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ABB Comp-AC User's Manual ACS 400 AC Drives for Speed

1. O ea Red LED X3 RS485 connector H g Termination jumper J2 ES pla X2 Panel connector 3 X1 I O connection see nus Analog input jumper J1 2 5 9 ues 6 SETTINGS 7 8 11 o Warning sticker 12 5 1 3 Warning Dangerous voltage c Wait 5 minutes after 15 disconnecting suppl 16 before proceeding See User s Manual 17 g 18 19 20 21 22 lic o X6 Connector for DDCS fan D communication im i module ACSAOQ RA 0368 H 212 2 2 2 2 Q GND 38 1 Additional PE ground terminals provided on PE V2 W2 frame sizes R3 and R4 Figure 11 Terminal Interface F Attaching a Warning Sticker The contents of the packing box include warning stickers in different languages Attach a warning sticker in the language of your choice on the inside plastic shell as indicated above ACS 400 User s Manual
2. XN 10V Analog reference 11 Relay output 1 Fault r i V Preset speed selection 013 4 Relay output 2 Running Ramp pair 1 2 selection DI5 vva SCR 7 2 External Reference 1 0 10 V lt gt 0 50 Hz AGND cx 4 10 Reference voltage 10 VDC s 2 Not used L 7 s 41s AGND X nA Output frequency 0 20 mA lt gt 0 50 Hz s AGND 424V 24 VDC 271110 DCOM1 11 DH Start Stop Activate to start ch DI2 Fwd Rev Activate to reverse rotation direction lt 08 Constant speed selection Constant speed selection mE DIS Ramp pair selection Activate to select ramp pair 2 16 RO1C Relay ouput 1 programmable 18 Default Fault gt 17 connected to 18 19 RO1B f A Relay ouput 2 programmable 2 RO2B Default Running gt 20 connected to 22 Constant speed selection 0 open 1 connected DI3 DIA Output 0 0 Reference through AI 1 0 Const speed 1 1202 0 1 Const speed 2 1203 1 1 Const speed 3 1204 ABB Standard parameter values 9905 MOTOR NOM VOLT 400 V 50 Hz 1440 rpm 2 011 2 50 Hz 0 KEYPAD 7 013 4 50 Hz 1105 EXT REF1 MAX 9907 MOTOR NOM FREQ 1106 EXT REF2 SELECT 9908 MOTOR NOM SPEED 1201 CONST SPEED SEL 1001 EXT 1 COMMANDS 1503 AO CONTENT MAX 1002 EXT 2 COMMA
3. 17 Protection lt 18 Motor Overload 19 Drive Overload Protection 19 Specifications Gis eee ak a ee es 20 Product Conformity 22 86501166 Lus eed i sut e VL 23 Programming sce Edu eo e ais 25 ACS PAN A Control 25 Control Modesa Saeed chee uer ES uer ur Giles 25 Output Display 26 Men Ae eve det 26 Setting Parameter 27 Adjust the Panel Display Contrast 27 ACS 400 User s Manual Menu Functions i usbeSXinesnieed ive Rea tees da 28 LED INGiGators c i rac i mete ctos ta Re ee P Rs 29 Resetting the Drive from the Control Panel 29 ACS100 PAN Control Panel 31 Control Modes 31 Display 5 i aS r 32 Menu 32 Setting Parameter Value 32 Menu Functions 9 2 uaa d eec E nas teen Hebd mad 33 Resetting the Drive from the Control Panel 33 Diagnostl6s 222 35 ACS 400 Basic lt
4. 107 The Control Word 108 References e mee Booed eR RR EOM Ra 109 Status 110 Actual Values 111 Fault and Alarm Status 113 APPENDIX 252 115 Local Control vs Remote Control 115 LoGaliControl 115 Remote 116 ACS 400 User s Manual Internal Signal Connections for the Macros 117 viii ACS 400 User s Manual Installation Study these installation instructions carefully before proceeding Failure to observe the warnings and instructions may cause a malfunction or personal hazard Preparation before installation To install the ACS 400 you need the following screwdrivers wire stripper tape measure 4 pieces of 5x12 mm screws or nuts and bolts depending on the mounting surface drill At this point it is a good idea to check the motor parameters and write them down supply voltage nominal current nominal frequency and nominal speed Unpacking the unit The ACS 400 is packed with this User s Manual Conduit Plate Warning Stickers and a separate Installation Guide The Installation Guide gives a summary of the installation instructions described here T
