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Drive Low Voltage AC Drives User's Manual for type ACS 160

1. EXT REF2 EXT REF1 EXT1 EXT2 CONST KEYPAD SELECT SELECT SEL SPEED SEL REF SEL 1106 1103 1102 1201 1101 Control DI2 DIS Terminals Al EXT Analogue KEYPAD inputs EXT2 Remote AH l Min freq erie i 2 Min freq ve NAREST Z I 1 Max freq Digital KEYPAD PID Local Po inputs 7 Local Apolic Const Crit sp DIT DI5 Al4 acri o PPPRE speeds Acc D AD cc Dec LAH ACT2 Al24 1 f ACTUALT i h oe i REF2 i 1 ACTUAL ACTUAL 2 VAL SEL I REF1 Hz 2008 4006 i Keypad l i Ref i i i Loc Rem 4 pake da a ers De Start Stop Direction 14 Oh NZ NOT SEL Local H Start Stop LES Bike EXT1 REQUEST RONA 4 KEYPA zem N Remote ENE Direction vy i DE EXT2 REVERSE KEYPAD i l i l DI4 l EXT1 EXT2 DIRECTION RUN ENABLE COMMANDS COMMANDS 1003 1601 Figure 31 The control signal connections of the PID Control macro ACS 160 User s Manual 115 116 ACS 160 User s Manual Appendix B Dimensions Motor Mounted eu G E 1 a TT z 1 Converter type Frame A B C D E Weight ACS 163 Size mm mm mm mm mm kg 1K1 3 A 2K7 3 A R1 99 112 157 221 171 3 9 4K1 3 A
2. Input signals Output signals DIP switch e Start stop and direction e An output AO Frequency rs DI1 2 3 Alt 46 0 10V e Analogue reference Al e Relay output 1 Fault AI2 lt 45 0 4 20 mA e Preset speed selection DI4 5 e Relay output 2 Running Connection example SCR 1 External Reference 1 0 10 V lt gt 0 50 Hz Ali 2 i AGND 3 Lt gt Reference voltage 10 VDC 10V Ja Not used Al2 5 AGND 6 Output frequency 0 20 mA lt gt 0 50 Hz LAO1 7 A AGND 8 24 VDC F2AV T3 DCOM 10 Momentary activation with DI2 activated Start D 11 S Momentary deactivation Stop DI2 12 Fwd Rev activate to reverse rotation direction DI3 8 Constant speed selection DIA 14 Constant speed selection DIS 15 Relay output 1 programmable _RO1A_ 16 Default operation Fault gt open RO1B 17 Relay output 2 programmable 2 18 Default operation Running gt closed lt MRO2B 19 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 3 wire default parameter values 1001 EXT 1 COMMANDS DI1P 2P 3 1201 CONST SPEED SEL 8 DI4 5 1002 EXT 2 COMMANDS NOT SEL 1402 RELAY OUTPUT 2
3. A Unfiltered signal 100 63 Bg i Filtered signal I I D para Time constant Figure 7 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 AIT 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 4mA 20 mA 100 20 Note In addition to this parameter setting the analog input must be configured for 0 20 mA current signal Refer to Reference Section L ACS 160 User s Manual 65 Group 14 Relay Outputs Code Description 1401 RELAY OUTPUT 1 Relay output 1 content Selects which information is indicated with relay output 1 0 NOT SEL Relay is not used and is de energised 1 READY The ACS 160 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 160 is r
4. 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 160 User s Manual 59 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 section Local and Remote Control and Appendix A 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 are defined with parameter 1001 Start Stop Direction commands and parameter 1103 reference
5. 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 meee Z DI4 DI3 DI2 DI1 56 ACS 160 User s Manual Code Description 0118 AH Relative value of analogue input 1 displayed in 0119 AI2 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 Tl LII DI5 Relay 2 status Relay 1 status 0122 AO Value of analogue output signal in milliamperes 0124 ACTUAL VALUE 1 PID controller actual value 1 ACT1 displayed in per cent 0125 ACTUAL VALUE 2 PID 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 controller 0127 PID ACT VALUE Feedback signal actual value for PID controller 0128 LAST FAULT Last recorded fault 0 no fault See Diagnostics Can be cleared with the control panel by pressing UP and DOWN buttons simultaneously when in parameter set mode 0129 PREVIOUS FAULT Previous recorded fault See Diagnostics Can be cleared with the control panel by pressing UP and DOWN but
6. 2106 PREMAGN MAX TIME Maximum premagnetising time ACS 160 User s Manual 71 Code Description 2107 START INHIBIT Start inhibit control Start inhibit means that a pending start command is ignored when e fault is reset or e Run Enable activates while start command is active or e mode change from local to remote takes place or e mode change from remote to local takes place or e 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 1 0N Start inhibit control enabled Drive will not start after fault is reset Run Enable is activated or mode is changed In order to start the drive again give start command anew 72 ACS 160 User s Manual 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 DIH to DI5 Digital input deactivated lt Ramp pair 1 ACCELER TIME 1 DECEL
7. 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 160 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 160 will wait after a fault occurs before attempting to reset If set to zero the ACS 160 will reset immediately 3104 AR OVERCURRENT O lt DISABLE 1 ENABLE If 1 is selected the fault motor overcurrent is reset automatically after the delay set by parameter 3103 and the ACS 160 resumes normal operation 3105 AR OVERVOLTAGE O DISABLE 1 ENABLE If 1 is selected the fault DC bus overvoltage is reset automatically after the delay set by parameter 3103 and the ACS 160 resumes normal operation 3106 AR UNDERVOLTAGE O DISABLE 1 ENABLE If 1 is selected the fault DC bus undervoltage is reset automatically after the delay set by parameter 3103 DELAY TIME and the ACS 160 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
8. 41 Application Macro Premagnetise 42 Application Macro Positioning 43 Parameter Guide cis sunsse ta naniinia ide vode ie ana dana eakana 45 ACS 160 Complete Parameter List 47 Group 99 Start up Data 55 Group 01 Operating Data 56 Group 10 Command Inputs nn 58 Group 11 Reference Select eeeeeeeeeeeeerreererreererrsrrrnsreses 60 Group 12 Constant Speeds n 64 Group 13 Analogue Inputs sseseeseeeeeeeeeeeeeeeeerteeterirrernneerneene 65 Group 14 Relay Outputs sseeseeeseeeeseeeesirerirerrrsrirsernrsrinnerensens 66 Group 15 Analogue Output 68 Group 16 System Controls nn 69 Group 20 Limits 70 Group 21 Start Stop eeeseseeeeseessresereeseesrersreensrerseensntrnsrennsernseee 71 Group 22 Accel Decel an 73 Group 25 Critical Freq 74 Group 26 Motor Control 75 Group 30 Fault Functions e 76 Group 31 Automatic Reset 81 Group 32 Supervision nnn 82 Group 33 Information 85 Group 34 Process Variables 86 Group 40 PID Control ssssssessieessiessiesiisesiserirserrrsrinsrrnnsrinesrnnsnnn 87 Group 41 PID Control 2 94 vi ACS 160 User s Manual Group 51 Ext Comm Module ssssssnnssesennneeenrrrsertnnrnrer
9. Drives amp Power Electronics 16250 W Glendale Drive New Berlin WI 53151 USA Telephone 262 785 3200 800 243 4384 Telefax 262 780 5135
10. Reference voltage 10 VDC 10V 4 Not used Al2 5 AGND 6 Output freguency 0 20 mA lt gt 0 50 Hz LAO1 7 QA AGND 8 24 VDC 24V 9 DCOM 40 Start Stop Active to start ACS 160 DI1 1 Fwd Rev Activate to reverse rotation DIZ 12 Constant Speed selection DI3 13 Constant Speed selection DI4 14 Premagnetise Activate to start premagnetising DI5 15 Relay output 1 programmable ROTA hie Default operation Fault gt open ROB 17 Relay output 2 programmable ROZA Jis Default operation Running gt closed RO2B 19 Constant speed selection 0 open 1 connected DI3 DI4 Output Reference through Al1 Constant speed 1 1202 Constant speed 2 1203 Constant speed 3 1204 O o 0 o Premagnetise default parameter values 1001 EXT 1 COMMANDS 2 D11 2 1201 CONST SPEED SEL 1002 EXT 2 COMMANDS O NOT SEL 1402 RELAY OUTPUT 2 1003 DIRECTION 3 REOUEST 1601 RUN ENABLE 1102 ExT1 EXT2 SEL 6 EXT1 1604 FAULT RESET SEL 1103 EXT REF1 SELECT 1 A11 2105 PREMAGN SEL 1106 EXT REF2 SELECT O KEYPAD 2201 ACC DEC 1 2 SEL Note Parameter 2107 START INHIBIT should be 0 OFF 42 ACS 160 User s Manual Application Macro Positioning This macro is intended for simple positioning tasks The default operation is appropriate for conveyor systems where items are repetitively moved a certain distance in the same or opposite direction Distance is
11. 2 RUN 1003 DIRECTION 1601 RUN ENABLE O NOT SEL 1102 ExT1 EXT2 SEL 1604 FAULT RESET SEL O KEYPAD 1103 EXT REF1 SELECT 2105 PREMAGN SEL O NOT SEL 1106 EXT REF2 SELECT 2201 ACC DEC 1 2 SEL O NOT SEL ACS 160 User s Manual 37 Application Macro Alternate This macro offers an I O configuration that is adopted to a sequence of DI control signals used when alternating the direction of rotation of the drive The value of parameter 9902 is 3 ALTERNATE Input signals Output signals DIP switch e Start stop and direction e An output AO Frequency Mizo DI1 2 AM 46 o 10V e Analogue reference Al1 e Relay output 1 Fault Al 45 0 4 20 mA e Preset speed selection DI3 4 Relay output 2 Running e Ramp pair 1 2 selection DI5 Connection example SCR 1 External Reference 1 0 10 V lt gt 0 50 Hz AH 2 nee AGND 3 H gt Reference voltage 10 VDC 10V 4 Not used Al2 5 AGND 6 QA Output frequency 0 20 mA lt gt 0 50 Hz LAO1 7 A AGND 8 24 VDC 24V 9 DCOM 10 Start fwd If DI1 state is the same as DI2 drive stops DM 11 _ _ Start reverse DI2 12 Constant Speed selection DI3 13 Constant Speed selection DI4 Tia Ramp pair selection Activate to select ramp pair 2 DIS 15 Relay outpu
12. 9 DI1 2 3 Seven Constant Speeds 1 7 are selected with three digital inputs Table 2 Constant Speed selection with digital inputs DI1 2 3 DI1 DI2 DI3 Function 0 0 0 Noconstant 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 64 ACS 160 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 6 1302 MAXIMUM Al1 Maximum value of Al1 Value corresponds to maximum reference set by parameter 1105 EXT REF1 MAX or 1108 EXT REF2 MAX See Figure 6 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
13. 13597 351Dh S Parameters can be modified only when the drive is stopped M Default value depends on the selected macro Default Profibus Code Name Range Resolution US Default par num User S M Group 99 START UP DATA 9902 APPLIC MACRO 0 7 14 1 O FACTORY 1927 v 9905 MOTOR NOM VOLT 380 400 415 400 V 460 V 1930 7 440 460 480 500 V 9906 MOTOR NOM CURR 0 5 IN 1 5 IN 0 1A 1 0 IN 1931 V 9907 MOTOR NOM FREQ 0 250 Hz 1 Hz 50 Hz 60 Hz 1932 v 9908 MOTOR NOM SPEED 0 3600 rpm 1 rpm 1440 rpm 1933 v 1750 rpm 9909 MOTOR NOM POWER 0 1 100 KW 0 1 kW iP 1934 v 9910 MOTOR COS PHI 0 50 0 99 0 01 0 83 0 83 1935 V Group 01 OPERATING DATA 0102 sPEED 0 9999 rpm 1 rpm 2 0103 OUTPUT FREQ 0 250 Hz 0 1 Hz 3 0104 CURRENT 0 1 A 4 0105 TORQUE 0 1 5 0106 POWER S 0 1 kW 6 0107 DC BUS VOLTAGE 0 999 9 V 0 1 V 7 0109 OUTPUT VOLTAGE 0 500 V 0 1 V 9 0110 JACS TEMP 0 150 C 0 1 C 10 0111 EXTERNAL REF 1 0 250 Hz 0 1 Hz 11 0112 EXTERNAL REF 2 0 100 0 1 12 0113 CTRL LOCATION 0 2 1 13 0114 RUN TIME R 0 9999 h 1h 14 0115 kWhcounTER R 0 9999kWh 1 kWh 15 0116 APPL BLK OUTPUT 0 100 0 1 16 0117 pi1 Di4 STATUS 0000 1111 1 17 0 15 decimal 0118 Jail 0 100 0 1 18 0119 Jal2 0 100 0 1 19 0121 DI5 amp RELAYS 0000 0111 1 21 0 7 dec
14. 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 60 ACS 160 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 JoysT 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 5 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 160 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 Al2 FAULT LIMIT to 1 FAULT and the ACS 160 will stop in case the control signal is lost A EXT REF 1 MAX EXT REF 1 MIN gt EXT REF 1 MIN 10 V 20 mA Hysteresis 4 of Full Scale EXT REF 1 MAX 2V 4mA EXT REF 1 MIN 0OV
15. 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 160 output current exceeds the ratings given in Reference Section P 6 DC UNDERVOLTAGE Intermediate circuit DC voltage is not sufficient e Mains phase may be missing e Fuse may be blown if ANALOGUE INPUT 1 Analogue input 1 loss Analogue input value is less than MINIMUM Al1 1301 See also parameter 3001 AI lt MIN FUNCTION 8 ANALOGUE INPUT 2 Analogue input 2 loss Analogue input value is less than MINIMUM AI2 1306 See also parameter 3001 AI lt MIN FUNCTION 9 MOTOR OVERTEMP Motor overtemperature condition as estimated by the ACS 160 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 inconsistent e MINIMUM AIT gt MAXIMUM Al1 parameters 1301 1302 e MINIMUM Al
16. DI3U4D Reference correction up is given to freguency reference when digital input DI3 is activated and reference correction down is given when digital input DI4 is activated 2 DI4U5D Same as above except that digital inputs in use are DI4 and DI5 1117 REF STEP MODE 0 FREQ STEP Fixed frequency step is added to or subtracted from basic frequency reference Frequency steps in Hz are defined with parameters 1118 REF STEP UP and 1119 REF STEP DOWN 1 PERCENTAGE STEP In this case frequency step is given as percentage of basic frequency reference Parameters 1118 REF STEP uP and 1119 REF STEP DOWN are defined as percentage values 1118 REF STEP UP Frequency reference step up Given as Hz or percentage depending on the value of parameter 1117 REF STEP MODE 1119 REF STEP DOWN Frequency reference step down Given as Hz or percentage depending on the value of parameter 1117 REF STEP MODE 1120 STEP DLY ON Switch on delay for reference step 1121 STEP DLY OFF Switch off delay for reference step 62 ACS 160 User s Manual EXT REF A EXT REF MAX EXT REF MIN p Analogue input signal EXT REF A EXT REF MIN EXT REF MAX 4 8 p Analogue input signal Figure 6 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 o
17. Mr 132 14 LOC I IL FU LI z E OUTPUT ACS 160 User s Manual 29 Menu Structure ACS 160 has a large number of parameters Of these only the so called basic parameters are initially visible The menu function LG is used to make the full parameter set visible OUTPUT display Parameter groups Parameters MIE lou TUT Setting Parameter Value Press ENTER to view the parameter value To set a new value press and hold ENTER until SET is displayed 220 Q s 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 Menu Functions Scroll the Parameter groups for the desired menu function Press and hold ENTER until the display blinks to start the function Select between basic and full menu Press and hold evre p IH lt lI JENU Visible if Full menu is active 30 ACS 160 User s Manual Copy parameters from drive to panel upload Press amp hold DIT _ ES LIL even a MENU Note Drive must be stopped and in local control Parameter 1602 PARAMETER LOCK must be setto 1 OPEN Copy parameters from panel to drive download Press 8 hold ON ENTER gt O MENU Note Drive must be stopped and in local control Parameter 160
18. THERMISTOR Motor thermal protection is activated with an I O signal based on motor thermistor This mode requires a motor thermistor or break contact of a thermistor relay connected to terminal X4 See Reference Section O When overtemperature is detected the drive stops if the parameter 3004 MOTOR THERM PROT is set to 1 FAULT lo In Trip time 3 5 3 0 60s 2 5 90s 2 0 180s 1 5 300 s 600 s 1 0 so 0 5 0 fo fark 0 02 04 06 08 1 0 12 lo output current In nominal current of the motor fo output frequency fark break point frequency parameter 3008 BREAK POINT Figure 16 Thermal protection trip times when parameters 3005 MOT THERM TIME 3006 MOT LOAD CURVE and 3007 ZERO SPEED LOAD have default values ACS 160 User s Manual 79 Tu 100 80 60 40 20 Figure 17 Underload curve types Ty nominal torque of the motor f y nominal frequency of the motor 80 ACS 160 User s Manual 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 lt 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
19. gt closed RO2B 19 Note Constant speed is not considered while in PID control PID Note Parameter 2107 START INHIBIT should be 0 OFF PID control parameters group 40 do not belong to the Basic parameter set PID Control default parameter values 1001 EXT 1 COMMANDS 1201 CONST SPEED SEL DI3 1002 EXT 2 COMMANDS 1402 RELAY OUTPUT 2 RUN 1003 DIRECTION 1601 RUN ENABLE DI4 1102 EXT1 EXT2 SEL 1604 FAULT RESET SEL 1103 EXT REF1 SELECT 2105 PREMAGN SEL NOT SEL 1106 EXT REF2 SELECT 2201 ACC DEC 1 2 SEL 3 2 4 O KEYPAD 0 0 NOT SEL ACS 160 User s Manual 41 Application Macro Premagnetise This macro is intended for those applications where the drive must start very quickly Building up the flux in the motor always takes time With the Premagnetise Macro this delay can be eliminated The value of parameter 9902 is 7 PREMAGN Input signals Output signals DIP switch e Start stop and direction e An output AO Frequency F DI1 2 Ali 46 0 10V e Analogue reference Al1 e Relay output 1 Fault Al2 0 4 20 mA e Preset speed selection DI3 4 Relay output 2 Running e Premagnetise DI5 Connection example SCR 1 External Reference 1 0 10 V lt gt 0 50 Hz Ali 2 STA AGND 3
20. 1 o 1606 8217 AUX POS CMD 0 4 1 0 1607 8218 SLOPEGAIN1 0 20000 1 980 1608 8220 SPEEDGAIN1 0 200 1 2 1610 8221 T WINDOW LO 0 65535 1 0 1611 8222 T WINDOW HI 0 16000 1 1 1612 8223 MAX TARGET LO O 65535 1 0 1613 8224 MAX TARGET HI 0 16000 1 1000 1614 ACS 160 User s Manual 53 Default Profibus Code Name Range Resolution US Default par num User S M 8225 HOME POS LO 0 65535 1 0 1615 8226 HOME POS HI 16000 16000 1 0 1616 8227 POS ACT LO 0 65535 1 1617 8228 POS ACT HI 32768 32767 1 1618 8229 DELTA DISTANCE 0 200 1 2 1619 The motor nominal power depends on the type of unit The maximum factor depending on the type of the frequency converter at 4 kHz switching freguency 54 ACS 160 User s Manual Group 99 Start up Data The Start up Data parameters are a special set of parameters for setting up the ACS 160 and for entering motor information Code Description 9902 APPLIC MACRO Application macro selection This parameter is used to select the Application Macro which will configure the ACS 160 for a particular application Refer to Application Macros for a list and description of available Application Macros O FACTORY 2 3 WIRE 4 lt MOTOR POT 6 PID CONTROL 8 13 reserved 1 ABB STANDARD 3 ALTERNATE 5 lt HAND AUTO 7 PREMAGN 14 POSITIONING 9905 MOTOR NOM VOLT Nominal motor voltage from mo
