequency refer to Figure 47 0 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 lout A Stall region 3010 STALL CURRENT Frequency 3011 STALL FREQ HI Figure 47 Motor stall protection 3010 STALL CURRENT Current limit for stall protection Refer to Figure 47 3011 STALL FREQ HI This parameter sets the frequency value for the stall function Refer to Figure 47 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 of the nominal frequency of the motor and higher than 5 Hz 0 NOT SEL Underload protection is not used
108. ference This value is given as percentage of maximum frequency 70 ACS 400 User s Manual EXT REF A EXT REF MAX EXT REF MIN p Analogue input signal EXT REF 4 EXT REF MIN EXTREFMAXJ f L Analogue input signal Al min Al max Figure 38 Setting EXT REF MINIMUM and EXT REF MAXIMUM The range of the analogue input signal is set by parameters 1301 and 1302 or parameters 1304 and 1305 depending on the analogue input used ACS 400 User s Manual 71 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 acts also as a so called fault speed which may be activated if the control signal is lost Refer to parameter 3001 AI lt MIN FUNCTION and parameter 3002 PANEL 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 DI 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 d
109. ference voltage 10 VDC 5 Al Not used m 6 AGND 7 AO1 Output frequency 0 20 mA lt gt 0 50 Hz s AGND 24V 424 VDC 10 DCOM1 11 DI Start Stop Activate to start ACS400 12 DI2 Fwd Rev Activate to reverse rotation direction 13 DI3 Constant Speed 1 Default 5 Hz 14 DIA Leave unconnected 15 DIS Ramp pair selection Activate to select ramp pair 2 16 IDCOM2 17 RO1C Relay output 1 programmable 18 RO1A _ Default operation Fault gt 17 connected to 18 1 RO1B j 20 RO2C Relay output 2 programmable z RO2A Default operation Running gt 20 connected to 22 22 RO2B 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 Factory 0 parameter values 1001 EXT 1 COMMANDS 2 DI1 2 1503 AO CONTENT MAX 50 0 Hz 1002 EXT 2 COMMANDS O NOT SEL 1601 RUN ENABLE O NOT SEL 1003 DIRECTION 3 REOUEST 1604 FAULT RESET SEL 6 START STOP 1102 ExT1 EXT2 SEL 6 Exr1 2008 MAXIMUM FREQ 50 Hz 1103 EXT REF1 SELECT 1 A1 2105 PREMAGN SEL O NOT SEL 1105 EXT REF1 MAX 50 Hz 2201 ACC DEC 1 2 SEL 5 DI5 1106 EXT REF2 SELECT O KEYPAD 4001 PID GAIN 1 0 1201 CONST SPEED SEL 3 DI3 4002 PID INTEG TIME 60 s 1401 RELAY OUTPUT 1 3 FAULT 1 4101 PID GAIN 1 0 1402 RELAY OUT
110. gure 61 on page 111 When ACS 400 output freguency 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 freguency 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 freguency 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 61 When ACS 400 output frequency exceeds value 8110 START FREQ 2 1 Hz and one auxiliary motor is 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 8110 START FREQ 2 1 Hz the second auxiliary motor is started After the second auxiliary motor is started 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 61 When ACS 400 output frequency exceeds 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 D is elapsed and if the output fr
111. gure 74 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 DI5 Interlock 2 DI4 Interlock 1 i RO2 RO1 230VAC 230VAC Pump 1 On Off Pump 2 On Off Alternation Switchgear f Figure 75 In this example the automatic pump alternation is in use 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 i i i NOT SEL Control l i Terminals 1AM EXT1 i Analogue l KEYPAD inputs esl EXT2 IRemote All Min freq Remote ge Digital KEYPAD is IL Max freq inputs Local PID oe i Di1 DI5 k Const sise AA ACT PFC speeds Acc Dec Al1 ACT Als i ACTUAL1 i l INPUT SEL l 4007 l l REF2 NE ACTUAL 2 ACTUAL l REF1 Hz INPUT SEL Yu SEL i Keypad 4008 006 l Ref l Loc Remt cac oce MES EEA 4 Start Stop Direction I NOT SEL Local 4 Start Stop DH EXT1 REQUEST e DNE A KEYPAD NOT SEL x Remote oRWARD
112. h 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 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 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 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
113. he 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 Feedback signal can be a combination of two actual values ACT1 and ACT2 Source for actual value 1 is selected by parameter 4007 and source for actual value 2 is selected by parameter 4008 1 acT1 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 ACT1 ACT2 Product 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 sqA1 sqA2 Sum of square roots of actual values 1 and 2 98 ACS 400 User s Manual Code Description 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 Analogue input 1 is used as actual value 2 2 Al2 Analogue input 2 is
114. igital inputs DI1 2 Table 13 Constant Speed selection with digital inputs DI1 2 DI1 DI2 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 14 Constant Speed selection with digital inputs DI1 2 3 DI 1 DI 2 DI 3 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 1202 CONST SPEED 1 CONST SPEED 7 1208 Constant speeds 1 7 72 ACS 400 User s Manual Group 13 Analogue Inputs Code Description 1301 MINIMUM Al1 Relative minimum value of Al1 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 See Figure 38 on page 71 130
115. ing 131 Exception Codes 132 Function Codes iss sev xA EE IEEE bej 132 The Control Word and the Status Word 133 References 136 Actual Values cerere noaa Belen dene tele A Peta neve 138 ACS 400 User s Manual vii Fault and Alarm Status 140 DIAgnOSKTICS ses naris x ur san FCR wees Saka ws 143 Generali asoa easaig A be alley amp wae d 143 Alarm and Fault displays 143 Fault Resetting 143 Appendix A 2 251 t GR EE kDa Rei 149 Local Control vs Remote Control 149 Local Control 149 Remote Control 150 Internal Signal Connections for the Macros 151 Appendix B i29 eL LERRA saves ILLE 153 ACS 400 Pump and Fan Control PFC Macro 153 Introduction 153 PIB Controll amp t 5 wesc a retra ob eee the ena ex mE 155 Relay Outputs sss 4 e Ra eR EE XS 156 Adding More I O to ACS 400 156 Setting up NDIO modules 156 Alternation Switchgear 156 Appendix C ss urb E RR 157 ACS 400 EMC Instructions 157 viii ACS 400 User s