5. 42 o 2 2 ACS 400 User s Manual Reference Sections A Installation Environment Stationary Use Ambient temperature 32 104 F 0 40 C Max ambient temperature 122 F 50 C if Py and 1 derated to 90 Installation altitude 0 3300 ft 1000 m if Py andl 100 Installation altitude 3300 6600ft 1000 2000 m if P and l derated 1 every 330 ft 100 m above 3300 ft 1000 m Relative humidity less than 9596 non condensing The ACS 400 must be installed in a heated indoor controlled environment that is suitable for the selected enclosure Drives are available in either an IP21 NEMA1 or IP54 NEMA12 enclosure The drive must be protected from airborne dust corrosive gases or liquids and conductive contaminants such as condensation carbon dust and metallic particles The IP54 NEMA12 enclosure provides protection from airborne dust and light sprays or splashing water from all directions Storage and Transportation Storage Temperature 40 158 F 40 70 C Transportation Temperature 40 158 F 40 70 C ACS 400 User s Manual B Dimensions in mm Units with IP 21 NEMA 1 Enclosures ES H2 1 SIDE Figure 2 IP 21 NEMA 1 enclosures Table 1 Di
6. 37 Application Macros 41 Application Macro Factory 0 42 Application Macro Factory 1 43 Application Macro ABB 5 44 Application Macro 3 wire 45 Application Macro Alternate 46 Application Macro Motor Potentiometer 47 Application Macro Hand Auto 48 Application Macro PID Control 49 Application Macro Premagnetize 50 ACS 400 Complete Parameter 16 51 Group 99 Start up 57 Group 01 Operating Data 58 Group 10 Command Inputs 60 Group 11 Reference 62 Group 12 Constant 66 Group 13 Analog 67 Group 14 Relay Outputs 68 Group 15 Analog 70 Group 16 System 71 Group 20 LIMIS apes tI eet ades 72 Group 21 5 73 vi ACS 400 User s Manual Group 22 74 Group 2
7. Min freq Digital KEYPAD PID Max freq inputs _ ____ Local Applic Const sp Speeds Acc Dec AH 2 12 ACTUALT INPUT SE REF2 96 i 4 ACTUAL i ACTUAL 2 VAL SEL 1 2 INPUT SEL 4006 n 4008 i Ref i Loc Rem 252505556 Start Stop Direction TN W NOT SEL Local d Start Stop LA DM REQUEST CN w Remote FORWARD Direction M 24 NOT SEL 2 HT Diese REVERSE KEYPAD EXT EXT2 DIRECTION RUN ENABLE COMMANDS FEMMANDS 1003 1601 Figure 47 The control signal connections of the PID Control macro 118 EP ED FADED 3AUA489002B5310 R0101 Rev A ACS400 US 04 Effective 2 1 99 ABB Drives amp Power Products 16250 W Glendale Drive New Berlin WI 53151 Telephone 414 785 8378 800 243 4384 Fax 414 780 5135
8. 40001 40099 are reserved for drive control registers 40101 40199 is reserved for the actual values parameter group 1 40201 40299 is reserved for parameter group 2 40301 40399 is reserved for fault and alarm information other parameter groups 49901 49999 is reserved for the start up data Register addresses 4GGPP are shown in Table 18 In this table GG is the group number and PP is the parameter number within the group Table 18 Parameter mapping 4GGPP GG PP 40001 40006 00 Drive control registers 01 Control word 02 Reference 1 03 Reference 2 04 Status word 05 Actual value 1 06 Actual value 2 40102 40130 01 OPERATING DATA 02 SPEED 30 OLDEST FAULT 41001 41003 10 COMMAND INPUTS 01 EXT1 COMMANDS 02 EXT2 COMMANDS 03 DIRECTION 41101 41108 11 REFERENCE SELECT 01 KEYPAD REF SEL 08 CONST SPEED 7 49901 49908 99 START UP DATA 02 APPLIC MACRO 08 MOTOR NOM SPEED The register addresses between the groups are invalid No reads or writes are allowed for these addresses If there is an attempt to read or write outside the parameter addresses the Modbus interface will return an exception code to the controller 106 ACS 400 User s Manual Exception Codes The ACS 400 supports the standard Modbus exception codes These are shown in Table 19 Table 19 Exception codes VALUE Code Name Meaning 01 ILLEGAL