21. 17 18 19 20 18 19 20 21 Maximum cable lengths can be found in section EMC Instructions and Maximum Cable Lengths 180 of nominal current lay 150 of nominal current lan No overloadability Derate to 90 when using 8 kHz switching frequency Rating is not valid if the ACS 160 is installed on top of anon ABB motor Follow local rules for cable cross sections Shielded motor cable is recommended when mounting the ACS 160 on the wall Fuse type UL class CC or T For non UL installations IEC269gG ACS 160 is suitable for use in a circuit capable of delivering not more than 65 kA rms symmetrical amperes 500 V Note Use 75 C 167 F rated power cable ACS 160 User s Manual 19 R Product Conformity CE Marking ACE mark is attached to the ACS 160 frequency converters to verity that the unit complies with the requirements of the European e Low Voltage Directive 73 23 EEC with amendments e EMC Directive 89 336 EEC with amendments Corresponding declarations and a list of main standards are available on request A vo See Appendix C for ACS 160 EMC Instructions A frequency converter and a Complete Drive Module CDM or a Basic Drive Module BDM as defined in IEC 61800 3 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 specif
22. 50 Hz LAO1 7 QA AGND 8 24 VDC 24V o DCOM 10 Start Stop Activate to start DM ri moo Forward Reverse Activate to reverse rotation direction DI2 12 Reference up Activate to increase reference DI3 13 Reference down Activate to decrease reference DI4 14 Constant speed 1 DIS 115 Relay output 1 programmable sej ROTA Default operation Fault gt open Relay output 2 programmable 2 RO2A 18 Default operation Running gt closed LRO2B_ 19 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 default parameter values 1001 EXT 1 COMMANDS 2 Di1 2 1201 CONST SPEED SEL 5 DI5 1002 EXT 2 COMMANDS O NOT SEL 1402 RELAY OUTPUT 2 2 RUN 1003 DIRECTION 3 REQUEST 1601 RUN ENABLE O NOT SEL 1102 EXT1 EXT2 SEL 6 EXT1 1604 FAULT RESET SEL O KEYPAD 1103 EXT REF1 SELECT 6 DI3U 4D 2105 PREMAGN SEL O NOT SEL 1106 EXT REF2 SELECT O KEYPAD 2201 ACC DEC 1 2 SEL O NOT SEL ACS 160 User s Manual 39 Application Macro Hand Auto This macro offers an I O configuration that is typically used in HVAC applications and in applications where two start stop locations are needed The value of parameter 9902 is 5 HAND AUTO Input signals Output signals DIP switch e Start stop DI1 5 and rev e An ou
23. 52 ACS 160 User s Manual Default Profibus Code Name Range Resolution US Default par num User M Group 52 STANDARD MODBUS 5201 STATION NUMBER 1 247 1 1 1051 5202 COMM SPEED 3 6 12 24 48 96 9600 bits s 1052 96 192 5203 PARITY 0 2 1 O NONE 1053 5204 COMM FAULT TIME 0 1 60 s 0 1s 1s 1054 5205 COMM FAULT FUNC JO 3 1 O NOT SEL 1055 5206 BAD MESSAGES O FFFF 1 1056 5207 GOOD MESSAGES O FFFF 1 1057 5208 BUFFER OVERRUNS O FFFF 1 1058 5209 FRAME ERRORS O FFFF 1 1059 5210 PARITY ERRORS O FFFF 1 1060 5211 CRC ERRORS 0 FFFF 1 1061 5212 BUSY ERRORS 0 FFFF 1 1062 5213 SER FAULT MEM 1 0 255 1 1063 5214 SER FAULT MEM 2 O 255 1 1064 5215 SER FAULT MEM 3 O 255 1 1065 Group 54 BRAKING 5401 MBRK OPEN DLY 0 2 5s 0 01 s 0 20 s 1087 5403 MBRK FREQ LVL 1 25 Hz 0 1 Hz 2 Hz 1089 Group 82 POSITIONING 8201 ENC PULSE NUM 1 8191 1 1024 1591 8202 ENC ERROR 0 1 1 O NOT SEL 1592 8203 ENC DELAY 0 1 60s 0 1s 5s 1593 8204 ENC SCALING 1 1 1 0 1594 8206 POS TABLE SEL 1 7 1 5 DI3 1596 8207 TARGET1 LO 0 65535 1 0 1597 8208 TARGET1 HI 16000 16000 1 o 1598 8209 TARGET2 LO 0 65535 1 o 1599 8210 TARGET2 HI 16000 16000 1 o 1600 8213 POS DELAY 0 65535 1 o 1603 8215 POS MODE 4 9 1 8 1605 8216 HOMING MODE 0 5
24. Al2 43 0 4 20 mA Constant speed 1 DI3 e Relay output 2 Running e Ramp pair 1 2 selection DI5 Connection example SCR 1 External Reference 1 0 10 V lt gt 0 50 Hz AH 2 1 AGND 3 T Reference voltage 10 VDC 10V 4 Not used Al2 5 AGND 6 Output frequency 0 20 mA lt gt 0 50 Hz AO1 7 mA AGND 8 424 VDC 24V Jo DCOM 10 Start Stop Activate to start ACS160 DIT 11 _ Fwd Rev Activate to reverse rotation direction DI2 12 Constant Speed 1 Default 5 Hz DI3 13 Leave unconnected DI4 14 Ramp pair selection Activate to select ramp pair 2 DI5 15 l Relay output 1 programmable ROTA Me Default operation Fault gt open ROTB 17 Relay output 2 programmable ROZA fis Default operation Running gt closed RO2B h9 Note DI 4 is used to configure ACS 160 It is read only once when power is connected All parameters marked with are determined by the DI4 input Factory 0 default parameter values 1001 EXT 1 COMMANDS 1201 CONST SPEED SEL 3 D13 1002 EXT 2 COMMANDS 1402 RELAY OUTPUT 2 2 RUN 1003 DIRECTION 1601 RUN ENABLE O NOT SEL 1102 ExT1 EXT2 SEL 1604 FAULT RESET SEL 6 START STOP 1103 EXT REF1 SELECT 2105 PREMAGN SEL O NOT SEL 1106 EXT REF2 SELECT 2201 ACC DEC 1 2 SEL 5 D15 34 ACS 160 Use
25. Hz 60 0 Hz 228 1504 MINIMUM AO 0 0 20 0 mA 0 1 mA OmA 229 1505 MAXIMUM AO 0 0 20 0 mA 0 1 mA 20 0 mA 230 1506 FILTER AO 0 10s 0 1s 0 1 s 231 Group 16 SYSTEM CONTROLS 1601 RUN ENABLE 0 6 1 0 251 v 1602 PARAMETER LOCK 0 1 1 1 OPEN 252 1604 FAULT RESET SEL 0 7 1 6 254 v 1605 LOCAL LOCK 0 1 1 O OPEN 255 1608 DISPLAY ALARMS 0 1 1 O NO 258 Group 20 LIMITS 2003 MAX CURRENT 0 5 In 1 5 ly 0 1A 1 5 IN 353 2005 OVERVOLT CTRL 0 1 1 1 ENABLE 355 2006 UNDERVOLT CTRL 0 2 1 1 ENABLE TIME 356 2007 MINIMUM FREQ 0 250 Hz 1 Hz 0 Hz 357 2008 MAXIMUM FREQ 0 250 Hz 1 Hz 50 Hz 60 Hz 358 ACS 160 User s Manual 49 Default Profibus Code Name Range Resolution US Default par num User S M Group 21 START STOP 2101 START FUNCTION 1 4 1 1 RAMP 376 v 2102 STOP FUNCTION 1 2 1 1 COAST 377 2103 TORQ BOOST CURR 0 5 In 0 1 TN 378 v 1 5 1 7 IN 2104 STOP DC INJ TIME O 250 s 0 1 s Os 379 2105 PREMAGN SEL 0 6 1 0 380 viv 2106 PREMAGN MAX TIME 0 0 130 0 s 0 1s 2 0 s 381 2107 START INHIBIT 0 1 1 1 ON 382 Group 22 ACCEL DECEL 2201 ACC DEC 1 2 SEL 0 5 1 5 401 viv 2202 ACCELER TIME 1 0 1 1800 s 0 1 1s 5 S 402 2203 DECELER TIME 1 0 1 1800 s 0 1 1s 5s 403 2204 ACCELER TIME 2 0 1 1800 s 0 1 1s 60 s 404 2205 DECELER TIME 2 0 1 1800 s 0 1 1s 60 s 405 2206 RAMP SHAPE 0 3 1 O LINEAR 40
26. Internal delay l Fout Start frequency internal parameter lt gt 5401 MBRK OPEN DLY ll brake delay l a2 lt I 1 Mechanical Brake Released open l rake On brake closed Figure 28 Operation of the electromechanical brake control Note Described functionality is valid from ACS 160 SW version 1 0 0 F ACS 160 User s Manual 99 Group 82 Positioning Built in positioning features of the ACS 160 make it possible to use the drive in simple positioning applications in many cases without an external PLC Possible application examples are indexing systems and positioning systems with two absolute positions Homing functions are also available Operation can be combined with electromechanical brake and with dynamic braking Default operation of the Positioning Macro is described in Application Macro section Note After selecting Positioning Macro by setting parameter 9902 APP MACRO 14 POSITIONING the drive must be switched off and then on again When Positioning Macro is selected the analogue output AO1 is not operational e To use positioning the ACS 160 must be equipped with an incremental pulse encoder Parame ters 8201 8204 are used to configure it See Table 5 for encoder specifications e Positioning mode is selected using parameter 8215 POS MODE In positioning mode the drive must be controlled from external control location EXT2 starting from SW revision 1 0 0 F
27. PID PARAM SET Selection between parameter sets can be done eg through a digital input PID sleep function can be used to stop the regulation when the output of the PID controller falls below preset limit Regulation is resumed when the process actual value falls below preset limit Alternatively sleep function can be activated and deactivated through a digital input Figure 31 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 PID integration time ACS 160 User s Manual 87 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 NM PID derivation time 4004 PID DERIV FILTER Time const
28. R2 99 112 157 261 171 4 6 1K1 3 B 2K7 3 B R1 135 149 157 221 171 5 5 4K1 3 B R2 135 149 157 261 171 6 3 Converter type Frame A B C D E Weight ACS 163 Size in in in in in Ib 1K1 3 R 2K1 3 R R1 3 9 4 4 6 2 8 7 6 7 8 6 4K1 3 R R2 3 9 4 4 6 2 10 3 6 7 10 14 1K1 3 S 2K1 3 S R1 5 3 5 9 6 2 8 7 6 7 12 13 4K1 3 S R2 5 3 5 9 6 2 10 3 6 7 13 89 ACS 160 User s Manual Wall mounted D D B Qt F 1 Peet Bat V EP E G be Converter type Frame A B c D E F G H Weight ACS 163 size mm mm mm mm mm mm mm mm kg 1K1 3 D 2K7 3 D R1 317 149 303 98 290 134 157 171 5 1 4K1 3 D R2 357 149 343 98 330 134 157 171 5 8 1K1 3 E 2K7 3 E R1 317 149 303 98 290 171 157 171 6 7 4K1 3 E R2 357 149 343 98 330 171 157 171 7 5 Converter type Frame A B c D E F G H Weight ACS 163 size in in in in in in in in Ib 1K1 3 U 2K1 3 U R1 12 5 587 11 93 3 86 11 4 5 28 6 18 6 73 11 24 4K1 3 U R2 14 1 5 87 13 5 3 86 13 0 5 28 6 18 6 73 12 79 1K1 3 V 2K1 3 V R1 12 5 5 87 11 93 13 86 11 4 16 73 6 18 6 73 14 77 4K1 3 V R2 14 1 5 87 13 5 3 86 13 0 6 73 6 18 6 73 16 53 118 ACS 160 User s Manu
29. RO2B connected gt RO2B 19 12 250 V AC 30 V DC 10 mA 2A Digital input impedance 1 5 ko Use multi strand 0 5 1 5 mm AWG 22 16 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 160 is powered down Note Terminals 3 6 and 8 are at the same potential Note If control panel is available other macros can also be selected The digital input operation depends on the selected macro 14 ACS 160 User s Manual Analogue input configuration The analogue input signal is selected with DIP switch Al open voltage input U and Al connected current input I Examples on selecting the analogue input signals All 8 Z s g Al2 18 2 Selected Signals Scale DIP switch 2 2 AH U 0 10V AM ZZ Z 2 Al2 0 4 20 mA a Z Ol xi 2 2 an AI U 0 10V Alt APE o Al2 U 0 10V AR 48 b AH zl 0 4 20 mA AM 45 Al2 0 4 20 mA AR 43 A x2 VB xs L Connection Examples Analogue Analogue inputs inputs 1 4 0 10V 48 010V 0 4 20ma 114
30. Screw in the four screws or affix the nuts and bolts depending on the mounting surface 4 Position the ACS 160 onto the fixings and securely tighten all four corners Note Only lift the ACS 160 by its metal chassis ACS 160 User s Manual G Mounting the ACS 160 on Top of the Motor To mount the converter on the top of the motor a motor mounting kit is required 1 Connect the motor either to star or delta configuration Check the motor rating plate 2 Connect the motor wires to the motor terminals 3 Connect the earthing wire to the earthing connector of the motor 4 Mount the adapter plate following the adapter plate installation instructions delivered with the motor mounting kit 5 Pull the wires through the converter and mount the converter A important The correct mounting is shown in the figure above The cooling ribs of the ACS 160 must be located at the N end This is because the converter is cooled by the air flow caused by the axial fan of the motor Use resistance measurements to verify correct earthing of motor and converter Note Make sure the motor is properly aligned with its load and firmly fastened at the foot or flange Incorrect assembly can cause vibrations which might reduce lifetime If the motor has a PTC connection parameter 3024 MOT THERM MODE must be set using the control panel 10 ACS
31. Siemens 1LA7 series motors CMK LS 71 112 For Leroy Somer LS series motors CMK VEM 71 112 For VEM K21R series motors Please contact your local ABB supplier for more information about these motor mounting kits PC Tools DriveWindow Light PC tool ACS 160 User s Manual 21 22 ACS 160 User s Manual Start up The safety instructions must be followed at all times during the start up procedure see l Safety Note Check that starting the motor does not cause any danger 1 Apply mains power The first time the drive is powered up it is controlled from 0 0 Hz the Control Terminals remote control REM OUTPUT FWD To switch to control panel use local control LOC and hold the MENU and ENTER buttons down simultaneously until first Loc is displayed d p ress MENU Loc 00 OUTPUT FWD 2 Check Parameters The following parameters must be set ABB Motors using the information from the motor g Motor3 CI F IP55 IEC34 CE name plate see example on right N E M2AA 030A 3GAA 082 001 ASA S m V Hz rmin kw a cose 9905 MOTOR NOM VOLT o 350420Y 50 1420 055 15 074 9906 MOTOR NOM CURR 220 240D 50 1420 0 55 26 0 74 9907 MOTOR NOM FREO 440 480Y 60 1700 065 15 0 73 9908 MOTOR NOM SPEED 9909 MOTOR NOM POWER 9910 MOTOR COS PHI ACS 160 User s Manual 23 Setting parameters 1 Press MENU to enter the Parameter Group Menu Menu fla
32. also parameter 3001 AI lt MIN FUNCTION Al2 LOSS Analogue input 2 loss Analogue input 2 value is less than MINIMUM Al2 1306 See also parameter 3001 AI lt MIN FUNCTION PANEL LOSS Panel communication loss Control panel is disconnected when Drive is in local control mode LOC is shown in the control panel display or Drive is in remote control mode REM and is parameterised to accept start stop direction or reference from the panel Refer to parameters in groups 10 COMMAND INPUTS and 11 REFERENCE SELECT See also parameter 3002 PANEL LOSS 19 ACS160 OVERTEMP ACS 160 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 160 Refer to parameters 3004 3008 21 UNDERLOAD Motor load is too low Check for a problem in the driven eguipment 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 23 Reserved 24 Reserved 108 ACS 160 User s Manual Description Reserved OUTPUT OVERLOAD Inverter overload condition The ACS 160 output current exceeds the ratings given in Reference Section P AUTOMATIC RESET ACS 160 is about to perform automatic fault reset operation As a result th
33. controlling commands start stop direction and frequency reference For example when controlled from external control location EXT1 the drive could receive start and stop through digital input DI1 To make this happen parameter 1001 EXT1 COMMANDS value must be set to 1 DI1 When controlled from external control location EXT2 the drive could receive the start stop command through digital input DI5 Parameter 1002 EXT2 COMMANDS value must be set to 6 D15 Parameter 1102 EXT1 EXT2 SEL is used to define how the drive is switched between control locations EXT1 and EXT2 As an example by setting parameter 1102 to value 3 D13 causes the drive to be in EXT1 when DI3 is deactivated and in EXT2 when DI3 is activated In the same way it is possible to define sources for frequency references When external control location EXT1 is selected external reference 1 REF 1 is used When external control location EXT2 is selected external reference 2 REF2 is used Parameters 1103 EXT REF 1 SELECT and 1106 EXT REF 2 SELECT are used to select sources for the references Source can e g be one of the analogue inputs or serial communication Refer to relevant parameter descriptions for more information Reference types External reference 1 and 2 have their own characteristic features e External reference 1 REF1 is a frequency reference providing set point for the output frequency of the drive This reference is always given in Hz e External re
34. e Tuning parameters 8218 SLOPE GAIN 1 8220 SPEED GAIN 1 and 8229 DELTA DISTANCE are used to optimise the operation when approaching the target position e Parameter 8216 HOMING MODE tells how the system should find its initial position when power is turned on In the simplest systems homing is not needed e There are two position reference sets Both include target position and separate speed profiles The position reference selection mechanism is configured using parameter 8206 POS TABLE SEL e Two ACS160 parameter locations are needed per position Most significant part of a position is given as full revolutions of the axis and least significant part is given as multiples of 1 65536 of one axis revolution Example Target 1 is at the distance of 52 full axis revolutions plus one quarter of a revolution In this case target is stored as Parameter 8207 TARGET 1 LO 1 4 65536 16384 Parameter 8208 TARGET 1 HI 52 Note Due to four segment panel display the displayed value needs to be multiplied by 10 when the parameter values goes over 9999 Table 5 Encoder specifications Supply voltage 24 V from terminals X1 9 24 V and X1 8 GND Max current consumption 100 mA Encoder outputs Connected to terminals X1 14 DI4 and X1 15 DI5 Signal leads with opposite phase are not used Max encoder cable length 3m Max pulse freguency 200 kHz For further information please contact your local ABB suppli