116. ing 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 starting on page 55 Connection Examples In the following connection examples please note e All the digital inputs are connected using negative NPN logic ACS 400 User s Manual 43 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 0 FACTORY DI4 is not connected Input signals Output signals DIP switch e Start stop and direction DI1 2 An output AO Frequency AH Sp T 0 10V du Analogue reference Al1 Relay output 1 Fault Al2 iy o 0 4 20 mA Constant speed 1 DI3 Ramp pair 1 2 selection DI5 Relay output 2 Running TILI SCR ohh 2 JAO External Reference 1 0 10 V lt gt 0 50 Hz H 3 AGND LL Hs rov Re
117. is diagnostic counter increases by one every time when 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 when 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 108 ACS 400 User s Manual Code Description 5211 CRC ERRORS This diagnostic counter increases by one every time when 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 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 ACS 400 User s Manual 109 Group 81 PFC Control Parameters for Pump Fan Control PFC Appendix B gives detailed information on PFC Chapter Application Macros describes the default signal connections Code Desc
118. ive from the Control Panel 38 ACS 400 Basic Parameters 39 Application Macros 43 Application Macro Factory 0 44 Application Macro Factory 1 45 Application Macro ABB Standard 46 Application Macro 3 wire 47 Application Macro Alternate 48 Application Macro Motor Potentiometer 49 Application Macro Hand Auto 50 Application Macro PID Control 51 Application Macro Premagnetise 52 Application Macro PFC Control 53 ACS 400 Complete Parameter List 55 Group 99 Start up Data 63 Group 01 Operating Data 64 Group 10 Command Inputs 66 Group 11 Reference Select 68 Group 12 Constant Speeds 72 Group 13 Analogue Inputs 73 Group 14 Relay Outputs 74 Group 15 Analogue Output 76 ACS 400 User s Manual Group 16 System Controls 77 Group 20 Limits 15 rre deb eed cash Fea 79 Group 21 Start Stop
119. lay for deactivation of PID sleep function Refer to parameter 4015 WAKE UP LEVEL and Figure 56 4018 SLEEP SELECTION PID sleep function control O 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 Dt DIS Sleep state is activated and deactivated using a digital input 100 ACS 400 User s Manual 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 SETPNT 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
120. loysq in variable torque applications See G and R A Warning Ensure the motor is suitable for use with the ACS 400 The ACS 400 must be installed by a competent person If in doubt contact your supplier Floating Network If the supply network is floating IT network 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 GND 1 GND 2 o O 020 QO O O e e Figure 15 Removing the grounding screws from frame size R1 and R2 frequency converters GND 1 GND 2 PE Uf vi wi ucs ue UZ v2 w2 qp Figure 16 Removing the grounding screws from frame size R3 and R4 frequency converters 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 the supply transformer with static screening between the primary and secondary windings can be used ACS 400 User s Manual 11 J Cable Connections IP 21 Units A package containing three screws and two gland plates is included with type IP 21 NEMA1 ACS 400 freguency converters Figure 17 Gland plate for power cables A and for control cables B type
121. ly when 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 DDCS 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 106 ACS 400 User s Manual 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 module Table 16 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 Others a OO CO N O oy A j MN 5102 5115 FIELDBUSPAR 2 FIELDBUSPAR 15 Refer to communication module documentation for more information on these parameters ACS 400 User s Manual 107 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
122. m 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 following table Interlock signals No of aux Motors ACS 400 digital param 8117 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 Dl2 Motor 2 DI2 Motor 4 Interlock signals are active low i e interlock is active when corresponding interlock signal is absent If 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 avail
123. mation on all the parameters and their alternative settings is given in chapter ACS 400 Complete Parameter List on page 55 Table 19 Communication parameters 2 STD MODBUS 3 STD MDB DDCS Code Parameter Name ACTEM Default Setting Function Information Settings 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 0 NONE O NONE Parity and stop bit setting 1 lt EVEN 2 ODD Group 50 COMMUNICATION 5003 COMM FAULT TIME 0 1 60 0s 1 0s Time limit for communication loss detection 5004 COMM FAULT FUNC 0 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 0 NOT SEL O NOT SEL Communication protocol selection 1 DDCS Normally must be set to STD MODBUS ACS 400 User s Manual 125 Control Locations The ACS 400 drive can receive control information from multiple sources including digital I O analogue I O keypad and Modbus fieldbus To control the ACS 400 via the serial communication channel 1 Modbus fieldbus it must be parameterised 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 20 Note especially
124. n gt AGND 9 24V 10 DCOM1 11 DH DI2 13 DIS 14 DIA __ DIS Note 46 IDCOM2 1 RO1C 18 RO1A 19 RO1B 20 RO2C 21 RO2A 22 RO2B EXT1 Manual or EXT2 PID reference 0 10 V Reference voltage 10 VDC Actual signal 0 20 mA PID Output freguency 0 20 mA lt gt 0 50 Hz 424 VDC Start Stop Activate to start ACS 400 Manual EXT1 EXT2 Selection Activate to select PID control Constant speed 1 not used if PID control Run enable deactivation always stops ACS 400 Start Stop Activate to start ACS 400 PID Relay output 1 programmable Default operation Fault gt 17 connected to 18 HU Relay output 2 programmable Default operation Running gt 20 connected to 22 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 1 D11 1503 AO CONTENT MAX 50 Hz 1002 EXT 2 COMMANDS 6 DI5 1601 RUN ENABLE 4 DI4 1003 DIRECTION 1 FORWARD 1604 FAULT RESET SEL O KEYPAD 1102 EXT1 EXT2 SEL 2 D12 2008 MAXIMUM FREQ 50 Hz 1103 EXT REF1 SELECT 1 A11 2105 PREMAGN SEL 0 NOT SEL 1105 EXT REF1 MAX