9. GND 2 AGND B SCR A GND SEA SCR 16 ACS 400 User s Manual M Replacing the Cover Do not turn the power on before replacing the front cover Replacing the front cover for IP21 NEMA 1 1 First locate the bottom mounting clips 2 Click the retaining lever to its place 3 Replace the control panel Replacing the front cover to IP 21 NEMA 1 units from size ACS401 x016 3 x and up 1 Hook the bottom end fingers of the lower part of the front cover 2 Click the retaining lever to its place 3 Hook the bottom end fingers 4 Click the retaining levers into place 5 Replace the control panel if available Replacing the front cover for IP54 NEMA 12 1 Replace the control panel 2 Replace the front cover N Applying Power When power is applied to the ACS 400 the green LED comes on Note Before increasing motor speed check that the motor is running in desired direction O Environmental Information The package is made of corrugated cardboard and can be recycled ACS 400 User s Manual 17 P Protection Features The ACS 400 has a number of protective features Overcurrent Overvoltage Undervoltage Overtemperature Output ground fault Output short circuit Input phase loss 3 l O terminal short circuit protection Motor overload protection see Section Q Output overload protection see Section R Stall protection Underloa
10. Note DI 4 is used to configure ACS 400 It is read only once when power is connected When DI 4 is connected 1 the following applies All parameters marked are determined by the DIA input Motor nominal values are 480 V and 60 Hz and 1720 rpm Input and output signals are scaled according to 60 Hz Maximum frequency is 60 Hz Note Remote stop signal must be present to activate start stop in local mode Factory 1 parameter values 9905 MOTOR NOM VOLT 480 V 1105 EXT REF1 MAX 60 Hz 9907 MOTOR NOM FREQ 60 Hz 1106 EXT REF2 SELECT 0 KEYPAD 9908 MOTOR NOM SPEED 1720 rpm 1201 CONST SPEED SEL 0 NOT SEL 1001 EXT 1 COMMANDS 4 DI1P 2P P 1503 AO CONTENT MAX 60 Hz 1002 EXT 2 COMMANDS 0 NOT SEL 1601 RUN ENABLE 0 NOT SEL 1003 DIRECTION 3 REQUEST 1604 FAULT RESET SEL 6 START STOP 2008 MAXIMUM FREQ 60 Hz 1102 EXT1 EXT2 SEL 6 ExT1 2105 PREMAGN SEL 0 NOT SEL 1103 EXT REF1 SELECT 1 11 2201 1 2 SEL 5 015 ACS 400 User s Manual 43 Application Macro ABB Standard This general purpose macro provides two more preset speeds compared to Factory Macro 0 Note The value of parameter 9902 is 1 ABB STANDARD Input signals Output signals jumper S1 Start stop and direction 011 2 An output AO Frequency