35. i nput Note Stop input DI2 deactivated panel START STOP button interlocked local Factory 1 default parameter values 1001 EXT 1 COMMANDS DI P 2P 3 1201 CONST SPEED SEL NOT SEL 1002 EXT 2 COMMANDS NOT SEL 1402 RELAY OUTPUT 2 RUN 1003 DIRECTION 1601 RUN ENABLE NOT SEL 1102 EXT1 EXT2 SEL 1604 FAULT RESET SEL START STOP 1103 EXT REF1 SELECT 2105 PREMAGN SEL NOT SEL 1106 EXT REF2 SELECT 2201 ACC DEC 1 2 SEL 0 2 0 6 0 5 DI5 ACS 160 User s Manual 35 Application Macro ABB Standard This general purpose macro is typical 2 wire I O configuration It gives two more preset speeds compared to Factory Macro 0 The value of parameter 9902 is 1 ABB STANDARD Input signals Output signals DiP switch e Start stop and direction e An output AO Frequency T DI1 2 Alt 46 o 10V e Analogue reference Al1 e Relay output 1 Fault Al2 45 0 4 20 mA e Preset speed selection DI3 4 Relay output 2 Running e Ramp pair 1 2 selection DI5 Connection Example SCR_1 External Reference 1 0 10 V lt gt 0 50 Hz AH 2 I AGND 3 T Reference voltage 10 VDC 10V 4 Not used Al2 5 AGND 6 Output frequency 0 20 mA lt gt 0 50 Hz LAO1 7 nA AGND 8 24 VDC 24V o DCOM 10 Start Stop
36. motor current as measured by the ACS 160 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 The control panel will not display the unit kW 0107 DC BUS VOLTAGE Displays the DC bus voltage as measured by the ACS 160 The voltage is displayed in Volts DC 0109 OUTPUT VOLTAGE Displays the voltage applied to the motor 0110 ACS TEMP Displays the temperature of the ACS 160 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 0 LOCAL 1 EXT1 2 EXT2 See chapters Local and Remote Control and Appendix A for description of different control locations 0114 RUN TIME R Shows the total running time of the ACS 160 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 160 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 Otherwise the value is from 0112 EXT REF 2
37. parameter set 2 is active 4017 WAKE UP DELAY Delay for deactivation of PID sleep function Refer to parameter 4015 WAKE UP LEVEL and Figure 23 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 DI1 DI5 Sleep state is activated and deactivated using a digital input 90 ACS 160 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 160 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 lon 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
38. power the undervoltage controller will decrease the motor speed in order to keep the DC bus voltage above the lower limit By decreasing the output freguency the inertia of the load will cause regeneration back into the ACS 160 thus keeping the DC bus charged and preventing an undervoltage trip This will increase power loss ride through on systems with a high inertia such as a centrifuge or a fan O DISABLE 1 ENABLE TIME Enable with 500 ms time limit for operation 2 ENABLE Enable without time limit for operation 2007 MINIMUM FREQ Operating range minimum output frequency Note Keep MINIMUM FREQ lt MAXIMUM FREQ 2008 MAXIMUM FREQ Operating range maximum output frequency 70 ACS 160 User s Manual Group 21 Start Stop ACS 160 supports several start and stop modes including flying start and torque 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 premagnetising 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 wi
39. reset automatically after the delay set by parameter 3103 DELAY TIME Trial time fa ima O x Xx X Time x Automatic reset Now Figure 18 Operation of automatic reset function In this example if the fault occurs at the moment Now it is automatically reset if parameter 3101 NR OF TRIALS value is greater than or equal to 4 ACS 160 User s Manual 81 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 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 supe
40. to zero and then corrected with the distance between actual and desired stopping position The purpose of this is to prevent the axis to creep from its original home position Correction is only made when the previous move has reached the target window area If two targets are used make sure that target reference is changed only at stop state 5 ABS MOVE 1 Selected target position is absolute Position counter is not reset when start command is given This mode is typically used when the load is moved between two positions 6 ABS MOVE CC1 Basic operation as in mode 5 Cyclic correction added Positioning counter is set to the value of home position parameters 8225 HOME POS LO and 8226 HOME POS HI when digital input 3 DI3 state changes from inactive to active state 7 ABS MOVE CC2 Basic operation as in mode 5 Cyclic correction added Positioning counter is set to the value of home position parameters 8225 HOME POS LO and 8226 HOME POS HI when digital input 3 DI3 state changes from active to inactive state 8 RELAT MOVE2 Same as mode 4 except that the position counter starts counting from the value set with parameters 8225 HOME POS LO and 8226 HOME POS HI every time when Start command is given This position mode provides no position correction possibilities 9 CONT MOVE1 Selected target is absolute Continuous move between home and target1 position Used for example for spinning wires A position time delay paramete
41. 0 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 Loe or later LCr is displayed e If the buttons are released while Loc is displayed the panel frequency reference is set to the current external reference and the drive is stopped 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 e Shaft direction is forward reverse e Drive is running and at set point FWD REV Blinking rapidly Drive is accelerating decelerating FWD REV Blinking slowly Drive is stopped Output Display When the control panel is powered up the panel displays the actual output frequency Whenever the MENU button is pressed and held the control panel resumes this OUTPUT display To toggle between output frequency and output current press the UP or DOWN button To set the output frequency press ENTER Pressing the UP DOWN buttons changes the output immediately Press ENTER again to return to OUTPUT display ve Heres
42. 004 PID DERIV FILTER 0 10s 0 1s 1s 854 4005 ERROR VALUE INV 0 1 1 O NO 855 4006 ACTUAL VAL SEL 1 9 1 1 ACT1 856 v 4007 ACT1 INPUT SEL 1 2 1 2 AI2 857 v 4008 ACT2 INPUT SEL 1 2 1 2 AI2 858 v 4009 ACT1 MINIMUM 0 1000 1 0 859 4010 ACT1 MAXIMUM 0 1000 1 100 860 4011 ACT2 MINIMUM O 1000 1 0 861 4012 ACT2 MAXIMUM O 1000 1 100 862 4013 PID SLEEP DELAY 0 0 3600 s 0 1 1s 60 s 863 4014 PID SLEEP LEVEL 0 0 120 Hz 0 1 Hz 0 Hz 864 4015 WAKE UP LEVEL 0 0 100 0 1 0 865 4016 PID PARAM SET 1 7 1 6 SET 1 866 4017 WAKE UP DELAY 0 60s 0 01 s 0 50 s 867 4018 SLEEP SELECTION 0 5 1 O INTERNAL 868 v 4019 SET POINT SEL 1 2 1 2 EXTERNAL 869 4020 INTERNAL SETPNT 0 0 100 0 0 1 40 870 Group 41 PID CONTROL 2 4101 PID GAIN 0 1 100 0 1 1 0 876 4102 PID INTEG TIME 0 0 1 600 s 0 1s 60 s 877 4103 PID DERIV TIME 0 60s 0 1s Os 878 4104 PID DERIV FILTER 0 10s 0 1s 1s 879 4105 ERROR VALUE INV 0 1 1 O NO 880 4106 ACTUAL VAL SEL 1 9 1 1 acT1 881 v 4107 ACT1 INPUT SEL 1 2 1 2 AI2 882 v 4108 ACT2 INPUT SEL 1 2 1 2 AI2 883 v 4109 ACT1 MINIMUM O 1000 1 0 884 4110 ACT1 MAXIMUM O 1000 1 100 885 4111 ACT2 MINIMUM O 1000 1 0 886 4112 ACT2 MAXIMUM O 1000 1 100 887 4119 SET POINT SEL 1 2 1 2 EXTERNAL 894 4120 INTERNAL SETPNT 0 0 100 0 0 1 40 0 895 Group 51 EXT COMM MODULE 5101 FIELDBUSPAR1 15 1026 5115 1040
43. 1 Hz 0 144 0 250 0 1 0 1120 STEP DLY ON O 25 0s 0 1s 0 145 1121 STEP DLY OFF O 25 0s 0 1s 0 146 Group 12 CONSTANT SPEEDS 1201 CONST SPEED SEL 0 10 1 3 0 151 viv 1202 CONST SPEED 1 O 250 Hz 0 1 Hz 5 Hz 152 1203 CONST SPEED 2 0 250 Hz 0 1 Hz 10 Hz 153 48 ACS 160 User s Manual Default Profibus Code Name Range Resolution US Default par num User M 1204 CONST SPEED 3 0 250 Hz 0 1 Hz 15 Hz 154 1205 CONST SPEED 4 0 250 Hz 0 1 Hz 20 Hz 155 1206 CONST SPEED 5 0 250 Hz 0 1 Hz 25 Hz 156 1207 CONST SPEED 6 0 250 Hz 0 1 Hz 40 Hz 157 1208 CONST SPEED 7 0 250 Hz 0 1 Hz 50 Hz 158 Group 13 ANALOGUE INPUTS 1301 MINIMUM Al1 0 100 1 0 176 1302 MAXIMUM AI 0 100 1 100 177 1303 FILTER Al1 0 10s 0 1s 0 1 s 178 1304 MINIMUM Al2 0 100 1 0 179 1305 MAXIMUM Al2 0 100 1 100 180 1306 FILTER Al2 0 10s 0 1s 0 1 s 181 Group 14 RELAY OUTPUTS 1401 RELAY OUTPUT 1 0 34 1 3 201 1402 RELAY OUTPUT 2 0 34 1 2 202 v 1403 RO 1 ON DELAY 0 3600 s 0 1s 1s Os 203 1404 RO 1 OFF DELAY 0 3600s 0 1s 1s Os 204 1405 RO 2 ON DELAY 0 3600s 0 1s 1s Os 205 1406 RO 2 OFF DELAY 0 3600s 0 1s 1s Os 206 Group 15 ANALOGUE OUTPUT 1501 AO CONTENT 102 137 1 103 226 1502 AO CONTENT MIN 0 0 999 9 0 1 0 0 Hz 227 1503 AO CONTENT MAX 0 0 999 9 0 1 50 0
44. 106 EXT REF2 SELECT 2201 ACC DEC 1 2 SEL O NOT SEL 40 ACS 160 User s Manual Application Macro PID Control This macro is intended for use with different closed loop control systems such as pressure control flow control etc The value of parameter 9902 is 6 PID CTRL Input signals Output signals DIP switch Start stop DI1 5 e An output AO Frequency iz Alt 46 0 10V e Analogue reference Al1 e Relay output 1 Fault z Actual value Al2 e Relay output 2 Running Al2 48 0 4 20 mA Control location selection DI2 Constant speed DI3 e Run enable D14 Connection example SCR 1 ODD EXT1 Manual or EXT2 PID reference 0 10 V ID 2 A Reference voltage 10 VDC 10V A H Actual signal 0 20 mA PID Al2 5 pPp AGND 6 Output frequency 0 20 mA lt gt 0 50 Hz LAO1 7 AGND 8 24 VDC 24V 9 DCOM 10 Start Stop Activate to start ACS 160 Manual DIT 11 EXT1 EXT2 Selection Activate to select PID control DI2 12 Constant speed 1 not used if PID control DI3 13 Run enable deactivation always stops ACS 160 DI4 14 Start Stop Activate to start ACS 160 PID DI5 15 Relay output 1 programmable ROTA 16 Default operation Fault gt open RO1B iz Relay output 2 programmable ROZA Jis Default operation Running
45. 160 User s Manual H Terminal Interface Use cable glands to ensure proper sealing see I Note The power supply input connectors are located in different places depending whether the unit has a built in RFI filter or not Note DC voltage can be measured between R and X4 2 Brake resistor cable connector R R Brake resistor earthing wire connector 1 PE E mains cable earthing wire connector Mains cable connector U1 V1 W1 ontrol panel Serial link connector Motor cable DIP switches earthing wire connector ain VO L PE Motor PTC connector terminal see K Motor cable X4 1 X4 2 connector see O U2 V2 W2 Units with built in RFI filter In units with built in RFI filter earthing wire PE connectors for motor and mains are located on the filter baseplate PE motor Mains cable connector cable earthing wire connecto PE mains cable earthing wire connector connector ACS 160 User s Manual 11 Cable Entries Cable glands of various sizes will be needed for the following cable entries Description Thread US Types Motor cable entry wall mounting M25 3 4 NPT plug Relay output cable entry M20 1 2 NPT plug Small signal I O cable entry M20 1 2 NPT plug Mains cable entry M25 3 4 NPT plug Motor cable entry Relay output cable entry Small signal I O cable entry Control panel Serial link connector Mains cabl
46. 2 gt MAXIMUM Al2 parameters 1304 1305 e MINIMUM FREQ gt MAXIMUM FREQ parameters 2007 2008 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 160 e Refer to parameters 5204 COMM FAULT TIME and 5205 COMM FAULT FUNC 14 EXTERNAL FAULT SIGNAL External fault is active See parameter 3003 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 16 DC BUS RIPPLE e Ripple voltages on the DC bus are too large e Mains phase may be missing e Fuse may be blown 110 ACS 160 User s Manual 17 UNDERLOAD Motor load is too low Check for a problem in the driven eguipment Refer to parameters 3013 3015 18 Reserved 19 Reserved 20 Al OUT OF RANGE Analogue input out of range Check Al level 21 29 HARDWARE ERROR Hardware error Contact supplier 30 BR RES OVERLOAD Brake resistor is overloaded Refer to parameter 2005 OVERVOLT CTRL 31 ENCODER FAULT Positioning macro is used but the drive is not receiving pulses Check the encoder and its connections Full display blinking Serial link failure Bad connection between the control panel and
47. 2 JAI FLT LIMIT 0 100 1 0 622 3023 JAI2 FLT LIMIT 0 100 1 0 623 3024 MOT THERM MODE 2 3 1 2 USER MODE 624 Group 31 AUTOMATIC RESET 3101 NR OF TRIALS 0 5 1 o 626 3102 TRIAL TIME 1 0 600 s 0 1s 30 s 627 3103 DELAY TIME 0 0 120 s 0 1s Os 628 3104 AR OVERCURRENT 0 1 1 O DISABLE 629 3105 AR OVERVOLTAGE 0 1 1 O DISABLE 630 3106 AR UNDERVOLTAGE 0 1 1 O DISABLE 631 3107 JAR AI lt MIN 0 1 1 O DISABLE 632 Group 32 SUPERVISION 3201 SUPERV 1 PARAM 102 137 1 103 651 3202 SUPERV 1 LIM LO o 652 3203 SUPERV 1 LIM HI o 653 3204 SUPERV 2 PARAM 102 137 1 103 654 3205 SUPERV 2 LIM LO 0 655 3206 SUPERV 2 LIM HI o 656 Group 33 INFORMATION 3301 SW VERSION 0 0 0 0 f f f f z H 676 3302 TEST DATE yy ww 7 677 Group 34 PROCESS VARIABLES 3402 P VAR 1 SEL 102 137 1 104 702 3403 P VAR 1 MULTIP 1 9999 1 1 703 3404 P VAR 1 DIVISOR 1 9999 1 1 704 3405 P VAR 1 SCALING 0 3 1 1 705 3407 P VAR 2 SEL 102 137 1 103 707 3408 P VAR 2 MULTIP 1 9999 1 1 708 3409 P VAR 2 DIVISOR 1 9999 1 1 709 3410 P VAR 2 SCALING 0 3 1 1 710 ACS 160 User s Manual 51 Default Profibus Code Name Range Resolution US Default par num User S M Group 40 PID CONTROL 4001 PID GAIN 0 1 100 0 1 1 0 851 4002 PID INTEG TIME 0 0 1 600 s 0 1 s 60 s 852 4003 PID DERIV TIME 0 60s 0 1s Os 853 4
48. 2 PARAMETER LOCK must be setto 1 OPEN Diagnostic Displays When a fault is active the relevant fault message flashes in the panel display When an alarm is active the relevant alarm message is shown in the panel display Alarms 1 7 arise from button operation 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 1 ITI L sei code alarm code l Zaa 1 Refer to Diagnostics section for complete list of alarms and faults Resetting the Drive from the Control Panel To reset a fault press the START STOP button Caution Resetting the fault may start the drive when in remote control Some faults can only be reset by turning power off Refer to section on Diagnostics Caution Turning the power on again may start the drive immediately ACS 160 User s Manual 31 32 ACS 160 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 fro
49. 4 AT TARGET Target positioning is reached Use only when positioning macro is used 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 slo ko Switch off delay for relay 1 1405 RO 2 ON DELAY NA as e Switch on delay for relay 2 Relay status 1406 RO 2 OFF DELAY 1403 ON DELAY 1404 OFF DELAY Switch off delay for relay 2 Figure 8 ACS 160 User s Manual 67 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 parameter 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 JAO CONTENT Content for analogue output Number of any parameter of the Operating Data group Group 01 1502 JAO CONTENT MIN Analogue output content minimum Display depends on parameter 1501 1503 JAO 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 FILTE
50. 6 Group 25 CRITICAL FREQ 2501 CRIT FREQ SEL 0 1 1 O OFF 476 2502 CRIT FREQ 1 LO 0 250 Hz 1 Hz 0 Hz 477 2503 CRIT FREQ 1 HI 0 250 Hz 1 Hz 0 Hz 478 2504 CRIT FREQ 2 LO 0 250 Hz 1 Hz 0 Hz 479 2505 CRIT FREQ 2 HI 0 250 Hz 1 Hz 0 Hz 480 Group 26 MOTOR CONTROL 2603 IR COMPENSATION 0 60 V 1V 10V 503 2604 IR COMP RANGE 0 250 Hz 1 Hz 50 Hz 60 Hz 504 2605 LOW NOISE 0 1 1 O OFF 505 v 2606 U f RATIO 1 2 1 1 LINEAR 506 v 2607 SLIP COMP RATIO 0 250 1 0 507 v Group 30 FAULT FUNCTIONS 3001 AI lt MIN FUNCTION 0 3 1 1 FAULT 601 3002 PANEL LOSS 1 3 1 1 FAULT 602 3003 EXTERNAL FAULT 0 5 1 O NOT SEL 603 3004 MOT THERM PROT 0 2 1 1 FAULT 604 3005 MOT THERM TIME 256 9999 s 1s 500 s 605 3006 MOT LOAD CURVE 50 150 1 100 606 3007 ZERO SPEED LOAD 25 150 1 70 607 3008 BREAK POINT 1 250 Hz 1 Hz 35 Hz 608 3009 STALL FUNCTION 0 2 1 O NOT SEL 609 50 ACS 160 User s Manual Default Profibus Code Name Range Resolution US Default par num User M 3010 STALL CURRENT 0 5 IN O 1A LKR 610 1 5 1 7 ly 3011 STALL FREQ HI 0 5 50 Hz 0 1 Hz 20 Hz 611 3012 STALL TIME 10 400 s 1s 20 s 612 3013 UNDERLOAD FUNC 0 2 1 O NOT SEL 613 3014 UNDERLOAD TIME 10 400 s 1s 20 s 614 3015 UNDERLOAD CURVE 1 5 1 1 615 302
51. 721 3 3 2 edition 0 118 in 1994 12 e 9 200 Hz max acceleration 10 m s 33 ft s In wall mounting e 2 9 Hz max amplitude 1 5 mm 0 06 in e 9 200 Hz max acceleration 5 m s 16 ft s Shock In motor mounting e max 300 m s 985 ft s 18 ms e max 250 m s 820 ft s 6 ms In wall mounting e max 70 m s 230 fi s 11 ms IEC 721 3 3 2 edition 1994 12 Free Fall not allowed e 76 cm 30 in according to ISTA 1A 6 ACS 160 User s Manual B Type Designation Label and Code Key The Type Designation Label is attached on the side of the drive Serial number ABB Industry Oy CE sm ywwaxxxx ACS 163 2K7 3 A Y year U1 3 380 500 V U2 3 0 U1 IP65 ww week f1 50 60 Hz 12 0 250 Hz 145A 241A sm oo123456 LIBEL IIIT R product revision number XXXX internal number AC S 163 xxx 3 x AC Drive Product Type S Standard product ACS 160 Product Family Input Supply 3 3 Power supply input Rated Output Power in kVA See ACS 160 rating table Section Q Voltage Rating 3 380 500 V AC Accessories A Motor mounting B Motor mounting filter D Wall mounting E Wall mounting filter R Motor mounting US market S Motor mounting filter US market U Wall mounting US market V Wall mounting filter US market ACS 160 User s Manual C Motor Check the compatibilit