125. n is active The drive may accelerate when PID sleep function is deactivated Refer to parameters 4018 SLEEP SELECTION 4013 PID SLEEP DELAY 4014 PID SLEEP LEVEL and 4015 WAKE UP LEVEL AUTOCHANGE The autochange function of Pump Fan Control block is active Refer to parameter group 81 PFC CONTROL and the appendix for more information 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 ALARMS is set to 1 YES ACS 400 User s Manual 145 Table 35 Faults 1 OVERCURRENT Output current is excessive e Motor load may be too high e Acceleration time may be too short parameters 2201 ACCELER TIME 1 and 2203 ACCELER TIME 2 e Motor or motor cable is faulty or connected wrong 2 DC OVERVOLTAGE Intermediate circuit DC voltage is excessive e Check mains for static or transient overvoltages e Deceleration time may be too short parameters 2202 DECELER TIME 1 and 2204 DECELER TIME 2 e Brake chopper if present may be underdimensioned 3 ACS400 OVERTEMP ACS 400 heat sink temperature is exce
126. node number setting 5 6 1401 1402 Relay Relay NDIO NDIO RELAY RELAY output output relay relay Joe den ae bed OUTPUT OUTPUT RO1 RO2 output 1 output2 pu pu i 1 i function function 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 function The time is counted only when 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 Autochange system there is a contactor between ACS 400 output terminals and the speed controlled motor The contactor is damaged if lopened 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 112 ACS 400 User s Manu
127. ns 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 31 Fault and alarm status words MAIN COMMAND WORD Description Read only copy of the Control Word See page 133 MAIN STATUS WORD Read only copy of the Status Word See page 135 FAULT WORD 1 Fault information When a fault is active the corresponding bit is set Bit descriptions are given in Table 32 FAULT WORD 2 Fault information When a fault is active the corresponding bit is set Bit descriptions are given in Table 32 ALARM WORD 1 Alarm information When an alarm is active the corresponding bit is set Bits remain set until whole alarm word is reset by writing 0 to it See Table 33 ALARM WORD 2 Alarm information When an alarm is active the corresponding bit is set Bits remain set until whole alarm word is reset by writing 0 to it See Table 33 Table 32 Bit descriptions for fault words 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 Analogue input 1 fault Analogue input 2 fault COIN Soj a A N oO Motor overtemperature Hardwar
128. ntrols the use of the Interlock function Warning If the Autochange function is used also the Interlocks must be taken into use see parameter 8118 AUTOCHNG INTERV O NOT SEL No Interlocks function is in use All digital inputs are available for other purposes 12DH Interlocks function is in use Depending on the number of motors the digital inputs are reserved for the interlock signals according to 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 Depending on the number of motors the digital inputs are reserved for the interlock signals according to following table Interlock signals No of aux motors param 8117 ACS 400 digital inputs NDIO module 1 NDIO module 2 DI1 free Dl2 Motor 1 DI3 DI5 free Not used Not used DI1 free Dl2 Motor 1 DI3 Motor 2 DI4 DI5 free DI1 free DI2 Motor 1 DI3 Motor 2 DI4 Motor 3 DI5 free DU DI2 DI3 DI4 DI5 free Motor 1 Motor 2 Motor 3 Motor 4 114 ACS 400 User s Manual Code Description 3 DI3
129. ocess 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 lt 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 PI 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 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 96 ACS 400 User s Manual 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
130. og input must be configured for 0 20 mA current signal Refer to section Connection Examples on page 22 ACS 400 User s Manual 73 Group 14 Relay Outputs Code Description 1401 RELAY OUTPUT 1 Relay output 1 content Selects which information is indicated with relay output 1 O NOT SEL Relay is not used and is de energised 1 READY The ACS 400 is ready to function The relay is energised unless no run enable signal is present or a fault exists and supply voltage is within range 2 RUN Relay energised when the ACS 400 is running 3 FAULT 1 Relay energised when power is applied and de energised upon a fault trip 4 FAULT Relay energised when a fault is active 5 ALARM Relay energised when an alarm is active To see which alarms cause the relay to energise refer to section Diagnostics on page 143 6 REVERSED Relay energised when motor rotates in reverse direction 7 SUPRV1 OVER Relay energised when first supervised parameter 3201 exceeds the limit 3203 See Group 32 Supervision starting page 91 8 SUPRV1 UNDER Relay energised when first supervised parameter 3201 drops below the limit 3202 See Group 32 Supervision starting page 91 9 SUPRV2 OVER Relay energised when second supervised parameter 3204 exceeds the limit 3206 See Group 32 Supervision starting page 91 10 SUPRV2 UNDER Relay energised when second supervised parameter 3204 drops below
131. oltage from motor rating plate This parameter sets the maximum output voltage supplied to motor by 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 mains voltage See Figure 36 9906 9907 MOTOR NOM CURR Nominal motor current from rating plate The allowed range is 0 5 Iy 1 5 ly of ACS 400 MOTOR NOM FREQ Nominal motor frequency from rating plate field weakening point See Figure 36 9908 MOTOR NOM SPEED Nominal motor speed from rating plate 9909 MOTOR NOM POWER Nominal motor power from rating plate 9910 MOTOR COS PHI Nominal motor cos phi from rating plate Output voltage MOTOR NOM VOLT MEE 1 MOTOR NOM FREQ B Output frequency Figure 36 Output voltage as a function of output frequency ACS 400 User s Manual 63 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 measure