11. The contents of the Control Word is presented in the following table The text in italics refers to the states in Figure 43 Table 21 The Control Word Bit Value Description 0 1 Enter READY TO OPERATE 0 Emergency OFF Ramp to stop according to parameter 2203 DECELER TIME 1 Enter OFF1 ACTIVE proceed to READY TO SWITCH ON unless other interlocks OFF2 are active 1 1 Continue operation OFF2 inactive 0 Emergency OFF coast to stop Enter OFF2 ACTIVE proceed to SWITCH ON INHIBITED 2 1 Continue operation OFF3 inactive 0 Emergency stop Drive ramps to stop according to parameter 2205 DECELER TIME 2 Enter OFF3 ACTIVE proceed to SWITCH ON INHIBITED 3 0 1 Enter OPERATION ENABLED Note that also the Run enable signal must be present on a digital input see parameter 1601 RUN ENABLE 0 Inhibit operation Enter OPERATION INHIBITED Unused 1 Normal operation Enter RAMP FUNCTION GENERATOR ACCELERATOR ENABLED 0 Halt ramping Ramp Function Generator output held 6 1 Normal operation Enter OPERATING 0 Force Ramp Function Generator input to zero 7 0 1 Fault reset enter SWITCH ON INHIBITED 0 Continue normal operation 8 to 10 Unused 11 1 Select external control location 2 EXT2 0 Select external control location 1 EXT1 12to 15 Unused Note Control and status word operation conforms to ABB Drives Profile with th
12. I9 Overvoltage Running Start inhibit Undervoltage Running 200 corresponds to 142 VAC input Start inhibit 230 corresponds to 162VAC input 55 eat sin Power 10 AWG6 16 AWG4 Terminals stranded stranded Torque Torque 1 3 1 5Nm 1 5 1 8Nm Control Terminals 0 5 1 5 AWG22 AWG16 Torque 0 4 Nm 420 corresponds to 295 VAC input 390 corresponts to 276 V input 35 AWG2 m stranded Torque 3 2 3 7Nm p uw D frowertosses fw s fe 1s gt e gt 20 ACS 400 User s Manual 400 V series 3 Input 380V 480V ACS401 10 50 60 Hz 006 X009 3 2 3 2 Frame size Nominal ratings See G Nominal motor Normal Duty Input current l4 NND Output current loNND Max output current louNDmax Nominal motor Heavy Duty Input current 1 Output current lon Max output current lonmax Output voltage Vo 0 V4 Switching 4 Standard frequency 8 Low noise Protection limits Overcurrent peak A 20 3 27 5 37 48 64 76 99 125 145 195 Overvoltage Running V DC 842 corresponds to 624 VAC input Start inhibit V DC 661 in input voltage range 380 415 VAC 765 in input voltage range 440 480 VAC Undervoltage Running V DC 333 corresponds to 247 VAC input
13. Output frequency A MAXIMUM FREQ Linear S curve Time Ramp time Figure 26 Definition of acceleration deceleration ramp time 74 ACS 400 User s Manual Group 25 Critical Freq In some mechanical systems certain speed ranges can cause resonance problems With this parameter group it is possible to set up to two different speed ranges that the ACS 400 will skip over Code Description 2501 CRIT FREQ SEL Critical frequencies activation OFF 1 ON 2502 CRIT FREQ 1 LO Critical frequency 1 start Note If LOW gt HI no critical frequency lock out will occur 2503 CRIT FREQ 1 HI Critical frequency 1 end 2504 CRIT FREQ 2 LO Critical frequency 2 start Note If LOW gt HI no critical frequency lock out will occur 2505 CRIT FREQ 2 HI Critical frequency 2 end Example A fan system vibrates badly from 18 Hz to 23 Hz and from 46 Hz to 52 Hz Set the parameters as follows CRIT FREQ 1 LO 18 Hz and CRIT FREQ 1 HI 23 Hz CRIT FREQ 2 LO 46 Hz and CRIT FREQ 2 HI 52 Hz foutput frer HL fL 2H gt frer Hz 18 23 46 52 Figure 27 Example of critical frequencies setting in a fan system with bad vibrations at frequency ranges 18 Hz to 23 Hz and 46 Hz to 52 Hz ACS 400 User s Manual 75 Group 26 Motor Control Code Descripti