52. ACS 160 is therefore dependent on the motor type and the speed at which the motor is rotating Wall mounted ACS 160 types have a fan unit to provide constant cooling air flow for the converter See section Q for continuous output current loy ratings e Loadability of the ACS 160 is 150 lox for 1 minute every 10 minutes e Atstarting the loadability of the ACS 160 is 180 loy for 2 seconds In the event of overload the ACS 160 will first indicate an alarm and then trip Parameter 0110 Acs TEMP can be used to monitor the power module temperature Note The motor should not be continuously supplied with current that is greater than the nominal current of the motor Normal temperature range of the ACS 160 is up to 40 C 104 F With derating using converter in up to 50 C 122 F ambient is possible Observe torque derating curves below T Ty Derating with mains voltage Derating with temperature 100 340 350 360 370 380 390 500 30 86 40 104 50 122 Mains input voltage V Ambient temperature C F Derating with output frequency ABB M3VA AA M2VA AA M3VRF S and M3ARF S motors 120 4 100 80 60 Motor without separate cooling Motor with separate 20 J H cooling 40 0 0 10 20 30 40 50 60 70 80 90 100 Frequency Hz Note The entire converter e
53. ACS CHK B3 80 262 ACS 163 2K1 3 D U ACS CHK B3 ACS CHK B3 100 328 ACS 163 2K7 3 D ACS CHK B3 ACS CHK C3 120 97394 ACS 163 4K1 3 D U ACS CHK C3 ACS CHK C3 140 27 459 1 Supply voltage 380 480 switching frequency 4 kHz 2 If the supply voltage is higher than or equal to 440 V the maximum cable length is 100 m Motor Mounted Units Compliance with EN61800 3 EMC Standard Second Environment ACS 160 types ACS 163 xKx 3 B S comply with the requirements of EN 61800 3 Second Environment Unrestricted and Restricted Distribution with switching frequency of 4 kHz or 8 kHz when mounted on the top of the motor For EMC information concerning ACS 160 types 163 xKx 3 A R please contact your local ABB supplier First Environment ACS 160 types ACS 163 xKx 3 B S comply with the requirements of EN 61800 3 First Environment Unrestricted and Restricted Distribution with switching frequency of 4 kHz or 8 kHz when mounted on the top of the motor 124 ACS 160 User s Manual Line Current Harmonics The product standard EN 61800 3 refers to EN 61000 3 2 which specifies limits for harmonic current emissions for equipment intended to be connected to public low voltage distribution systems Low Voltage Public Supply Network The limits and requirements of the EN 61000 3 2 apply for equipment with rated current lt 16 A The ACS 160 is a professional equipment to be used in trades professions or industries and is not inten
54. Activate to start DA 1 j Fwd Rev Activate to reverse rotation direction DI2 12 Constant speed selection DI3 13 Constant speed selection DI4 14 Ramp pair selection Activate to select ramp pair 2 DI5 15 Relay output 1 programmable ROTA fe Default operation Fault gt open RO1B 17 Relay output 2 programmable ROZA fis Default operation Running gt closed _ RO2B 1 Constant speed selection 0 open 1 connected DI3 DI4 Output Reference through Al1 Const speed 1 1202 Const speed 2 1203 O ol o Const speed 3 1204 ABB Standard default parameter values 1001 EXT 1 COMMANDS 2 D11 2 1201 CONST SPEED SEL 7 DI3 4 1002 EXT 2 COMMANDS O NOT SEL 1402 RELAY OUTPUT 2 2 RUN 1003 DIRECTION 3 REQUEST 1601 RUN ENABLE O NOT SEL 1102 ExT1 EXT2 SEL 6 EXT1 1604 FAULT RESET SEL O KEYPAD 1103 EXT REF1 SELECT 1 A11 2105 PREMAGN SEL O NOT SEL 1106 EXT REF2 SELECT O KEYPAD 2201 ACC DEC 1 2 SEL 5 DI5 36 ACS 160 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
55. Drive T User s Manual Low Voltage for type ACS 160 freguency AC Drives converters from 0 55 to 2 2 kW 0 74 to 3 Hp AA ED ED PA ID IB ACS 160 Frequency Converter User s Manual 3BFE 64364120 REV C EN Effective 17 5 2002 copyright 2002 ABB Oy Safety A A PP PPP DBD Warning Only a competent electrician may install the ACS 160 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 DC voltage at terminals R and X4 2 before servicing the unit See H Warning Even when the motor is stopped there are dangerous voltages present at Power Circuit terminals U1 V1 W1 and U2 V2 W2 Warning Even when the ACS 160 is powered down there may be dangerous external voltages at relay terminals 16 RO1A 17 RO1B 18 RO2A 19 RO2B Warning Never attempt to repair a broken unit contact the supplier Warning The ACS 160 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 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 ACS 160 must not be powered up more than 3 times in 5 minutes to avoid overheating the charging resistors Warning The heatsink may reach
56. ER TIME 1 is used Digital input activated Ramp pair 2 ACCELER TIME 2 DECELER TIME 2 is used 2202 JACCELER TIME 1 Ramp 1 time from zero to maximum frequency 0 MAXIMUM FREQ 2203 IDECELER 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 freguency A MAXIMUM FREQ Linear S curve Time Ramp time Figure 10 Definition of acceleration deceleration ramp time ACS 160 User s Manual 73 Group 25 Critical Freq In some mechanical systems certain speed ranges can cause resonance problems With this parameter group it is possible to set up to two different speed ranges that the ACS 160 will skip over Code Description 2501 CRIT FREQ SEL Critical frequencies activation 0 OFF 1 ON 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 critica
57. OAD FUNCTION Removal of motor load may indicate a process malfunction The protection is activated if e The motor torque drops below the load curve selected by parameter 3015 UNDERLOAD CURVE e This condition has lasted longer than the time set by parameter 3014 UNDERLOAD TIME e 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 1 FAULT When the protection is activated the ACS 160 coasts to stop Fault indication is displayed 2 WARNING A warning indication is displayed 3014 UNDERLOAD TIME Time limit for underload protection 78 ACS 160 User s Manual Code Description 3015 UNDERLOAD CURVE This parameter provides five selectable curves shown in Figure 17 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 3022 AH 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 3024 MOT THERM MODE 2 USER MODE In this mode the user can define the operation of thermal protection by setting parameters 3005 MOTOR THERM TIME 3006 MOT LOAD CURVE 3007 ZERO SPEED LOAD and 3008 BREAK POINT 3
58. OmA 2 2 EXT REF 1 MIN Figure 5 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 160 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 AI 10 COMM Al The reference is given through serial communication The analogue input 1 signal is combined to the fieldbus reference sum or multiplication 11 DISU 4D R NC 12 DI3U 4D NC 13 DI4U 5D NC Selections 11 12 and 13 are the same as selections 5 6 7 respectively with the exception that the reference value is not copied when e moving from EXT1 to EXT 2 or e moving from EXT2 to EXT1 or e moving from local to remote ACS 160 Users Manual 61 1104 EXT REF1 MIN Sets the minimum f
59. PID input Process actual value WAKE UP DELAY A parameter 4017 Le Wake up level Time PID Output Output frequency ty SLEEP DELAY parameter 4013 SLEEP LEVEL parameter 4014 Time STOP START Figure 23 Sleep function operation ACS 160 User s Manual 91 4015 WAKE UP A NON INVERTED ERROR VALUE A LEVEL 1108 EXT REF2 MAX 100 75 SETPOINT APPLIED WAKE UP LEVEL 0 1107 EXT REF2 MIN gt Figure 24 Example of how the applied wake up level floats with the set point here parameter 4015 WAKE UP LEVEL equals to 75 PID control non inverted case INVERTED ERROR VALUE A 4015 WAKE UP LEVEL 0 1108 EXT REF2 MAX 60 APPLIED WAKE UP LEVEL 100 SETPOINT 1107 EXT REF 2 MIN v gt Figure 25 Example of how applied wake up level floats with the set point here parameter 4015 WAKE UP LEVEL eguals to 60 PID control inverted case 92 ACS 160 User s Manual APPLIED WAKE rel re j UP LEVEL N O SLEEP DEACTIVATED m 4 ma E Ps TIME EXPIRES gt TIME Figure 26 Wake up level operation with non inverted error value TIME EXPIRES APPLIED WAKE oe UP LEVEL y lt A ACT VALUE Figure 27 Wake up level operation with inverted error value ACS 160 User s Manual 93 Group 41 PID Control 2 Parameters of this group belong to PID parameter set 2 The operation of
60. R Filter time constant for AO AO mA 1505 1504 p AO content AO mA A 1505 1504 p AO content Figure 9 Analogue output scaling 68 ACS 160 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 160 is ready to start without an external run enable signal 1 5 DI1 DI5 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 160 will coast to stop and not start until the run enable signal resumes 6 COMM The run enable signal is given through serial communication Command Word bit 3 1602 PARAMETER LOCK Parameter lock for control panel 0 LOCKED Parameter modification disabled 1 OPEN Panel operations are allowed and parameter modification is enabled Note This parameter is not affected by macro selection 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 re
61. a high temperature 100 C 212 F Note For more technical information contact your local ABB supplier ACS 160 User s Manual iii Note about compatibility The supplied ACS 160 frequency converter and this manual are compatible with the software revision 1 0 0 E and later Positioning macro is documented as it is in software revision 1 0 0 F and later iv ACS 160 User s Manual Table of Contents Sa PETE Le iii IntrOdUuCNON cnrs ee ona aaa 1 INSTANAUON nine int vei ae babji bika ooo lead 3 Step by Step Instructions for Installing the ACS 160 4 Mounting on the Wall ACS 163 xKx 3 D E U V 4 Mounting on the Motor ACS 163 xKx 3 A B R S 5 Reference Sections ns 6 A Environment for Storage Transportation and Stationary Use 6 B Type Designation Label and Code Key 7 G MOIO Sotele tetet a kar desl ee iee a era aR 8 D Floating Network 8 E Mounting the Options ne 8 F Mounting the ACS 160 on the Wall 9 G Mounting the ACS 160 on Top of the Motor 10 H Terminal Interface aT E 11 lCabl Entries zni MR NN LATE aa 12 J Routing the Motor Cables cc cccccceeeseeeeeeeeeseeeeeseneeeeeneeeteas 13 K Control Terminal aieia oaas asii aa a 14 L Connection Examples 15 M Replacing the Cov
62. activated if parameters 1401 RELAY OUTPUT 1 or 1402 RELAY OUTPUT 2 has value 34 AT TARGET The relay is deactivated when next position start command is given 104 ACS 160 User s Manual Code Description 8223 8224 MAX TARGET LO MAX TARGET HI Maximum target position limit refer to example on page 100 Operation When the absolute value goes above this limit the output frequency is forced to 0 Hz No alarm lor fault indication is given 8225 8226 HOME POS LO HOME POS HI Home position refer to example on page 100 This value is set to position counter in situations defined by parameters 8216 HOMING MODE and 8215 POS MODE 8227 8228 POS ACT LO POS ACT HI Position actual value refer to example on page 100 Displays the actual position read only 8229 DELTA DISTANCE Turning parameter Use this together with parameters 8218 SLOPE GAIN 1 and 8220 SPEED GAIN1 If the position difference between two consecutive 4 ms time instances is smaller than this parameter value the positioning speed is increased with the amount of parameter 8820 SPEED GAIN1 value If the difference is greater then positioning speed is decreased The purpose of parameters 8220 SPEED GAIN1 and 8229 DELTA DISTANCE is to make actual positioning speed near target depended on the load and to ensure that the target is reached ACS 160 User s Manual 105 106 ACS 160 User s Manual Diagnost
63. al Appendix C EMC Instructions and Maximum Cable Lengths Mandatory Installation Instruction According to the EMC Directive for type ACS 160 frequency converters EMC stands for Electromagnetic Compatibility This is the ability of electrical and electronic equipment to operate without problems within an electromagnetic environment and without disturbing or interfering with nearby equipment The EMC Directive defines the requirements for immunity and emissions of electrical equipment used in European Economic Area The EMC product standard EN 61800 3 covers the requirements stated for frequency converters Depending on the type of ACS 160 frequency converters the requirements of EN 61800 3 for Second Environment and First Environment restricted and unrestricted distribution are met For turther information refer to the following pages of this appendix Product standard EN 61800 3 Adjustable speed electrical power drive systems Part 3 EMC product standard including specific test methods defines First Environment as environment that includes domestic premises It also includes establishments directly connected without intermediate transformers to a low voltage power supply network which supplies buildings used for domestic purposes Second Environment includes establishments other than those directly connected to a low voltage power supply network which supplies buildings used for domestic purposes The following section describes the va
64. ant for the filter of D part By increasing the filter time constant it is possible to smooth the effect of the D part and suppress noise 4005 ERROR VALUE INV Process error value inversion Normally a decrease in feedback signal causes an increase in drive speed If a decrease in feedback signal is desired to cause a decrease in speed set ERROR VALUE INV to 1 YES 0 NO 1 YES 4006 ACTUAL VAL SEL PID controller feedback actual signal selection 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 ACTI Actual value 1 is used as the feedback signal 2 ACT1 ACT2 Difference of actual values 1 and 2 is used as the feedback signal 3 ACT1 ACT2 Sum of actual values 1 and 2 4 ACTI ACT2 Product of actual values 1 and 2 5 ACTI ACT2 Quotient of actual values 1 and 2 6 MIN A A2 Smaller of actual values 1 and 2 7 MAX A1 A2 Greater of actual values 1 and 2 8 sqrt A1 A2 Square root of difference of actual values 1 and 2 9 sgA1 sqA2 Sum of square roots of actual values 1 and 2 88 ACS 160 User s Manual Code Description 4007 JACT1 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 JACT2 INPUT SEL Sour
65. anual Recommended Allowed Symmetrical shielded cable three phase A separate PE conductor is required if the conductors and a concentric or otherwise conductivity of the cable shield is lt 50 symmetrically constructed PE conductor of the conductivity of the phase conductor and a shield PE hield conductor z and shield shield PE PE Not allowed for motor cables A four conductor system three phase eS conductors and a protective conductor D Allowed for motor cables with phase i conductor cross section up to 10 mm O Figure 33 Cable recommendations and restrictions Shield 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 34 Braided metallic screen Inner insulator moi L3 Insulation jacket FT 4 db Figure 34 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 if you are using cable without a separate PE conductor At the motor end the motor cable screen must be earthed 360 degrees with an EMC cable gland e g ZEMREX SCG Screened cable glands or the screen wires must be twisted togeth
66. ary positioning mode commands selection 0 NOT SEL 1 DI2 Digital input 2 DI2 is used to give auxiliary positioning start stop commands This command does not start or stop the ACS 160 modulation During homing this command acts only as start enable 2 STOP 0 Hz Positioning frequency reference is set to 0 Hz when positioning target window has been reached 3 STOP MODUL Modulation is stopped when positioning target window has been reached 4 EXT FREQ Enables external frequency reference use at positioning mode 9 Frequency reference is selected with parameter 1106 EXT REF2 SELECT Allowed selections parameter 1106 EXT REF2 SELECT 0 1 or 2 External frequency reference update can be controlled with digital input DI2 e DI2 is inactive frequency is sampled at turning points e DI2 is active frequency reference is sampled continuously 8218 SLOPE GAIN 1 Frequency reference deceleration slope control Values above 1000 delays the beginning of the deceleration ramp and make target position approach faster Values below 1000 increase the effective deceleration time and make target position approach slower 8220 SPEED GAIN 1 Gain factor of positioning speed control during deceleration Higher value means higher speed 8221 T WINDOW LO 8222 T WINDOW HI Target position window limit refer to example on page 100 Operation When the actual value of position is inside the target area target ref target window the relay output is
67. ce for actual value 2 ACT2 1 Al1 Analogue input 1 is used as actual value 2 2 Al2 Analogue input 2 is used as actual value 2 4009 JACT1 MINIMUM Minimum value for actual value 1 ACT1 Refer to Figure 22 and to Group 13 parameters for analogue input minimum and maximum settings 4010 JACT1 MAXIMUM Maximum value for actual value 1 ACT1 Refer to Figure 22 and to Group 13 parameters for analogue input minimum and maximum settings 4011 JACT2 MINIMUM Minimum value for actual value 2 ACT2 Refer to parameter 4009 4012 JACT2 MAXIMUM Maximum value for actual value 2 ACT2 Refer to parameter 4010 ACT1 A ACT1 MAXIMUM ACT1 MINIMUM p Analogue input signal Al min Al max ACT1 A ACT1 MINIMUM ACT1 MAXIMUM I I r T p Analogue input signal Al min Al max Figure 22 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 160 User s Manual 89 Code Description 4013 PID SLEEP DELAY Time delay for the sleep function see Figure 23 If the ACS 160 output frequency is below a set level parameter 4014 SLEEP LEVEL longer than PID SLEEP DELAY ACS 160 is stopped Alarm 28 is displayed when PID sleep is active 4014 PID SLEEP LEVEL Level for activation of sleep function see Figur
68. cted 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 DIS deactivated Stop and DIS activated Start 7 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 DI1F 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 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 58 ACS 160 User s Manual 1002 EXT2 COMMANDS Defines the connections and the source of Start Stop and Direction commands for external control location 2 EXT2 Refer to parameter 1001 ExT1 COMMANDS above 1003