132. on commands for External control location 1 ExT1 0 NOT SEL No Start Stop Direction command source for ExT1 is selected 12DH Two wire Start Stop connected to digital input DI1 DIH deactivated Stop DI1 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 Forward DI2 activated Reverse To control direction 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 2P3 Three wire Start Stop Direction Start Stop connected as with DI1P2P Direction is connected to digital input DI3 DI3 deactivated Forward DI3 activated Reverse To control Direction value of parameter 1003 DIRECTION should be REQUEST 5 DITP2P 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 n
133. onding 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 freguency 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 2 EXT REF2 MAX parameter 1108 Scaling Parameter 1107 EXT REF2 MIN is not used Fieldbus Reference Fieldbus reference is selected by setting a reference selection parameter 1103 EXT REF1 SELECT or 1106 EXT REF2 SELECT to COMM COMM AI1 or COMM AI1 The latter two enable correction of the fieldbus reference using analogue input Al1 The following table explains these selections Note that the analogue input value is a percentage value 0 100 which can be seen in parameter 0118 Al1 When the analogue input is 50 the correction is 0 When the input is 50 gt 50 96 the correction reduces respecti
134. onsistent e MINIMUM Al1 gt MAXIMUM Al1 parameters 1301 1302 e MINIMUM Al2 gt MAXIMUM AI2 parameters 1304 1305 MINIMUM FREQ gt MAXIMUM FREQ parameters 2007 2008 e PFC block tries to use IO extension module NDIO but the DDCS link is not parameterised 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 e 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 3008 EXTERNAL FAULT 15 OUTPUT EARTH FAULT Earth fault The load on the incoming mains system is out of balance e There may be a fault in the motor or motor cable e Motor cable may be too long 146 ACS 400 User s Manual 16 DC BUS RIPPLE Ripple voltages on the DC bus are too large e Mains phase may be missing e 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 e Check the DDCS option module and the optic fibres e Check the status of the fieldbus adapter Refer to appropriate fieldbus adapter manual e Check connections between external control system and fieldbus ada
135. ormally 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 lt DI5 4 Two wire Start Stop Direction Start Stop is connected to digital input DI5 Direction is connected to digital input DI4 DI4 deactivated Forward and DI4 activated Reverse To control direction 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 value of parameter 1003 DIRECTION should be REQUEST 9 DITF 2R Start forward command is given when DI1 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 lt 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 direction to Forward Note Stop signal must be activated before Start command can be given 66 ACS 400 User s Manual 1002 EXT2 COMMANDS Defines the connections and the source of Start Stop and Dire
136. p 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 lt LINEAR 1 FAST S CURVE 2 MEDIUM S CRV 3 SLOW S CURVE Output frequency A MAXIMUM FREQ Linear S curve t Time Ramp time Figure 42 Definition of acceleration deceleration ramp time 82 ACS 400 User s Manual Group 25 Critical Freg 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 120N 2502 CRIT FREQ 1 LO Critical frequency 1 start Note If LOW gt HI no critical 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
137. ponds 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 130 ACS 400 User s Manual Register Mapping The drive parameters are mapped to the 4xxxx area so that e 40001 40099 are reserved for drive control registers e 40101 40199 is reserved for the actual values parameter group 1 e 40201 40299 is reserved for parameter group 2 e 40301 40399 is reserved for fault and alarm information e other parameter groups e 49901 49999 is reserved for the start up data Register addresses 4GGPP are shown in Table 24 In this table GG is the group number and PP is the parameter number within the group Table 24 Parameter mapping 4GGPP GG PP 40001 40006 00 Drive control registers 01 Control word 02 Reference 1 03
138. premagnetising time 80 ACS 400 User s Manual 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 e 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 12 ON 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 ACS 400 User s Manual 81 Group 22 Accel Decel Two acceleration deceleration ramp pairs can be used If both ramp pairs are used 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 selection 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 Ram
139. pter 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 Analogue input out of range Check Al level 21 26 HARDWARE ERROR Hardware error Contact supplier 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 147 148 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 70 below shows the ACS 400 control locations The selection between local control LOC and remote control REM can be done by pushing the MENU and ENTER buttons simultaneously when ACS100 PAN is used and by pushing the LOC REM button when 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 70 Control locations Local Control The control commands are given explicitly from the control panel when the ACS 400 is in local control Paramet