69. ded for sale to the general public The ACS 160 with a total rated power greater than 1 kW conforms with EN 61000 3 2 Below 1 kW use the following units to comply with class A limits of EN 61000 3 2 ACS163 1K1 3 B S E V and ACS163 1K6 3 B S E V Industrial Networks If ACS 160 is used in an industrial installation for which the EN 61000 3 2 is not relevant a reasonable economical approach which considers the total installation shall be used Typically a single low power equipment like ACS 160 does not cause a significant voltage distortion to network However the user shall be aware of the values of the harmonics currents and voltages occurring within the power supply system before connecting the ACS 160 as well as the internal impedance of the supply system The current harmonic levels of the ACS 160 under rated load conditions are available on request and the assessment procedure given in appendix B of the EN 61800 3 may be used as guide Distribution Networks Isolated from Earth ACS 160 types 163 xKx B S E V cannot be used in an isolated or high impedance earthed industrial distribution networks ACS 160 User s Manual 125 126 ACS 160 User s Manual AA ED ED PA ID ID 3BFE 64364120 REV C EN Effective 17 5 2002 2002 ABB Oy Subject to change without prior notice ABB Oy BAU Drives P O Box 184 00381 Helsinki FINLAND Telephone 358 10 2211 Telefax 358 10 222 2681 ABB Inc
70. digital input 2 DI2 e DI2 is inactive Reference set 1 is selected e DI2 is active Reference set 2 is selected Reference set is selected with digital input 3 DI3 e DI3 is inactive Reference set 1 is selected e DI3 is active Reference set 2 is selected Table 6 Reference sets when parameter 8206 1 5 Reference Set 1 Reference Set 2 Target position low part TARGET 1 LO 8207 TARGET 2 LO 8209 Target position high part TARGET 1 HI 8208 TARGET 2 Hi 8210 Positioning frequency reference ICONST SPEED 1 1202 CONST SPEED 2 1203 Target window frequency reference ICONST SPEED 3 1204 Homing frequency reference ICONST SPEED 6 1207 CONST SPEED 3 1204 CONST SPEED 6 1207 Acceleration time IACCELER TIME 1 2202 IACCELER TIME 2 2204 Deceleration time DECELER TIME 1 2203 DECELER TIME 2 2205 6 SET 1 EXT F REF2 SELECT 7 SET2 EXTF REF2 SELECT Table 7 Reference sets when parameter 8206 6 7 Reference set 1 is used except the positioning frequency reference is selected with parameter 1106 EXT Reference set 2 is used except the positioning frequency reference is selected with parameter 1106 EXT Reference Set 1 Reference Set 2 Target position low part TARGET 1 LO 8207 TARGET 2 LO 8209 Target position high part TARGET 1 HI 8208 TARGET 2 Hi 8210 Positioning freguency refe
71. e drive may start after the reset operation Refer to parameter group 31 AUTOMATIC RESET PID SLEEP PID sleep function is active The drive may accelerate when PID sleep function is deactivated Refer to parameters 4018 SLEEP SELECTION 4013 PID SLEEP DELAY 4014 PID SLEEP LEVEL and 4015 WAKE UP LEVEL Reserved Reserved BR RES OVERLOAD Brake resistor is nearly overloaded Refer to brake resistor instructions 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 160 User s Manual 109 Table 9 Faults Fault Code 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 ACS160 OVERTEMP ACS 160 heat sink temperature is excessive Temperature trip limit is 105
72. e 23 When the ACS 160 output frequency falls below the sleep level the sleep delay counter is started When the ACS 160 output frequency rises above the sleep level the sleep delay counter is reset 4015 WAKE UP LEVEL Level for deactivation of sleep function This parameter sets a process actual value limit for the sleep function see Figure 23 The limit floats with the process reference Non inverted error value 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 deactivated See Figure 24 and Figure 26 Inverted error value 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 deactivated See Figure 25 and Figure 27 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 SET 2 PID
73. e Control The versatile braking features of the ACS 160 include capability to control electromechanical brake Electromechanical brake can be controlled by using programmable relay outputs of the ACS 160 The brake is applied when the motor is in stop the relay output is de energised Electromechanical brake control is enabled by first setting parameter 1401 RELAY OUTPUT 1 or 1402 RELAY OUTPUT 2 to value 32 MEC BR CNTRL Parameters 5401 MBRK OPEN DLY and 5403 MBRK FREQ LVL are used to adjust the operation of the mechanical brake Refer to Figure 28 Note Observe the relay output ratings as given in Reference Section K When necessary use an additional contactor to supply the brake coil Code Description 5401 MBRK OPEN DLY Release delay for external brake This delay specifies the time which passes from the brake open command to the moment when the brake is mechanically open Note Value of this parameter should be slightly longer than the actual time it takes for the external brake to release Too large of a value may lead to overcurrent tripping as the motor shaft can not rotate due to operation of the brake 5403 MBRK FREQ LVL The level of output frequency below which the external brake is applied This frequency level should be low enough that the speed of the motor is reduced almost to zero during the closing delay of the external brake 98 ACS 160 User s Manual Start Stop AM lt gt
74. e entry A Si Motor cable entry motor mounting 12 ACS 160 User s Manual J Routing the Motor Cables Note The motor cable outputs are located in different places depending on whether the unit is going to be mounted on the wall or on the motor Wall mounting U2 V2 W277 U W A PE h WY A Note For cable selection and ensuring installation compatibility with the EMC instructions see Appendix C for EMC Instructions and Maximum Cable Lengths Motor mounting U2 V2 W IH ACS 160 User s Manual K Control Terminals Main I O terminal X1 Description Identification X1 Terminal for signal cable screen Connected internally to frame earth SCR 1 Analogue input channel 1 programmable Al 1 2 Default 0 10 V R 200 kQ DIP switch Al1 open lt gt 0 from frequency reference 0 20 mA R 500 Q DIP switch Al1 closed lt gt 0 from frequency reference Resolution 0 1 accuracy 1 Analogue input circuit common Connected internally to frame earth through 1 MQ AGND 3 10 V 10 mA reference voltage output for analogue input potentiometer accuracy 2 10 V 4 Analogue input channel 2 programmable Al 2 5 Default 0 20 mA R 500 Q DIP switch Al2 closed lt gt 0 from frequency reference 0 10 V Rj 200 kQ DIP switch Al2 open lt gt 0 fnom fre
75. e rotation direction of the motor disconnect the mains power direction from the ACS 160 and wait 5 minutes for the intermediate circuit V capacitors to discharge Verify that the power is off Exchange the position of any two motor cable phase conductors at the lt 4 reverse motor terminals or at the motor connection box direction Apply the mains power and start the drive Rotation can also be changed from control panel by pressing the REVERSE button parameter 1003 must be set to REQUEST 5 Connect the I O Control Signals Disconnect the mains supply of the ACS 160 and wait 5 minutes for the intermediate circuit capacitors to discharge Note The unit is delivered with Factory macro 0 pre set For the following instructions Factory macro 0 is selected for all other macros refer to the section on Application Macros For analogue speed reference connect potentiometer 2 10 kQ to terminals 1 4 Default setting for Al 1 is voltage Default motor nominal values are 400 V 50 Hz and 1440 rpm for unit types ACS 163 xKx 3 A B D E 460 V and 60 Hz and 1750 rpm for ACS 163 xKx 3 R S U V type units ACS 160 User s Manual 25 6 Start the Drive from I O Switch on the mains Make sure panel display is on remote control REM If not switch to KEM 0 0 Hz remote control by pressing MENU and ENTER simultaneously until OUTPUT PDI REM is displayed To start the drive activate digital input DI 1 Factory mac
76. eded To help you mark the fixing point for installation of your ACS 160 a Wall Mounting Template is included Step by step instructions The installation of the ACS 160 has been broken down into a number of steps that are listed on page 4 and page 5 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 Safety ACS 160 User s Manual 3 Step by Step Instructions for Installing the ACS 160 Mounting on the Wall ACS 163 xKx 3 D E U V G CHECK the environment See A v 2 C CHECK voltage supply and fuses D See B Q v 5 4 CHECK the motor See C v C MOUNT the options if necessary See E v 5 INSTALL the ACS 160 on the wall v 09 wn D D D D I TI C 4 IDENTIFY power and control terminals v 7 C CHECK DIP switches v C CONNECT power terminals v 5 CONNECT control wires on D D A ao D o I See H K L y REPLACE the cover ep D D v TURN the power on No Co NR a ee Rok Ne PS S ZG See Start up 4 ACS 160 User s Manual Mounting on the Motor ACS 163 xKx 3 A B R S G 4 CHECK the environment _ See A 2 CHECK volta
77. er 100 ACS 160 User s Manual Code Description 8201 ENC PULSE NUM Number of encoder pulses per revolution 8202 ENC ERROR Defines the action of the ACS 160 in encoder error situation O NOT SEL Encoder error supervision disabled 1 FAULT The drive is stopped with coast stop and fault indication is given when the following conditions are fulfilled e drive is running and output frequency is over 0 Hz e no encoder pulses are detected for the time defined with parameter 8203 ENC DELAY 8203 ENC DELAY The delay before the encoder fault is given See parameter 8202 ENC ERROR 8204 ENC SCALING Sets the counting direction for the position counter 0 and positive values DIRECTION 1 Negative values DIRECTION 2 Example If motor is rotating in forward direction and position counter value is counting in positive direction see parameters 8227 POS ACT LO and 8228 POS ACT HI DIRECTION 1 is selected Otherwise DIRECTION 2 must be selected ACS 160 User s Manual 101 Code Description 8206 POS TABLE SEL Position reference set selection 1 REF SET 1 Reference set 1 is used 2 REF SET 2 Reference set 2 is used 3 AI2 4 DI2 5 DI3 Reference set is selected with analogue input 2 Al2 Al2 0 5 V 0 10 mA Reference set 1 is selected Al2 5 10 V 10 20 mA Reference set 2 is selected Reference set is selected with
78. er 16 N Protection Features 16 O Motor Overload Protection 17 P Loadability of ACS 160 18 O Type Series and Technical Data 19 R Product Conformity nn 20 S RECYGCIING 22e reel aeranta tate 20 TOPIONE EE RS de ister ety canis eni E bel la ki leni 21 Start up ose ccczccctcdiadventnadbaidotsdeccasecpateundecbinebinebcneiaiedenedestasesnes 23 PROG FANNING r cession evan esa 27 Local and Remote Control 27 External Control Locations 27 Reference types 27 Control Panelini ani aii aaa ne ka aken 28 ACS 160 User s Manual Control Modes ee 29 Output Display ss 29 Menu Structure iii 30 Setting Parameter Value 30 Menu FUNCTIONS 00000 eee ceeee ee eeene eee eeeeeneeeeeeeeaeeeeeeeaeeeeesenaeeeeeeenaas 30 Diagnostic Displays 31 Resetting the Drive from the Control Panel 31 Application Macros ns 33 Application Macro Factory 0 34 Application Macro Factory 1 35 Application Macro ABB Standard 36 Application Macro 3 wire 37 Application Macro Alternate eeeeeeeeeeeeirrseerrrsererrrseerrreeene 38 Application Macro Motor Potentiometer 39 Application Macro Hand Auto eeeeeeeeeereseerrserreiseerenses 40 Application Macro PID Control
79. er into a bundle not longer than five times its width and connected to the PE terminal of the motor ACS 160 User s Manual 121 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 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 35 Figure 35 A double shielded twisted pair cable on the left and a single shielded twisted multipair cable on the right The analogue and digital input signals should be run in separate screened cables Relay controlled signals providing their voltage does not exceed 48 V can be run in the same cables as digital input signals It is recommended that the relay controlled si
80. essage length for the ACS 160 is 32 bytes If a message exceeding 32 bytes is received this diagnostic counter increases by one every time a character which cannot be placed in the buffer is received 5209 FRAME ERRORS This diagnostic counter increases by one every time when a character with a framing error is received from the bus e Communication speed settings of the devices connected in the bus differ e 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 e Parity settings of the devices connected on the bus differ e Ambient noise levels may be too high 5211 CRC ERRORS This diagnostic counter increases by one every time when a message with a CRC error is received e Ambient noise levels may be too high e CRC calculation is not performed correctly 5212 BUSY ERRORS This diagnostic counter increases by one every time the ACS 160 receives a character from the bus while it is still processing the previous message e There might be two stations with the same station number e 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 160 User s Manual 97 Group 54 Braking Electromechanical Brak
81. eypad I Ref t t i Loc Rem L___________ EEE Pe Dr Be Danone s p i i l e Start Stop f NOT SEL Local DI1 DI5 N EXT1 EINE Remote Direction KEYPAD NOT SEL hi FORWARDe i DH DIS_ EXT2 REVERSE i Seamer Enabled DI1 DI5 EXT1 EXT2 DIRECTION RUN ENABLE ES 1003 1601 Figure 29 Selecting control location and control source ACS 160 Users Manual 113 EXT REF2 EXT REF1 EXT1 EXT2 CONST SP KEYPAD SELECT SELECT SELECT SELECT REF SEL ao z 1106 1103 1102 1201 101 Control ExT1 DI3 4 Terminals l i I i i AH EXT Analogue KEYPAD inputs i EXT2 Remote Al Al2 Al1 2 D11 5 emote DI3 4 Min T Digital KEYPAD f Local x Ire inputs poo Loca Const Crit sp DIDIS speeds Acc Dec Re vesi Mamaia 4 l i I 4 REF2 l l i i i REF1 Hz Keypad Ref ocR m lisiiiss trie sent Rene sets Start Stop Direction NOT SEL Local Start Stop DI1 DI5 EXT1 JA REQUEST a Remote Ne Direction KEYPAD i NOT SEL FORWARD i _DI1 DI5 EXT2 REVERSE l E Enabled KEYPAD DIDIS PO AMANDS E MMANOS ATEN SRE 1001 1002 1003 4 J601 Figure 30 The control signal connections of the ABB Standard Alternate and Premagnetise macros 114 ACS 160 User s Manual
82. ference 2 REF2 is given as percentage Reference 2 can be either a frequency reference or alternatively process reference when PID control is used Reference 2 is internally converted to frequency so that 100 corresponds to parameter 2008 MAXIMUM FREQ However when PID Control macro is used reference 2 is fed directly to the PID controller as percentage It should be noted that also in remote control mode references 1 and 2 can be received from the keypad if necessary This depends on the values of parameters 1103 EXT REF1 SELECT and 1106 EXT REF2 SELECT ACS 160 User s Manual 27 In local control mode the parameter 1101 KEYPAD REF SEL is used to define which reference type Hz or percentage is used EXT1 Start Stop Direction Keypad Reference 1 REF1 Hz or Keypad Reference 2 REF2 EXT2 Start Stop Direction External Reference 1 Hz Figure 1 Control locations and reference types Control Panel Start Stop Direction External Reference 2 The control panel can be connected to and detached from the converter at any time Control modes Active fault indicator Display modes START STOP REVERSE Units Shaft direction MENU ENTER 28 ACS 160 User s Manual Control Modes The very first time the drive is powered up it is controlled from the Control Terminals remote control REM The ACS 16
83. fers from the nominal value Output current relative to 9906 MOTOR NOM CURR A 150 3006 MOT LOAD CURVE 100 _ a l 3007 ZERO SPEED LOAD 50 Frequency 3008 BREAK POINT Figure 14 Motor load curve ACS 160 Users Manual 77 Code Description 3007 ZERO SPEED LOAD This parameter defines the maximum allowable current at zero speed relative to 9906 MOTOR NOM CURR Refer to Figure 14 3008 BREAK POINT Break point of motor load curve Refer to Figure 14 for an example of a motor load curve See Figure 16 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 15 0 NOT SEL Stall protection is not used 1 FAULT When the protection is activated the ACS 160 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 t 7 Ts Zlo V region 3010 STALL CURRENT I Frequency 3011 STALL FREQ HI Figure 15 Motor stall protection 3010 STALL CURRENT Current limit for stall protection Refer to Figure 15 3011 STALL FREQ HI This parameter sets the frequency value for the stall function Refer to Figure 15 3012 STALL TIME This parameter sets the time value for the stall function 3013 UNDERL
84. g becomes visible 2 Press UP DOWN arrows to move between groups select the start up group 99 3 Press ENTER to view individual parameters 4 Press UP DOWN arrows to move between parameters select the parameter to be changed for example 9905 5 Press and hold ENTER until SET is displayed 6 Use UP DOWN arrows to alter the value 7 Store the modified value by pressing ENTER 8 Press MENU twice to return to OUTPUT display Repeat the above steps for the other parameters After entering the required motor data it would be a good idea to check the other basic parameter settings To see basic parameters refer to section ACS 160 Complete Parameter List basic parameters are shaded grey in the table 0 0 to the driven equipment in case of incorrect rotation direction of the motor it is Note Check that starting the motor does not cause any danger If there is a risk of damage recommended to disengage the driven equipment when first start is performed 24 ACS 160 User s Manual 3 Perform the First Start The motor is now ready to run Press START STOP button to start the motor To set the output frequency in local control press ENTER Pressing the UP DOWN buttons changes the output immediately Press ENTER to return to OUTPUT display To stop the drive press START STOP button 4 Check Rotation Direction Check that the motor is running in the correct direction sa D forward To change th
85. g frequencies 2607 SLIP COMP RATIO A squirrel cage motor will slip under load The slip can be compensated by increasing the frequency as the motor torque increases This parameter defines the gain for the slip 100 means full slip compensation 0 means no slip compensation D sei ih compensation range zoo a H f Hz Field weakening point Figure 12 Operation of IR compensation ACS 160 User s Manual 75 Group 30 Fault Functions ACS 160 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 frequency stall time and current Code Description 3001 Al lt MIN FUNCTION Operation in case of Al signal drops below fault limit 3022 Al1 FLT LIMIT or 3023 AI2 FLT LIMIT 0 NOT SEL No operation 1 FAULT A fault indication is displayed and the ACS 160 coasts to stop 2 CONST SP 7 A warning indication is displayed and the speed is set accordi
86. ge supply and fuses D See B Q v 5 4 CHECK the motor V C MOUNT the options if necessary y 5 C INSTALL the ACS 160 on the motor v Ce IDENTIFY power and control terminals v 7 q CHECK DIP switches v CONNECT power terminals v 5 CONNECT control wires v REPLACE the cover v m C TURN the power on See E m D Q ao D D I See H See H K L Le D D PSI NP a eG ep x See Start up ACS 160 User s Manual Reference Sections A Environment for Storage Transportation and Stationary Use ACS 160 Stationary Use Storage and Transportation in the protective package Installation Site Altitude e 0 1000 m 0 3300 ft if Pry and Ip 100 1000 2000 m 3300 6600 ft if Py and Ip derated 1 every 100 m 330 ft above 1000 m 3300 ft Ambient Temperature 10 40 C 14 104 F in 40 70 C 40 158 F motor mounting 0 40 C 32 104 F in wall mounting max 50 C 122 F with derating See P Contamination Levels According to IP65 classification IEC 721 3 3 e chemical gases Class 3C3 Storage e solid particles Class 3S3 s chemical gases Class 162 e solid particles Class 183 Transportation e chemical gases Class 2C2 e solid particles Class 2S2 Sinusoidal Vibration In motor mounting e 2 9 Hz max amplitude 3 mm IEC
87. gnals 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 160 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 When mounting control panel far away from the converter use CA PAN L 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 8 in to avoid excessive radiation to the cable 122 ACS 160 User s Manual Wall Mounted Units Compliance with EN61800 3 EMC Standard Second Environment Use a converter type which complies with the 2nd environment EMC requirements as specified in Table 10 and follow the instructions for all cable screen connections The motor cable lengths have to be limited as specified in Table 10 and must have effective screen according to Figure 34 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 10 Maximum motor cable lengths m ft to comply with EN 61800 3 2nd Environment Wall mount
88. he relay is de energised B Initially the relay is energised Figure 20 Operating data supervision using relay outputs when LOW gt HIGH 84 ACS 160 User s Manual Group 33 Information Code Description 3301 SW VERSION Software version 3302 TEST DATE Displays the test date of the ACS 160 yy ww ACS 160 User s Manual 85 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 Value is calculated by taking given parameter from the operating data group Group 1 and multiplying and dividing it with given coefficients The number of displayed decimal digits is configurable See example below Code Description 3402 P VAR 1 SEL Selection of process variable 1 Number of any parameters of the group 1 OPERATING DATA excluding parameters 0134 PROCESS VAR 1 and 0135 PROCESS VAR 2 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 21 Value Display 0 125 1 12 5 2 1 25 3 0 125 Figure 21 Display with different decimal point locations when calculated value is 125 3407 P VAR 2 SEL Selection of process variable 2 Number of any pa
89. ic 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 marking For more information about UL cUL and C tick markings please contact your local ABB supplier S Recycling A product to be disposed of contains valuable raw material that should be recycled thus preserving energy and natural resources Instructions for disposal are available from your local ABB supplier Both the manual and the package which is made of corrugated cardboard are recyclable 20 ACS 160 User s Manual T Options Brake Resistors CA BRK R1 1 Integral brake resistor for ACS 160 0 55 0 75 kW 0 74 1 Hp CA BRK R1 2 Integral brake resistor for ACS 160 1 1 1 5 KW 1 5 Hp CA BRK R2 Integral brake resistor for ACS 160 2 2 kW 3 Hp Cable Glands CA MGS Cable gland set metric thread Control Panel CA PAN L Seven segment control panel with IP65 kit and 3 m 10 ft extension cable Fieldbuses CFB PDP Fieldbus adapter for Profibus DP CFB IBS Fieldbus adapter for Interbus S CFB CAN Fieldbus adapter for CANOpen CFB LON Fieldbus adapter for LonWorks CFB DEV Fieldbus adapter for DeviceNet CFB RS Adapter for RS485 and RS232 Motor Mounting Kits CMK SIE 71 90 For Siemens 1LA7 series motors CMK SIE 100 112 For
90. ics General This chapter describes the various alarm and fault codes 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 Such action will void guarantee endanger correct operation and increase downtime and expense Alarm and Fault displays The seven segment display unit of the control panel indicates alarms and faults using codes ALxx or FLxx where xx is the corresponding alarm or fault code Alarms 1 7 arise from button operation 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 or through serial communication mode by writing 0 into them Fault Resetting Faults can be reset either from the control panel by pressing START STOP button by digital input Parameter 1604 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 160 can be configured to automatically
91. imal ACS 160 User s Manual 47 Default Profibus Code Name Range Resolution US Default par num User S M 0122 jao 0 20 mA 0 1 mA 22 0124 JACTUAL VALUE 1 0 100 0 1 24 0125 JACTUAL VALUE 2 0 100 0 1 25 0126 CONTROL DEV 100 100 0 1 26 0127 PID ACT VALUE 100 100 0 1 27 0128 LAST FAULT 0 26 1 28 0129 PREVIOUS FAULT 0 26 1 29 0130 OLDEST FAULT 0 26 1 30 0131 SER LINK DATA 1 O 255 1 31 0132 SER LINK DATA 2 O 255 1 32 0133 SER LINK DATA 3 O 255 1 33 0134 PROCESS VAR 1 34 0135 PROCESS VAR 2 35 0136 RUN TIME 0 00 99 99 kh 0 01 kh 36 0137 MWh COUNTER 0 9999 MWh 1 MWh 37 Group 10 COMMAND INPUTS 1001 EXT1 COMMANDS 0 10 1 2 4 101 viv 1002 EXT2 COMMANDS 0 10 1 0 102 v v 1003 DIRECTION 1 3 1 3 103 viv Group 11 REFERENCE SELECT 1101 KEYPAD REF SEL 1 2 1 1 REF1 Hz 126 1102 ExT1 EXT2 SEL 1 8 1 6 127 viv 1103 EXT REF1 SELECT 0 13 1 1 128 viv 1104 JEXT REF1 MIN 0 250 Hz 1 Hz 0 Hz 129 1105 EXT REF1 MAX 0 250 Hz 1 Hz 50 Hz 60 Hz 130 1106 EXT REF2 SELECT 0 13 1 0 131 viv 1107 JEXT REF2 MIN 0 100 1 0 132 1108 EXT REF2 MAX 0 500 1 100 133 1115 REF STEP SEL 0 2 1 0 140 1117 REF STEP MODE 0 1 1 142 1118 REF STEP UP 0 250 Hz 0 1 Hz 0 143 0 250 0 1 0 1119 REF STEP DOWN 0 250 Hz 0
92. ing with Input voltage EMC filter Switching frequency 2nd Environment Restricted Distribution Unrestricted Distribution 400 V 480 V 400 V 480 V Type 4 kHz 8 kHz 4 kHz 8 kHz 4 kHz 8 kHz 4 kHz 8 kHz m ft m ft m ft m ft m ft m tf m ft m ft ACS 163 1K1 3 E V 40 131 20 66 20 66 10 33 40 131 20 66 20 66 10 33 ACS 163 1K6 3 E V 60 197 20 66 20 66 10 33 60 197 20 66 20 66 10 33 ACS 163 2K1 3 E V 80 262 20 66 20 66 10 33 80 262 20 66 20 66 10 33 ACS 163 2K7 3 E 90 295 50 164 40 131 30 98 90 295 50 164 40 131 30 98 ACS 163 4K1 3 E V 100 328 100 328 80 262 80 262 100 328 100 328 80 262 80 262 First Environment Use a converter type which complies with the 1st environment EMC reguirements as specified in Table 11 and follow the instructions for all cable screen connections The motor cable lengths have to be limited as specified in Table 11 and must have effective screen according to Figure 34 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 11 Maximum cable lengths m ft to comply with EN 61800 3 1st Environment Wall mounting with Input voltage EMC filter Switching frequency 1st Environment Restricted Distribution Unrestricted Distribution 400 V 480 V 400 V 480 V Type 4 kHz 8kHz 4kHz 8 kHz 4 kHz 8 kHz 4 kHz 8 kHz m f
93. ions Parameter settings for configuring desired response to certain abnormal external conditions 31 Automatic Reset Parameter settings for automatically resetting some faults 32 Supervision Parameter settings for any 2 parameters of group 01 to be supervised in co operation with relays 33 Information Read only parameters for information about the software version and production date 34 Process Variables Parameter settings for creating custom process variables 40 PID Control Parameter settings for the first set of PID Control parameters 41 PID Control 2 Parameter settings for the second set of PID Control parameters 51 Ext Comm Module Parameter settings for external fieldbus communication modules 52 Standard Modbus Parameter settings for standard Modbus serial communication 54 Braking Parameter settings for selecting additional braking features 81 Positioning Parameter settings for positioning applications ACS 160 Users Manual 45 46 ACS 160 User s Manual ACS 160 Complete Parameter List Initially only the so called basic parameters shaded grey in the table below are visible Use the appropriate menu function of the control panel to make the full parameter set visible Refer to Menu Functions Note InterBus S CFB IBS and CANopen CFB CAN Users The Parameter Index equal Drive Parameter No 12288 converted to hexadecimal Example the index for drive parameter 1309 is 1309 12288
94. l frequency lock out will happen Example A fan system vibrates badly from 18 Hz to 23 Hz and from 46 Hz to 52 Hz Set the parameters as follows CRIT FREQ 1 LO 18 Hz and CRIT FREQ 1 HI 23 Hz CRIT FREQ 2 LO 46 Hz and CRIT FREQ 2 HI 52 Hz foutput face H fil AH OL f2H gt frer Hz 18 23 46 52 Figure 11 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 74 ACS 160 User s Manual Group 26 Motor Control Code Description 2603 IR COMPENSATION Table 3 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 Py kW 0 55 0 75 1 1 1 5 2 2 overheating Refer to Table 3 IRcomp V 33 30 27 25 23 2604 IR COMP RANGE IR compensation range Defines frequency after which IR compensation is 0 V 2605 LOW NOISE Motor acoustical noise option O 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 must be derated see reference section N 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 operatin
95. lected 1 lt DH Two wire Start Stop connected to digital input DI1 DI1 deactivated Stop DI activated Start 2 DH 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 2P 3 Three wire Start Stop Direction Start Stop connected as with DI1P 2P Direction is connected to digital input DI3 DI3 deactivated Forward DI3 activated Reverse To control Direction value of parameter 1003 DIRECTION should be REQUEST 5 DIWPR2P 3P Start Forward Start Reverse and Stop Start and Direction commands are given simultaneously with two separate momentary push buttons the P stands for pulse The Stop push button is normally closed and connected to digital input DI3 The Start Forward and Start Reverse push buttons are normally open and connected to digital inputs DI1 and DI2 respectively Multiple Start push buttons are conne
96. ll start smoothly at the current frequency The drive will automatically search the correct output frequency 3 TORQUE BOOST Automatic torque boost might be necessary in drives with high starting torque Torque boost is only applied at start Boosting is stopped when output frequency exceeds 20 Hz or when output frequency is equal to reference See also parameter 2103 TORQ BOOST CURR 4 FLY BOOST Activates both the flying start and torque boost Note If torque boost is used the switching frequency is always 4 kHz In this case parameter 2605 Low NOISE is ignored 2102 STOP FUNCTION Conditions during motor deceleration 1 COAST Motor coasts to stop 2 RAMP Ramp deceleration as defined by the active deceleration time 2203 DECELER TIME 1 or 2205 DECELER TIME 2 2103 TORQ BOOST CURR Maximum supplied current during torque boost See also parameter 2101 START FUNCTION 2104 STOP DC INJ TIME DC injection time after modulation has stopped If 2102 STOP FUNCTION is 1 COAST ACS 160 uses DC braking If 2102 STOP FUNCTION is 2 RAMP ACS 160 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 DI1 DI5 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
97. m the panel Note Selecting an application macro with parameter 9902 APPLIC MACRO will set all other parameters to their default values except the group 99 Start up Data parameters the parameter lock 1602 and groups 51 52 serial communication parameters 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 160 Complete Parameter List Connection Examples In the following connection examples please note All the digital inputs are connected using negative NPN logic List of available macros a Application Macro Factory 0 Application Macro Factory 1 Application Macro ABB Standard Application Macro 3 wire Application Macro Alternate Application Macro Motor Potentiometer Application Macro Hand Auto Application Macro PID Control o O MN O oO BR 0 Dp Application Macro Premagnetise 10 Application Macro Positioning ACS 160 User s Manual 33 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 Alt z 4 0 10V e Analogue reference Al1 e Relay output 1 Fault
98. measured by calculating pulses from an encoder When the distance has been travelled i e desired position reached the drive stops and waits for a new start Simultaneously the output relay activates signalling that target position has been reached refer to Figure 2 Homing is an additional configurable feature selected with parameters Homing means that the load is driven at slow speed to known position home position The value of parameter 9902 is 14 POSITIONING Input signals Output signals DIP switch e Start stop DI1 e Relay output 1 Fault je th Alt 46 0 10V e Positioning Jogging select DI2 e Relay output 2 Target reached Z e Target position select DI3 Al2 45 1 0 4 20 mA e Jogging reference Al1 e Encoder pulses DI4 and DI5 Connection example SCR 1 Jog speed AH 2 T AGND 3 r H 10V 4 Not used AI2 5 AGND 6 Not used LAO1 7 AGND 8 24V 9 __ DCOM 40 Start Stop Activate to start DI1 11 Cable length max 3 m Jog Positioning Activate to select positioning mode DI2 12 Target Position Activate to select position 2 DI3 13 TCLK A Encoder pulses DI4 14 ChA 4 Encoder TCLK B Encoder pulses DI5 15 ChB Relay output 1 programmable ROTA 16 1024 pulses rev Default operation Fault gt open RO1B 17 Relay output 2 programmable _RO2A jis RO2B 19 Defa
99. n the analogue input used ACS 160 User s Manual 63 Group 12 Constant Speeds The ACS 160 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 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 0 NOT SEL Constant speed function disabled 1 5 DI1 DI5 Constant Speed 1 is selected with digital inputs DI1 DI5 Digital input activated Constant Speed 1 activated 6 DI1 2 Three Constant Speeds 1 3 are selected with two digital inputs Constant Speed selection with digital inputs DI1 2 Table 1 Constant Speed selection with digital inputs DI1 2 DI1 DI 2 Function 0 0 No constant speed 1 0 Constant speed 1 1202 0 1 Constant speed 2 1203 1 1 Constant speed 3 1204 0 DI deactivated 1 DI activated 7 DI3 4 Three Constant Speeds 1 3 are selected with two digital inputs as in DI1 2 8 DI4 5 Three Constant Speeds 1 3 are selected with two digital inputs as in DI1 2
100. nclosure forms a cooling surface to dissipate surplus heat Painting the converter is therefore not allowed If the ACS 160 drive is attached on top of motors other than specified the allowed continuous torque ratings must be verified by thermal tests Contact your local ABB representative for more information 18 ACS 160 Users Manual Q Type Series and Technical Data Motor Mounted Wall Mounted Filterless 3 Input U ACS 163 380 500 V 10 Built in filter 3 Input U 380 480 V 10 ACS 163 1K1 3 B S Frame Size Nominal ratings See B Nominal motor Py Input current l y Continuous output current lon Max current x max Max starting Current Continuous output Current sguared torque lonsq Output voltage Up O U Switching 4 Standard freguency fsw 8 Low noise Protection limits Overcurrent peak 7 1 9 5 Overvoltage Trip limit 875 Undervoltage Trip limit V DC 333 Overtemperature C F 105 221 inside power module Max wire sizes and screw torque of connectors Power terminals mm single core 4 AWG 12 stranded 2 5 AWG 14 torque 0 8 Nm kkk Control terminals mm 0 5 1 5 AWG22 AWG16 torque 0 4 Nm Line fuse 3 A 4 4 6 10 10 4 ACS163 Power losses at nominal point Power circuit W 17 23 33 45 66 17 23 45 Control circuit W 16