140. r IP 21 NEMA1 Opening units frame size R1 and R2 unit width 125 mm 1 Remove the control panel 2 In the control panel slot there is a little hole Lift the retaining lever inside 3 Remove the cover Figure 8 Opening the frame size R1 and R2 frequency converters of type IP 21 NEMA1 Opening units frame size R3 and R4 unit width 203 mm 1 Remove the control panel if fitted 5 Press the retaining lever and pull 2 Lift the retaining lever and simultaneously 6 Remove the lower part of the front cover pull the upper front cover slightly 3 Lift the other retaining lever e g with a screwdriver 4 Open the upper part of the front cover and remove it N lis UST qd Figure 9 Opening the frame size R3 and R4 frequency converters of type IP 21 NEMA1 ACS 400 User s Manual IP 54 NEMA12 1 Take the screws off 2 Remove the front cover 3 Remove control panel if needed Figure 10 Opening type IP 54 NEMA1 frequency converters 8 ACS 400 User s Manual E Terminal Interface RS485 termination DIP switch X3 RS485 connector see J Analogue input DIP switch X1 I O connection see J Figure 11 Terminal interface F Attaching a Warning Sticker ge Green LED see P Red LED see P
141. r s Manual 89 Group 31 Automatic Reset The automatic reset system can be used for resetting overcurrent overvoltage undervoltage and analogue input loss faults automatically Number of allowed automatic reset operations within a certain time is selectable Warning If parameter 3107 AR AI MIN is enabled the drive may restart even after a long stop when the analogue input signal is restored Ensure that the use of this feature will not cause physical injury and or damage equipment Code 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 O 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
142. r 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 ACS 400 receives process reference setpoint through analogue input 1 process actual value through analogue input 2 and Start Stop commands through digital input 1 The interlocks are connected to digital input 4 speed regulated motor and digital input 5 constant speed motor Run Enable signal is received through the digital input 2 and PFC control is activated deactivated through the digital input 3 The default output signal is given through the analogue 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 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 153 Mains Supply 3 va Input Power ACS 400 Process Act Value 2 Process Ref Value gt RI 24 V supply 4 DI5 Interlock 2 DI4 Interlock 1 f RO2 RO1 Pump 1 HRAS On Off Pump 1 A Regulated speed ol Pump2 On Off Pump 2 Constant speed 24 V d c 230 V a c Fi
143. rameter If analogue 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 analogue output Number of any parameter of the Operating Data group Group 01 1502 AO CONTENT MIN Analogue output content minimum Display depends on parameter 1501 1503 AO CONTENT MAX Analogue 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 1504 p AO content 1504 p AO content Figure 41 Analogue output scaling 76 ACS 400 User s Manual 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 DH DIS To activate the run enable signal the selected digital input must be activated If the voltage drops and deactivates the selected digital input 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 disabl
144. re defined with parameter 1001 Start Stop Direction commands and parameter 1103 reference 7 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 68 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 analogue input 1 2 Al2 Reference is given through analogue input 2 3 Al1 soysT 4 AI2 JOYST Reference is given through analogue 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 37 See also parameter 1003 DIRECTION Caution Minimum reference for joystick should be 0 3 V 0 6 mA or higher If a 0 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 EXT REF 1 MIN
145. ription 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 level 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 also 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 and 8104 REFERENCE STEP2 the process reference is increased along the increasing pumping capacity The reference steps compensate the growing pressure loss and prevent the pressure fall at the end of the pipe 8104 8105 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 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 FREG 1 Sets a freguency limit See Fi
146. ro offers an I O configuration that is typically used in HVAC applications The value of parameter 9902 is 5 HA Input signals Start stop DI1 5 and rev DI2 4 e Two an references Al1 Al2 Control location selection DI3 ND AUTO Output signals An output AO Frequency Relay output 1 Fault DIP switch Al 9 0 10 V Relay output 2 Running SCR Al1 AGND Al2 AO1 1 2 MENS 4 10V 5 6 7 8 AGND 9 24V 10 DCOM1 11 DM 12 DI2 a DIS h DIB 46 IDCOM2 1 RO1C 18 RO1A 1 RO1B 20 RO2C 2 RO2A 22 RO2B 24 VDC Start Stop Activate to start ACS 400 Hand Forward Reverse Activate to reverse rotation direction Hand EXT1 EXT2 Selection Activate to select auto control Forward Reverse Auto Start Stop Activate to start ACS 400 Auto Reference voltage 10 VDC External reference 2 0 20 mA lt gt 0 50 Hz Auto Control Output frequency 0 20 mA lt gt 0 50 Hz Relay output 1 programmable H Default operation Fault gt 17 connected to 18 m Relay output 2 programmable Default operation Running gt 20 connected to 22 Note Parameter 2107 START INHIBIT should be 0 OFF Hand Auto parameter values 10
147. rotection 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 45 shows motor thermal time definition Motor load A Temp Rise gt t 100 7 gt 63955 22 L gt t Mot therm time Figure 45 Motor thermal time 3006 MOT LOAD CURVE Motor current maximum limit MOTOR LOAD CURVE 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 3007 ZERO SPEED LOAD 50 l r Frequency 3008 BREAK POINT Figure 46 Motor load curve 3007 ZERO SPEED LOAD This parameter defines the maximum allowable current at zero speed relative to 9906 MOTOR NOM CURR Refer to Figure 46 86 ACS 400 User s Manual Code D