101. ng to parameter 1208 CONST SPEED7 3 LAST SPEED A warning indication is displayed and the speed is set to the level the ACS 160 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 160 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 160 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 DIT 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 160 is stopped and the motor coasts to stop and fault indication is displayed 76 ACS 160 User s Manual Code Description 3004 MOT THERM PROT Motor overtemperature function This parameter defines the operation of the mo
102. o 10V ACS 160 ree x1 SCR 41k SCR 11 AH 2 Alt 2 AGND AGND 3 FOV 4 TOV Al2 5 Al2 5 AGND 6 F IVF AGND 6 AO1 7 0 20 mA AO1 7 AGND 8 Ground the cable screen AGND 8 on the sourcing end 24V lo 24V jo DCOM 49 Z J DCOM 10 4 D n DH a1 DI2 12 DI2 12 DI3 13 DI3 13 DI4 14 DI4 14 DI5 15 DI5 15 DI configuration 0V ROTA 16 NPN connected ROTA 16 ROIB 17 ROIB 17 DI configuration PNP connect RO2A jig RO2A 48 NF connected RO2B with external RO2B h19 19 power supply Note These are connection examples only ACS 160 User s Manual 15 M Replacing the Cover Do not turn the power on before replacing the cover Make sure the grounding plug is inserted in its place N Protection Features The ACS 160 has a number of protective features e Overcurrent e Input phase loss e Overvoltage e O terminal short circuit protection e Undervoltage e Motor overload protection see O e Overtemperature e Output overload protection see P e Output earth fault e Stall protection Underload Brake resistor overload protection Output short circuit Note Whenever the ACS 160 detects a fault condition the fault relay opens The motor stops and the ACS 160 will wait to be reset If the fault persists and no external cause has been identified contact your ACS 160 supplier 16 ACS 160 User s Manual O Motor Overload Protection ACS 160 provides two ways for motor
103. on how to commission the ACS 160 Programming part consists of sections on local and remote control panel operation application macros complete parameter list and diagnostics Control signals dimensions and EMC instructions are appended to the back of the manual General overview of the ACS 160 The ACS 160 is a compact frequency converter designed for harsh environmental conditions The strong aluminium enclosure provides IP65 protection for the control electronics Mounting of the ACS 160 is flexible e The ACS 160 can be mounted directly on the top of a TEFC totally enclosed fan cooled type asynchronous motor This is done by means of a mounting kit which allows the converter to be attached to the motor terminal box e The ACS 160 can be mounted on a wall nearby the motor In this case an external fan unit is needed The fan unit provides the necessary cooling for the converter The control panel is provided with the wall mounted unit Motor mounting kits for various motors are provided as options Custom made motor mounting kits for other motors can be designed upon request contact your local ABB supplier for more information Delivery The ACS 160 is delivered in three basic ways 1 Wall mounted For mounting instructions see Step by Step Instructions on page 4 2 Motor mounted For mounting instructions see Step by Step Instructions on page 5 3 Drive amp Motor combination For installation instructions refer to u
104. ormance v A Supervision v A PID v A Fieldbus v Braking Positioning Group Name Description 99 Start up Data Parameter settings for setting up the drive and for entering motor information 01 Operating Data Read only parameters for drive operation data including actual signals and fault memories 10 Command Inputs Parameter settings for start stop and direction commands 11 Reference Select Parameter settings for reference commands locations 12 Constant Speeds Parameter settings for constant speed value input 13 Analogue Input Parameter settings for max min and filter for the analogue input 14 Relay Outputs Parameter settings for relay output characteristics 15 Analogue Outputs Parameter settings for analogue output 16 System Controls Parameter settings for enabling disabling parameter access run enable etc 20 Limits Parameter settings for limiting operating features and overvoltage control 21 Start Stop Parameter settings for selecting start and stop modes flying start torgue boosting DC hold ramp coast etc 22 Acc Decel Parameter settings for defining the two acceleration deceleration ramp pairs 25 Critical Freg Parameter settings for setting critical freg to avoid resonance problems 26 Motor Control Parameter settings for selecting motor control features like IR compensation and low noise u f ratio 30 Fault Funct
105. overload protection in accordance with the National Electric Code US software I t model which is the default setting and PTC input For more information see Group 30 Fault Functions parameters If the motor current lou from the frequency converter exceeds the motor nominal current In for a prolonged period the ACS 160 automatically protects the motor against overheating by tripping The trip time depends on the extent of the overload lout In the output frequency and motor nominal frequency from as shown in figure below Times given apply to a cold start lout In Trip time 15 300 s 600 s co 1 0 0 5 gt Output frequency 0 35 Hz Use of motor PTC input The motor PTC input can only be used in motor mounting Set parameter 3024 MOT THERM MODE to 3 THERMISTOR When the motor PTC is used the software overload protection for the motor does not function connector Motor cable connector X4 1 X4 2 U2 V2 W2 Warning Use of motor PTC is not allowed in wall mounting because connector X4 is in main circuit potential Requirements for the motor PTC input cable in motor mounting are wire size 0 5 1 5 mm 22 16 AWG temperature rating 105 C 221 F and voltage rating 500 V minimum ACS 160 User s Manual 17 P Loadability of ACS 160 Motor mounted ACS 160 types are primarily cooled by the air flow caused by the axial fan of the motor Cooling performance of the
106. parameters 4101 4112 4119 4120 is analogous with set 1 parameters 4001 4012 4019 4020 PID parameter set 2 can be selected by parameter 4016 PID PARAM SET 94 ACS 160 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 For standard Modbus communication see Group 52 Parameters 5204 COMM FAULT TIME and 5205 COMM FAULT FUNC can be used to detect communication loss between the drive and the fieldbus communication module Code Description 5101 FIELDBUSPAR 1 Parameter 1 of the fieldbus adapter module Value reflects the type of adapter connected Table 4 List of module types Value Module type o No module connected Profibus CFB PDP Modbus Interbus S CFB IBS CS31 bus CANopen CFB CAN DeviceNet CFB DEV LONWORKS CFB LON Modbus Others ojoj NI oaJ a AJOI mM Reserved 5102 FIELDBUSPAR 2 FIELDBUSPAR 15 5115 Refer to communication module documentation for more information on these parameters ACS 160 User s Manual 95 Group 52 Standard Modbus The ACS 160 features one serial link connector which can be used for control panel for Modbus communication and for other fieldbus adapters When standard Modbus communication is used
107. parameters 5201 5203 are used to set up station number communication speed and parity An adapter is required to connect the ACS 160 either to RS232 or to RS485 type bus type code CFB RS It is also possible to connect the ACS 160 to other fieldbus systems for example Profibus For this purpose a fieldbus adapter is required that is able to convert the external fieldbus protocol to the standard Modbus protocol Fieldbus communication modules of this kind are set up using Group 51 parameters Note Modifications of parameters 5201 5203 take effect on the next power up Modification of station number communication speed or parity may cause the communication to control panel or fieldbus adapter not to operate if they are connected after the drive is powered up It is however always possible to ensure that communication starts operating simply by turning the power off from the drive ensuring that the control panel or desired fieldbus adapter is connected and then turning the power on again Code Description 5201 STATION NUMBER Sets the slave number for the ACS 160 in Modbus network Range 1 247 5202 COMM SPEED Defines the communication speed of the ACS 160 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
108. quency reference Resolution 0 1 accuracy 1 Analogue input circuit common Connected internally to frame earth through 1 MQ AGND 6 Analogue output programmable Default 0 20 mA load lt 500 Q lt gt 0 f output AO IZ freguency Common for DI return signals AGND 8 Auxiliary voltage output 24 V DC 180 mA reference to AGND Short circuit protected 24 V 9 Digital input common To activate a digital input there must be 24 V or 24 V between that DCOM 10 input and DCOM The 24 V may be provided by the ACS 160 X1 9 or by an external 12 24 V source of either polarity DI Configuration Factory 0 Factory 1 Start Stop Activate to start Motor will ramp Start If DI 2 is activated momentary DI 1 11 up to frequency reference Disconnect to activation of DI 1 starts the ACS 160 stop Motor will coast to stop Reverse Activate to reverse rotation Stop Momentary inactivation always stops DI 2 12 direction the ACS 160 Jog Activate to set output frequency to Reverse Activate to reverse rotation DI3 13 jogging frequency default 5 Hz direction Has to be deactivated Has to be activated DI4 14 Ramp pair selection ACC1 DEC1 or ACC2 DEC2 DI5 15 Relay output 1 programmable default fault relay RO1A 16 Fault RO1A and RO1B not connected PE RO1B 17 12 250 V AC 30 V DC 10 mA 2A Relay output 2 programmable default running RO2A 18 Running RO2A and
109. r 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 e Start stop and direction e An output AO z DI1 2 3 Frequency Alt 46 o 10Vv e Analogue reference Al1 e Relay output 1 Fault Al2 43 0 4 10mA e Ramp pair 1 2 selection DI5 e Relay output 2 Running Connection example SCR_ 1 External Reference 1 0 10 V lt gt 0 50 Hz An 2 AGND 3 TO Reference voltage 10 VDC 10V 4 Not used Al2 5 AGND 6 Output frequency 0 20 mA lt gt 0 50 Hz AO1 7 GA AGND 8 24 VDC 24V s Momentary activation with DI2 activated Start DIT m N Momentary deactivation Stop DI2 12 Fwd Rev activate to reverse rotation direction DI3 13 gt Has to be connected DI4 14 Ramp pair selection Activate to select ramp pair 2 DI5 as Relay output 1 programmable ROTA Jie Default operation Fault gt open RO1B 17 Relay output 2 programmable RO2A fis Default operation Running gt closed __ RO2B 19 Note DI 4 is used to configure ACS 160 It is read only once when power is connected All parameters marked with are determined by the D14
110. r 8213 POS DELAY and external frequency reference parameter 8217 AUX POS CMD can be defined ACS 160 User s Manual 103 Code Description 8216 HOMING MODE Homing mode is possible only when external control locations EXT2 is selected 0 NOT SEL Homing is not used 1 3 reserved 4 HOMING 1 Homing frequency reference is set with parameter 1207 CONST SPEED 6 Homing direction is defined with digital input 3 DI3 e direction is forward when DIS is inactive e direction is reverse when DI3 is active Home position is set to position counter when DI3 state changes After this homing speed reference is internally forced to zero Load decelerates from homing freguency to zero Positioning is enabled when stop command is given 5 lt HOMING 2 Like HOMING 1 with the following difference e direction is reverse when DI3 is inactive e direction is forward when DIS is active 6 HOMING 3 Like HOMING 4 and HOMING 5 with the exception that homing direction is defined with analogue input Al1 e direction is forward when Al1 0 4 V 0 8 mA e direction is reverse when Al1 6 10 V 12 20 mA Note When value 4 or 5 is selected the drive will perform homing operation when it is powered up and it receives the first start command External control place EXT 2 must be selected After the homing operation is completed the drive will go to positioning mode as set by parameter 8215 POS MODE 8217 AUX POS CMD Auxili
111. rameters of the group 1 OPERATING DATA excluding parameters 0134 PROCESS VAR 1 and 0135 PROCESS VAR 2 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 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 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 The following settings are then needed 3402 P VAR 1 SEL lt 0103 OUTPUT FREO 3403 P VAR 1 MULTIP 314 3404 P VAR 1 DIVISOR lt 1000 3405 P VAR 1 SCALING lt 1 Check what is the decimal point location on variable selected with parameter 3402 P VAR 1 SEL In this case the chosen variable 0103 OUTPUT FREQ is displayed with 0 1 Hz resolution Therefore 3405 1 must be selected See Figure 21 86 ACS 160 User s Manual Group 40 PID Control The PID Control Macro allows the ACS 160 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
112. rations Refer to section on 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 PARAM LOCAL LOCK Control panel function is not allowed e Parameter 1602 PARAMETER LOCK denies parameter editing e Parameter 1605 LOCAL LOCK denies local control mode 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 AT OVERVOLTAGE Overvoltage controller is active 12 DC UNDERVOLTAGE Undervoltage controller is active 13 DIRECTION LOCK Rotation direction if fixed by parameter 1003 DIRECTION 14 SERIAL COMM LOSS Serial communication through Standard Modbus Channel is lost e Check connections between external control system and the ACS 160 e Refer to parameters 5204 COMM FAULT TIME and 5205 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 160 Last three exception response codes are stored into parameters 5213 5215 AIT LOSS Analogue input 1 loss Analogue input 1 value is less than MINIMUM Al1 1301 See
113. rence EXT REF2 SELECT 1106 EXT REF2 SELECT 1106 Target window frequency reference ICONST SPEED 3 1204 CONST SPEED 3 1204 Homing frequency reference ICONST SPEED 6 1207 CONST SPEED 6 1207 Acceleration time IACCELER TIME 1 2202 IACCELER TIME 2 2204 Deceleration time DECELER TIME 1 2203 DECELER TIME 2 2205 Note When Ext Ref 2 is seleted then values 0 1 and 2 are only ones allowed for parameter 1106 Parameter1201 CONST SPEED SEL must be set to 0 NOT SEL Parameter 2201 ACC DEC 1 2 SELECT must be set to 0 NOT SEL Frequency reference acceleration and deceleration times can be set only when the drive is stopped 102 ACS 160 User s Manual Code Description 8207 8208 TARGET 1 LO TARGET 1 HI Target position 1 reference values See example on page 100 8209 8210 TARGET 2 LO TARGET 2 HI Target position 2 reference values See example on page 100 8213 POS DELAY Stop delay scaling factor at positioning mode 9 Stop time at turning points can be scaled with this parameter If the parameter value is zero then the delay is always zero Delay ms POS DELAY 40 Positioning frequency reference Hz 8215 POS MODE Positioning mode selection 4 RELAT MOVE1 Selected target position is relative to previous target position When start command is given the position counter is first reset
114. requency reference for external reference 1 in Hz When analogue input signal is at minimum external reference 1 equals to EXT REF1 MIN See Figure 6 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 6 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 6 e If the PID Control macro is selected this parameter sets the minimum process reference e If 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 6 e If the PID Control macro is selected this parameter sets the maximum process reference e If any other macro than PID Control is selected this parameter sets the maximum frequency reference This value is given as percentage of maximum frequency 1115 REF STEP SEL Frequency reference modification selection 0 NOT SEL Reference modification is not used 1
115. reset certain faults Refer to parameter group 31 AUTOMATIC RESET Warning If an external source for start command is selected and it is active the ACS 160 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 Use of the ACS 160 without control panel If no control panel or serial communication is in use and the fault persists check the following e Motor cable connections for possible short circuit e The supply voltage and cables e If analogue input is used check the DIP switch settings ACS 160 User s Manual 107 Table 8 Alarms Alarm Name Description 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 START ACTIVE Control panel function is not allowed while start is active 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 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 configu
116. rious markings used to verify the correct usage of directives and rules CE Marking A CE mark is attached to ACS 160 frequency converters to verify that the unit follows the provisions of the European Low Voltage and EMC Directives Directive 73 23 EEC as amended by 93 68 EEC and Directive 89 336 EEC as amended by 93 68 EEC ACS 160 User s Manual 119 To ensure compatibility follow the instructions given in this manual and the instructions delivered with different accessories 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 Motor Cable wall mounting 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 32 Insulation jacket Copper wire screen Helix of copper tape Inner insulation Cable core Figure 32 Minimum requirement for motor cable screen e g MCMK NK Cables 120 ACS 160 User s M