148. s Use shielded motor cable Route the motor cable away from control wires and the power supply cable to avoid electromagnetic interference mnl module remi f MAINS U1 vi wA V2 W2 MOTOR ejo eje e ec o B Figure 25 Motor cable connection for frame sizes R1 and R2 IP 54 NEMA12 Note See ACS 400 EMC Instructions on page 157 ACS 400 User s Manual 17 z o o NEN C Pacs UVW PE Figure 26 Motor cable connection for frame sizes R3 and R4 IP 54 NEMA12 o Note See ACS 400 EMC Instructions on page 157 Figure 27 Fixing the gland plate for control cables B type IP 54 NEMA12 freguency converters 18 ACS 400 User s Manual Figure 28 Control cable connections IP 54 NEMA12 Note See ACS 400 EMC Instructions on page 157 19 ACS 400 User s Manual K Control Terminals Main I O terminal X1 Table 6 X1 Identification Description 1 SCR Terminal for signal cable screen Connected internally to frame earth 2 Al1 Analogue input channel 1 programmable Default 0 10 V R 2
149. s 1s 4005 ERROR VALUE INV 0 1 1 O NO 4006 ACTUAL VAL SEL 1 9 1 1 acT1 Y 4007 ACT1 INPUT SEL 1 2 1 2 A2 Y 4008 ACT2 INPUT SEL 1 2 1 2 A2 Y 4009 ACT1 MINIMUM O 1000 1 0 4010 ACT1 MAXIMUM O 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 1 0 Y 4102 PID INTEG TIME O 600 s 0 1 s 60 s Y 4103 PID DERIV TIME 0 60s 0 1s 0s 4104 PID DERIV FILTER 0 10s 0 1 s 1s 4105 ERROR VALUE INV 0 1 1 O NO 4106 ACTUAL VAL SEL 1 9 1 1 acT1 Y 4107 ACT1 INPUT SEL 1 2 1 2 A2 Y 4108 ACT2 INPUT SEL 1 2 1 2 A12 Y 4109 ACT1 MINIMUM O 1000 1 0 4110 ACT MAXIMUM O 1000 1 100 4111 JACT2 MINIMUM O 1000 1 0 4112 ACT2 MAXIMUM O 1000 1 100 4119 SET POINT SEL 1 2 1 2 EXTERNAL 4120 INTERNAL SETPNT 0 0 100 0 0 1 40 0 60 ACS 400 User s Manual Code Name Range Resolution
150. s 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 panel 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 160 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 36 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 36 and the cable must have effective screen according to Figure 79 At the motor end the cable screen must be
151. sed when stall alarm or fault exists 27 UNDERLOAD Relay is energised when underload alarm or fault exists 28 PID SLEEP Relay is energised 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 Note This value can be selected only when the drive is stopped 30 AUTOCHANGE Relay is energised when PFC autochange operation is performed This option should be selected only when PFC control macro is used 31 STARTED Relay is energised when drive receives start command even if Run Enable signal is not present Relay is de energised 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 JT L Switch off delay for relay 1 1405 RO 2 ON DELAY ipm Switch on delay for relay 2 Relay status 1406 HK t H RO 2 OFF DELAY 1403 ON DELAY 1404 OFF DELAY Switch off delay for relay 2 Figure 40 ACS 400 User s Manual 75 Group 15 Analogue Output Analogue 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 pa
152. ssive Temperature trip limit is 95 C e Check air flow and fan operation e Check motor power against unit power 4 SHORT CIRCUIT Fault current Possible reasons for this fault are e There is a short circuit in the motor cable s or motor e Supply disturbances 5 OUTPUT OVERLOAD Inverter overload condition The ACS 400 output current exceeds the ratings given on page 25 of this manual 6 DC UNDERVOLTAGE Intermediate circuit DC voltage is not sufficient e Mains phase may be missing e Fuse may be blown 7 ANALOGUE INPUT 1 Analogue input 1 loss Analogue input value is less than MINIMUM Al1 3022 See also parameter 3001 AI lt MIN FUNCTION 8 ANALOGUE INPUT 2 Analogue input 2 loss Analogue input value is less than MINIMUM AI2 3023 See also parameter 3001 AI 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 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 11 PARAMETERING Parameter values are inc
153. st switch to star connection and then back to delta connection before the ACS 400 inverter starts switching ACS 400 User s Manual 119 120 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 analogue 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 Modbus fieldbus connection Communication settings of Channel 1 can be configured by the user To control the ACS 400 via Modbus ACS 400 must be parameterised to accept control commands and or freguency references from Channel 1 Channel 0 is reserved for drive control panels ACS PAN and ACS100 PAN and for the DriveWindow PC tool Optional serial communication features ACS 400 can also be connected to number of other fieldbuses using special fieldbus adapter modules These adapters are connected using an optical DDCS link DDCSzDistributed Drives Control System For more information on these options contact your supplier ACS 400 Channel 1 S Channel 0
154. t Defines relative analogue input value where frequency reference reaches minimum value Range 0 100 Default value 0 Group 15 ANALOGUE OUTPUT 1503 AO CONTENT MAX Defines output frequency where analogue output reaches 20 mA Default value 50 0 Hz or 52 Hz depending on the selected application macro Note Analogue output content is programmable Values given here are valid only if other analogue output configuration parameters have not been modified Description of all parameters is given in ACS 400 Complete Parameter List starting on page 55 Group 20 LIMITS 2003 MAX CURRENT Maximum output current Range 0 5 Iy 1 5 1 7 ly where Iy is nominal current of the ACS 400 Default value 1 5 In 2008 MAXIMUM FREG Maximum output freguency Range 0 250 Hz Default value 50 Hz or 52 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 41 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 Default value 1 COAST Group 22 IAACCELER DECELER 2202 ACCELER TIME 1
155. t Speed selection Lh DI5 Premagnetise Activate to start premagnetising 16 DCOM2 17 RO1C Relay output 1 programmable 18 ROIA Default operation Fault gt 17 connected to 18 19 ROIB j 20 RO2C Relay output 2 programmable 21 ROZA Default operation Running gt 20 connected to 22 22 Constant speed selection 0 open 1 connected DI3 DIA Output 0 0 Reference through Al1 1 0 Constant speed 1 1202 0 1 Constant speed 2 1203 1 1 Constant speed 3 1204 Premagnetise parameter values 1001 EXT 1 COMMANDS 1503 AO CONTENT MAX 50 Hz 1002 EXT 2 COMMANDS 1601 RUN ENABLE O NOT SEL 1003 DIRECTION 1604 FAULT RESET SEL O KEYPAD 1102 EXT1 EXT2 SEL 2008 MAXIMUM FREQ 50 Hz 1103 EXT REF1 SELECT 2105 PREMAGN SEL 5 DI5 1105 EXT REF1 MAX 2201 ACC DEC 1 2 SEL O NOT SEL 1106 EXT REF2 SELECT O KEYPAD 4001 PID GAIN 1 0 1201 CONST SPEED SEL 4002 PID INTEG TIME 60 s 1401 RELAY OUTPUT 1 FAULT 1 4101 PID GAIN 1 0 1402 RELAY OUTPUT 2 4102 PID INTEG TIME 60 s 52 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 The value of parameter 9902 is 8 PFC CONTROL Input signals Start and stop DI1 Analogue reference Al1 e Actual value Al2 Ou
156. t be set to 1 OPEN ACS 400 User s Manual 37 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 CI I cil I D UE TAL ILI tault code alarm code Figure 35 Fault and alarm messages Refer to Diagnostics section for 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 Caution Turning the power on again may start the drive immediately 38 ACS 400 User s Manual ACS 400 Basic Parameters 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 sufficient in applications where the preprogrammed application macros of the ACS 400 can provide all desired func
157. t speed selection 16 IDCOM2 17 ROTC Relay output 1 programmable 18 ROTA Default operation fault gt 17 connected to 18 19 RO1B 20 RO2C z RO2A Relay output 2 programmable gt RO2B Default operation running gt 20 connected to 22 Constant speed selection 0 open 1 connected DI4 DI5 Output 0 0 Reference through Al1 1 0 Constant speed 1 1202 0 1 Constant speed 2 1203 1 1 Constant speed 3 1204 Note Stop input DI2 deactivated panel START STOP button interlocked local Application Macro 3 wire parameter values 1001 EXT 1 COMMANDS 4 DHP 2P 3 1503 AO CONTENT MAX 50 Hz 1002 EXT 2 COMMANDS O NOT SEL 1601 RUN ENABLE O NOT SEL 1003 DIRECTION 3 REOUEST 1604 FAULT RESET SEL O KEYPAD 1102 EXT1 EXT2 SEL 6 Exr1 2008 MAXIMUM FREQ 50 Hz 1103 EXT REF1 SELECT 1 A11 2105 PREMAGN SEL O NOT SEL 1105 EXT REF1 MAX 50 Hz 2201 ACC DEC 1 2 SEL O NOT SEL 1106 EXT REF2 SELECT O KEYPAD 4001 PID GAIN 1 0 1201 CONST SPEED SEL 8 DI4 5 4002 PID INTEG TIME 60 s 1401 RELAY OUTPUT 1 3 FAULT 1 4101 PID GAIN 1 0 1402 RELAY OUTPUT 2 2 RUN 4102 PID INTEG TIME 60 s ACS 400 User s Manual 47 Application Macro Alternate This macro offers an I O configuration that is adopted to a sequence of DI control signals used wh
158. t the supplier ACS 400 User s Manual iii Note about compatibility The supplied ACS 400 freguency converter and this manual are fully compatible with ACS PAN A Control Panel revision and later If you use a control panel with older revision code certain new parameter names and alarms will not be displayed properly In this case refer to displayed numeric parameter values parameter numbers and alarm codes instead iv ACS 400 User s Manual Table of Contents Safety snore ferenn RO u eR TI O PE aera iii installation sis o t er nee 894 vate tthe RE 1 Step by Step Instructions for Installing the ACS 400 2 Reference Sections 3 Environment for Storage Transportation and Stationary Use 3 Dimensions MM 4 Mounting the ACS 400 onthe Wall 6 Removing the Cover 7 Terminal Interface 9 Attaching a Warning Sticker 9 Type Designation Label and Code Key 10 MOLOI ona sauer Sama uta Atta a a uae ee deter 11 Floating Network 11 Cable Connections 12 Control Terminals 20 Connection Examples 22 Replacing the Cover 23 Power Om ea iue acid aa
159. th amendments Corresponding declarations and a list of main standards are available on request Note See ACS 400 EMC Instructions on page 157 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 frequency converter and the related safety standard is mentioned in the documentation of the equipment UL cUL and C Tick Markings The ACS 400 has UL cUL and C Tick markings for all power ranges and both IP 21 and IP 54 protection classes ACS 400 User s Manual 27 U Accessories ACS 400 PAN A Control panel for use with the ACS 400 ACS 100 PAN Control panel for use with the ACS 100 ACS 140 ACS 400 PEC 98 0008 Panel Extension Cable kit for use with the ACS 100 ACS 140 ACS 400 ACS400 IFxx 3 RFI input filters ACS BRK Braking units NOCH Output chokes RS485 232 Adapter DDCS Communication Module For using fieldbus adapters and I O extension modules ACS 400 is supported by DriveWare Contact your supplier Flange Mounting Set For more information contact your local ABB supplier 28 ACS 400
160. tionality For a full description of programmable features provided by the ACS 400 see ACS 400 Complete Parameter List starting page 55 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 O 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 Application Macros starting page 43 for 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 9906 MOTOR NOM CURR Nominal motor current from motor name plate Values for this parameter range from 0 5 In 1 5 In where Iy is nominal current of the ACS 400 Default value Iw 9907 MOTOR NOM FREQ Nominal motor frequency from motor name plate Range 0 250 Hz Default value 50 Hz ACS 400 User s Manual 39 Code Name User S 9908 MOTOR NOM
161. tput signals e Control location selection DIS Run enable DI2 DIP switch An output AO Frequency IS AH 99 0 10 V Al2 Sp 0 4 20mA e Relay output 1 Speed regulated motor Relay output 2 Auxiliary motor tr 1 SCR cole TAH EXT1 Manual or EXT2 PID PFC reference 0 10 V Hrs AGND aa 4 410V Reference voltage 10 VDC PO h A2 Actual signal 0 20 mA PID Z 6e AGND 7 AO1 Output freguency 0 20 mA lt gt 0 52 Hz s AGND s 24V 424 VDC aa 4 Bae Start Stop Activate to start ACS 400 1 DI2 Run enable Deactivation always stops ACS 400 n s DI3 EXT1 EXT2 Selection Activate to select PFC control 14 DI4 Interlock Deactivation stops ACS 400 1 15 DIS Interlock Deactivation stops constant speed motor 16 DCOM2 1 RO1C Relay output 1 programmable 18 RO1A Default operation Speed regulated motor switched on 19 RO1B gt 17 connected to 19 2 RO2C Relay output 2 programmable 21 RO2A Default operation Auxiliary motor switched on gt 20 22 RO2B connected to 22 Note Parameter 2107 START INHIBIT should be 0 OFF PFC parameter values 1001 EXT 1 COMMANDS 1503 AO CONTENT MAX 52 Hz 1002 EXT 2 COMMAN