117. rnenee erene 95 Group 52 Standard Modbus 96 Group 54 Braking Electromechanical Brake Control 98 Group 82 Positioning n 100 Diagnostics oi savani tensiestenaatadaasaceatinandedaccenterecetstavanave 107 General ascents conga ihe sett ein aaa ees 107 Alarm and Fault displays 107 Fault Resetting nn 107 AppendiX Ay usi nine cesov neia et ovaden ri cicevecwscustavecets 113 Control SigNalS ss asist a t either trade tienne 113 Appendix ARS 117 DIMBNSIONS ssusiverseccrenrresasenennnenndeenegeuese 117 Motor Mounted a 117 Wall mounted i208 sala ear Waa ana rte ea ds 118 Appendix C ai raaa a apa rana aa Naana paranana sanaat sasari 119 EMC Instructions and Maximum Cable Lengths 119 ACS 160 User s Manual vii viii ACS 160 User s Manual Introduction About this manual The User s Manual is intended for those installing commissioning and using the ACS 160 frequency converter The user is expected to have basic knowledge of electrical principles and wiring practices This manual is divided into three parts Installation Start up and Programming Installation part consists of Step by Step Instructions for installing the ACS 160 and of Reference Sections detailing the installation process Start up section gives instructions
118. ro 0 As default digital input DI 2 is deactivated and the rotation direction is forward To reverse the rotation direction activate DI 2 Output frequency is controlled by analogue input AI 1 For further information on I O settings refer to the section on Application Macros 7 Stop the drive from I O To stop the drive deactivate digital input DI 1 Factory macro 0 26 ACS 160 User s Manual Programming Local and Remote Control The ACS 160 drive can be in two alternative control modes e In remote control mode the drive is controlled externally through the digital and analogue inputs or through serial communication This mode is active when REM is visible on the control panel display e In local control mode the drive is controlled from the keypad of the drive s own control panel This mode is active when LOC is visible on the control panel display User can change between local and remote control modes by pressing the MENU and ENTER buttons simultaneously External Control Locations In remote control mode the drive can accept controlling commands from two alternative external locations These external locations are called EXT1 and EXT2 In the simplest applications the drive always receives controlling commands from EXT1 The EXT2 control location is needed in complex applications like PID control For both external control locations it is possible to define separately from which source the drive is receiving the
119. rvised parameter 3204 82 ACS 160 User s Manual Value of supervised parameter hi 3203 low 3202 A Energised 1 De energised 0 B 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 19 Operating data supervision using relay outputs when LOW lt HIGH ACS 160 User s Manual 83 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 1401 RELAY OUTPUT 1 1402 RELAY OUTPUT 2 value is SUPRV1 UNDER Or SUPRV2 UNDER Note Case LOW gt HIGH represents a special hysteresis with two separate supervision limits Depending on whether the supervised signal has gone below value HIGH 3203 or above value LOW 3202 determines which limit is being used Initially HIGH is used until the signal goes above value LOW After this the limit used is LOW until the signal goes back below value HIGH A Initially t
120. ser documentation delivered with the unit ACS 160 User s Manual 1 ACS 160 User s 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 160 you need the following Wall mounting screwdrivers wire stripper tape measure drill Z 5 mm 0 20 in screws cable glands Motor mounting screwdrivers wire stripper tape measure drill cable glands 8 mm 0 31 in wrench At this point it is a good idea to check the motor parameters and write them down supply voltage UN Nominal current IN Nominal frequency Fn cos phi nominal power and nominal speed Unpacking the unit Check that there are no sign of damage Before attempting installation and operation check the information on the ACS 160 nameplate to ensure that the unit is of the correct model See B Depending on the type of unit you have purchased check that you have received all the necessary parts The delivery package should include the unit itself this manual and a detachable Quick Installation and Start up Guide The Quick Guide gives a summary of the installation instructions described here The wall mounted unit is already equipped with a wall mounting kit For a motor mounted unit you will need a motor mounting kit In addition cable glands of appropriate sizes are ne
121. set 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 the drive cannot be changed from remote mode to local mode O 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 1608 DISPLAY ALARMS Controls the visibility of some of the alarms see Diagnostics 0 NO Some of the alarms are suppressed 1 lt YES All of the alarms are enabled ACS 160 User s Manual 69 Group 20 Limits Code Description 2003 MAX CURRENT Maximum output current The maximum output current that the ACS 160 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 limit the overvoltage controller automatically decreases the braking torque by increasing output frequency Caution If a braking resistor is connected to the ACS 160 this parameter value must be set to 0 to enable proper operation of the chopper Do not set this parameter to 0 if braking resistor is not connected O DISABLE 1 ENABLE 2006 UNDERVOLT CTRL DC undervoltage controller enable If the DC bus voltage drops due to loss of input
122. stop bits With Modbus communication the number of stop bits is 2 with no parity bit and 1 with even or odd parity 0 NONE 1 EVEN 2 ODD 5204 COMM FAULT TIME Communication time out delay When communication link is lost after the time set by COMM FAULT TIME the communication fault function is activated Parameter 5205 COMM FAULT FUNC 96 ACS 160 User s Manual Code Description 5205 COMM FAULT FUNC Communication fault function O NOT SEL No operation 1 FAULT A fault indication is displayed and the ACS 160 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 160 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 5206 BAD MESSAGES This diagnostics counter increases by one every time the ACS 160 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 160 During normal operation this counter is increasing constantly 5208 BUFFER OVERRUNS Longest possible m
123. t 1 programmable p ROTA he Default operation Fault gt open RO1B 7 Relay output 2 programmable 5 ROZA Jis Default operation Running gt closed RO2B 19 Constant speed selection 0 open 1 connected DI3 DI4 Output Reference through Al1 Constant speed 1 1202 Constant speed 2 1203 Constant speed 3 1204 O 090 o Alternate default parameter values 1001 EXT 1 COMMANDS 9 DI1F 2R 1201 CONST SPEED SEL 1002 EXT 2 COMMANDS O NOT SEL 1402 RELAY OUTPUT 2 1003 DIRECTION 3 REQUEST 1601 RUN ENABLE 1102 EXT1 EXT2 SEL 6 EXT1 1604 FAULT RESET SEL 1103 EXT REF1 SELECT 1 A11 2105 PREMAGN SEL 1106 EXT REF2 SELECT O KEYPAD 2201 ACC DEC 1 2 SEL 38 ACS 160 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 e Start stop and direction e An output AO Frequency DI1 2 e Reference up DI3 e Relay output 1 Fault e Reference down DI4 e Relay output 2 Running e Preset speed selection DI5 Connection example SCR 1 Not used AH 2 AGND 3 Reference voltage 10 VDC anv s Not used AGND 5 Output freguency 0 20 mA lt gt 0
124. t m ft m ft m ft m ft m ft m ft m ft ACS 163 1K1 3 E V 10 33 10 33 10 33 10 33 5 16 5 16 5 16 5 16 ACS 163 1K6 3 E V 10 33 10 33 10 33 10 33 5 16 5 16 5 16 5 16 ACS 163 2K1 3 E V 10 33 10 33 10 33 10 33 5 16 5 16 5 16 5 16 ACS 163 2K7 3 E 10 33 10 33 10 33 10 33 5 16 5 16 5 16 5 16 ACS 163 4K1 3 E V 10 33 10 33 10 33 10 33 5 16 5 16 5 16 5 16 ACS 160 User s Manual 123 Non compliance with EN 61800 3 EMC Standard When EMC requirements do not need to be fulfilled the maximum motor cable lengths are specified in Table 12 below Table 12 Maximum motor cable lengths m ft Wall mounting without Input voltage EMC filter Switching frequency 400 V 500 V T 4 kHz 8kHz 4kHz 8kHz ype m ft m ft m ft m ft ACS 163 1K1 3 D U 40 131 20 66 20 66 10 33 ACS 163 1K6 3 D U 60 197 40 131 20 66 10 33 ACS 163 2K1 3 D U 80 262 60 197 20 66 10 33 ACS 163 2K7 3 D 100 328 80 262 40 131 30 98 ACS 163 4K1 3 D U 100 328 100 328 80 262 80 262 Output chokes can be used to increase motor cable length as specified in Table 13 The enclosure rating for output chokes is IP20 Table 13 Maximum motor cable lengths with output chokes m ft Type Input choke output choke 1 ja sare na ACS 163 1K1 3 D U ACS CHK A3 ACS CHK B3 60 197 ACS 163 1K6 3 D U ACS CHK A3
125. tant 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 ACS160 TEMP Relay is energised when ACS 160 overtemperature alarm or fault exists 66 ACS 160 User s Manual Code Description 21 ACS OVERLOAD Relay is energised when ACS 160 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 energised 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 30 reserved 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 32 MEC BR CNTRL Relay is used to control electromechanical brake Refer to Group 54 Braking for more information 33 BCH FAULT Relay is de energised if brake resistor is overloaded Refer to brake resistor instructions for more information 3
126. the ACS 160 Note Faults are indicated by a red blinking LED and are reset by turning the power off for a while ACS 160 User s Manual 111 112 ACS 160 User s Manual Appendix A Control signals The drive can receive its control signals through the digital and analogue inputs from the control panel or through serial communications Using parameters in groups 10 11 12 and 16 it is possible to define sources for start and stop signal direction frequency reference run enable signal EXT1 EXT2 selection signal and for fault reset signal Figure 29 illustrates this principle showing how the parameters are used to select sources for controlling signals By selecting application macro using parameter 9902 APP MACRO the values of the parameters are set to their macro dependent values Figure 30 and Figure 31 show how drive s internal signals are affected when various macros are selected EXT REF1 EXT1 ExT2 EXT REF2 CONST SP KEYPAD SELECT SELECT SELECT SELECT REF SEL Control 1106 1103 1102 1201 1101 Terminals 1 I Al1 2 DI1 5 EXT1 l Analogue i KEYPAD EXT2 1 I puts f ail Remote Al1 2 DI1 5 ns l DI1 DI5 Min freq Max fre Digital KEYPAD Applic l Local k inputs Local l PID Const Crit speed poges Acc Dec i i l l REF2 REF1 Hz K
127. tons simultaneously when in parameter set mode 0130 OLDEST FAULT Oldest recorded fault See Diagnostics 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 160 in thousands of hours kh 0137 MWh COUNTER Counts the megawatt hours of ACS 160 in operation ACS 160 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 section Local and Remote Control and Appendix A Code Description 1001 EXT1 COMMANDS Defines the connections and the source of Start Stop Direction commands for External control location 1 EXT1 0 NOT SEL No Start Stop Direction command source for ExT1 is se
128. tor rating plate This parameter sets the maximum output voltage supplied to motor by ACS 160 MOTOR NOM FREQ sets the frequency at which output voltage is equal to the MOTOR NOM VOLT The ACS 160 cannot supply the motor with a voltage greater than the mains voltage See Figure 4 9906 MOTOR NOM CURR Nominal motor current from rating plate The allowed range is 0 5 Iy 1 5 IN Where In is the nominal current of the ACS 160 9907 MOTOR NOM FREQ Nominal motor frequency from rating plate field weakening point See Figure 4 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 eo i MOTOR NOM FREQ B Output frequency Figure 4 Output voltage as a function of output frequency ACS 160 User s Manual 55 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
129. tor thermal protection function which protects the motor from overheating 0 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 160 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 13 shows motor thermal time definition If thermal protection according to UL requirements for NEMA class motors is desired use this rule of thumb MOTOR THERM TIME equals 35 times t6 t6 in seconds is the time that the motor can safely operate at six times its rated current given by the motor manufacturer The thermal time for a Class 10 trip curve is 350 s for a Class 20 trip curve 700 s and for a Class 30 trip curve 1050 s Motor load A Temp Rise i 100 2 68 t Mot therm time Figure 13 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 dif
130. tput AO Frequency T DI2 4 AN 0 10 V e Two an references Al1 Al2 e Relay output 1 Fault Al2 10 4 20 mA e Control location selection DI3 Relay output 2 Running Connection example SCR 1 External Reference 1 0 10 V lt gt 0 50 Hz Hand Control AH 2 Ta z AGND 3 1 Reference voltage 10 VDC 410V 4 External reference 2 0 20 mA lt gt 0 50 Hz Auto Control Al2 5 O AGND 6 Output frequency 0 20 mA lt gt 0 50 Hz AO1 7 A AGND 8 24 VDC 24V 9 DCOM 10 Start Stop Activate to start ACS 160 Hand DIT 11 Forward Reverse Activate to reverse rotation direction Hand DI 12 EXT1 EXT2 Selection Activate to select auto control DI3 13 Forward Reverse Auto DI4 14 Start Stop Activate to start ACS 160 Auto DI5 15 Relay output 1 programmable ROTA 16 Default operation Fault gt open _ RO1B 17 Relay output 2 programmable ROZA fis Default operation Running gt closed RO2B 19 Note Parameter 2107 START INHIBIT should be 0 OFF Hand Auto default parameter values 1001 EXT 1 COMMANDS 1201 CONST SPEED SEL O NOT SEL 1002 EXT 2 COMMANDS 1402 RELAY OUTPUT 2 2 RUN 1003 DIRECTION 1601 RUN ENABLE O NOT SEL 1102 ExT1 EXT2 SEL 1604 FAULT RESET SEL O KEYPAD 1103 EXT REF1 SELECT 2105 PREMAGN SEL O NOT SEL 1
131. ult operation At target gt closed Note After selecting the macro turn power off and then on again e The encoder should be mounted on the axis of the motor e Use parameters 8207 8210 to adjust the target positions according to the application e Described default functionality is valid from ACS 160 SW version 1 0 0 F Positioning default parameter values 1001 EXT 1 COMMANDS 1 D11 1201 COST SPEED SELL O NOT SELL 1002 EXT 2 COMMANDS 1 D11 1402 RELAY OUTPUT 2 34 AT TARGET 1003 DIRECTION 3 REQUEST 1601 RUN ENABLE O NOT SELL 1102 EXT1 EXT2 SELL 2 DI2 1604 FAULT RESET SELL 6 START STOP 1103 EXT REF1 SELECT 1 A11 2105 PRIMING SELL O NOT SELL 1106 EXT REF2 SELECT 1 A11 2201 ACT DEC 1 2 SELL O NOT SELL ACS 160 User s Manual 43 Start Stop gt Time Target pos Position counter gt Time Relay bei Closed losed Open Close Time Target pos 1 Target pos 2 gt QO Figure 2 Default operation of the Positioning Macro when positioning is active Homing Operation f tq gt T Target 1 Target 2 Home position Figure 3 Example of homing operation For separate documentation about macro positioning please contact your local ABB supplier 44 ACS 160 User s Manual Parameter Guide Set up Operating Information A Configuration v A Perf
132. unning 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 Diagnostics section 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 8 SUPRV1 UNDER Relay energised when first supervised parameter 3201 drops below the limit 3202 See Group 32 Supervision 9 SUPRV2 OVER Relay energised when second supervised parameter 3204 exceeds the limit 3206 See Group 32 Supervision 10 SUPRV2 UNDER Relay energised when second supervised parameter 3204 drops below the limit 3205 See Group 32 Supervision 11 AT SET POINT Relay energised when output freguency is egual to reference freguency 12 FAULT RST Relay energised when the ACS 160 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 on Diagnostics 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 cons
133. y of the motor By default the motor must be a three phase induction motor with Un from 380 to 500 V and fy either 50 Hz or 60 Hz The motor nominal current IN must not exceed the continuous output current lox of the ACS 160 See Q A Warning Ensure the motor is suitable for use with the ACS 160 The ACS 160 must be installed by a competent person If in doubt contact your local ABB supplier D Floating Network In IT networks do not use units which are equipped with built in RFI filter The mains become connected to earth through the filter capacitors In floating networks this may cause danger or damage the unit E Mounting the Options The optional Brake resistor Fieldbus adapter and Control panel can be attached as shown in the picture below For more detailed instructions see documentation delivered with the options Brake resistor Control panel Fieldbus adapter 8 ACS 160 User s Manual F Mounting the ACS 160 on the Wall A Wall Mounting Template is included in the box Wu BE ena V e 200 Sog 200 gt lt 21 sj D 4 sa Ad The ACS 160 should be mounted on a solid surface Ensure minimum air flow gaps of 200 mm 7 9 in and 30 mm 1 18 in as shown in the figure a above ff j 1 Using the mounting template in the package mark the position of the fixing holes 2 Drill the holes 3

Drive Low Voltage AC Drives User's Manual for type ACS 160

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