162. ts can be used to select between the external frequency reference and seven configurable constant speeds 1202 CONST SPEED 1 1208 CONST SPEED 7 EXT REF2 EXT REF1 EXT1 EXT2 CONST SP KEYPAD SELECT SELECT SELECT SELECT REF SEL Control 1106 1103 1102 1201 1101 Terminals 1 I Al1 2 DI1 5 EXT1 f Analogue KEYPAD EXT2 i or I Re Remote Al1 2 DH 5 zr j DH DI5 Min freq Digital KEYPAD Applic Local ES inputs bocal PID Const i i Crit speed DIS Speeds pes Acc Dec J I i j REF2 i REF1 Hz TI a Keypad l Ref t t i Loc Rem L L l EEES l Se 225 2 po i 1 e Start Stop NOT SEL Local EN DIH DI5 N EXTI WT Remote Direction KEYPAD I NOT SEL x FORWARD T DIt DIS 5 EXT2 REVERSE x Enabled i DI1 DI5 EXT1 EXT2 DIRECTION RUN ENABLE COMMANDS BOMMANDS 1003 1601 Figure 71 Selecting control location and control source 150 ACS 400 User s Manual Internal Signal Connections for the Macros EXT REF2 EXT REF1 EXT1 EXT2 CONST SP KEYPAD SELECT SELECT SELECT SELECT REF SEL M 1106 1103 1102 1201 1101 Control EXM DI34 NE dE EXT Analogue KEYPAD i i inputs i EXT2 NI Remote
163. uildings used for domestic purposes With ACS 400 no RFI filter is needed in Second Environment Note This is a product of the restricted sales distribution class according to IEC 61800 3 Ina domestic environment this product may cause radio interference in which case the user may be required to take adequate measures 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 The statutory rules defines the essential requirements for emissions of electrical equipment used in Australia and New Zealand The standard IEC 61800 3 1996 Adjustable speed electrical power drive systems Part 3 EMC product standard including specific test methods covers the detailed requirements for frequency converter The frequency converter ACS 400 comply with the IEC 61800 3 limits for first environment restricted distribution and second environment The compliance for first environment is valid with the following provisions e The frequency converter is equipped with RFl filter e The motor and control cables are chosen as specified in this manual e The installation rules of this manual are followed With ACS 400 no RFI filter is needed in Second Environment ACS 400
164. us preserving energy and natural resources Instructions for disposal are available from ABB sales and service companies ACS 400 User s Manual 23 P Protection Features The ACS 400 has a number of protective features e Overcurrent Input phase loss 3 Overvoltage O terminal short circuit protection Undervoltage Motor overload protection see Q Overtemperature Output overload protection see R Output earth fault Stall protection Output short circuit Underload The ACS 400 has the following LED alarm and fault indicators e For location of LEDs see section E or if ACS PAN A control panel is connected see the instructions on page 29 Table 8 Red LED off Green LED blinking ABNORMAL CONDITION POSSIBLE CAUSES ABNORMAL CONDITION Acceleration or deceleration ramp is e ACS 400 cannot fully follow control too fast in relation to load torque commands requirement Blinking lasts 5 seconds Ashort voltage interruption Table 9 Red LED on Green LED on FAULT POSSIBLE CAUSES ACTION Transient overcurrent Give a stop signal to reset fault Over undervoltage Give a start signal to restart the drive Overtemperature Motor overload see section Q CHECK NOTE the supply line for disturbances fthe drive fails to start check that the the drive for mechanical problems that input voltage is within the tolerance might cause overcurrent range thatthe heat sink
165. uxiliary motors is large and e 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 fibre 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 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 e 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 e Connect power to NDIO modules e Activate DDCS protocol by setting parameter 5005 PROTOCOL SEL to 1 DDCS e 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
166. vely increases the reference used Table 30 Correcting the fieldbus reference through analogue input Parameter Setting Effect of Al1 Value on Fieldbus Reference COMM None COMM lt AI1 Corrected fieldbus reference given fieldbus reference analogue input Al1 value COMM AI1 Corrected fieldbus reference given fieldbus reference analogue input Al1 value 50 136 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 corrected fieldbus reference is 25 30 50 5 or 2 5 Hz 2 If setting Comm AI1 is used then corrected fieldbus reference is 25 30 50 15 or 7 5 Hz REF A 100 50 FIELDBUS REFERENCE f H gt AM 50 100 ACS 400 User s Manual 137 Actual Values Actual values are read only values containing information on the operation of the drive Actual values are 16 bit words containing 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 2 50 Hz Actual Value 2 Holding Register 40006 Actual output current Scaling 10 2 1 A 138 ACS 400 User s M
167. y on page iii ACS 400 User s Manual 1 Step by Step Instructions for Installing the ACS 400 1 C CHECK the environment D See A 2 C MOUNT the ACS 400 on 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 and fuses See B C co o o O n D D m T See EH I op oO D lo o 7 C CHECK the motor S 3 CHECK DIP switch See E J L 9 4 CONNECT power terminals See E H I 4 CONNECT control wires See ne l D o o 4 REPLACE the cover 12 C TURN the power on Figure 1 The references after each step refer to one or more of the Reference Sections on the following pages in this User s Manual See N pw NA ee Re Lm 2 ACS 400 User s Manual Reference Sections A Environment for Storage Transportation and Stationary Use Table 1 ACS 400 Stationary Use Storage and Transportation in the protective package Installation Site Altitude e 0 1000 m if Py and Ip 100 e 1000 2000 m if Py and lp derated 1 every 100 m above 1000 m Ambient Temperature 0 40 C 40 70 C e max 50 C if Py and l derated to 90 Relative Humidity lt 95 non condensing Contamination Levels No conductive dust allowed IEC 721 3 3 The ACS 400 should be installed in clean air according

Drive Low Power AC Drives User`s Manual for type ACS 400

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