14. Range is 0 1 1800 s Default value 60 0 s Group 26 MOTOR CONTROL 2606 V f RATIO V f below field weakening point 1 LINEAR 2 SQUARE LINEAR is used for constant torque applications SQUARE is used for centrifugal pump and fan applications to increase motor efficiency and to reduce motor noise Default value 1 LINEAR Group 33 INFORMATION 3301 SW VERSION Software version code S Parameters which can be modified only when the drive is stopped 40 ACS 400 User s Guide Application Macros Application Macros are preprogrammed parameter sets They minimize the number of different parameters to be set during start up 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 parameter values that are determined by the digital input 014 cannot be modified Parameter Values Selecting an application macro with parameter 9902 APPLIC MACRO will set all other parameters except the language selection 9901 the parameter lock 1602 and groups 50 and 52 serial communication parameters to their default values Default values of certain parameters depend on the selected macro These are listed with the description of each macro Default values for other parameters are given in ACS 400 Complete Parameter List starting on page 51 Conn
15. Default Fault gt 17 connected 18 Relay ouput 2 programmable iJ Default Running gt 20 connected to 22 Constant speed is not used while in PID control PID Jumper S1 0 10 V 0 4 20 mA EXT1 Manual or EXT2 PID reference 0 10 V Start Stop Activate to start ACS 400 Manual EXT1 EXT2 Selection Activate to select PID control Constant speed 1 not used if PID control Run enable deactivation always stops ACS 400 Start Stop Activate to start ACS 400 PID PID control parameters group 40 are not contained in the Basic parameter set PID Control parameter values 9905 MOTOR NOM VOLT 400 V 1105 EXT REF1 MAX 50Hz 9907 MOTOR NOM FREQ 50 Hz 1106 EXT REF2 SELECT 1 9908 MOTOR NOM SPEED 1440 rpm 1201 CONST SPEED SEL 3 DI3 1001 EXT 1 COMMANDS 1 pit 1503 AO CONTENT MAX 50Hz 1002 EXT 2 COMMANDS 6 DI5 1601 RUN ENABLE 4 D14 1003 DIRECTION 1 FORWARD 1604 FAULT RESET SEL 0 KEYPAD 2008 MAXIMUM FREQ 50 Hz 1102 EXT1 EXT2 SEL 2 D12 2105 PREMAGN SEL 0 NOT SEL 1103 EXT REF1 SELECT 1 A11 2201 ACC DEC 1 2 SEL 0 NOT SEL ACS 400 User s Manual 49 Application Macro Premagnetize This macro is intended for those applications where the drive must start very quickly Building up the flux in the motor always takes time Using the Premagnetize Macro will min
16. OUTPUT EARTH FAULT Output ground fault DC BUS RIPPLE DC bus ripple too high Check power supply for phase loss or imbalance UNDERLOAD Underload Reserved DDCS LINK DDCS link fault FL20 HARDWARE ERROR Hardware error Contact the factory Full display blinking ACS100 PAN COMM LOSS ACS PAN Serial link failure Bad connection between the control panel and the ACS 400 Note Faults that are indicated by a red blinking LED are reset by turning the power off and on Other faults are reset from the control panel See parameter 1604 FAULT RESET SEL 36 ACS 400 User s Manual ACS 400 Basic Parameters The ACS 400 has a large number of parameters Of these only the basic parameters are initially visible Setting up only a few basic parameters is sufficient for applications where the preprogrammed application macros of the ACS 400 can provide all desired functionality For a full description of programmable features provided by the ACS 400 see ACS 400 Complete Parameter List starting on page 51 The following table lists the basic parameters S Parameters can be modified only when the drive is stopped Code Name User Group 99 START UP DATA 9901 LANGUAGE Language selection 0 ENGLISH UK 4 SPANISH 8 DANISH 12 reserved 1 ENGLISH US 5 PORTUGUESE 9 FINNISH 2 GERMAN 6 DUTCH 10 SWEDISH 3 ITALIAN 7 FRENC
17. 3600 s 0 15 1 6 1404 RELAY 1 OFF DELAY 0 3600s 0 15 15 6 1405 RELAY 2 ON DELAY 0 3600 s 0 15 1 6 1406 RELAY 2 OFF DELAY 0 3600 s 0 15 15 6 Group 15 ANALOG OUTPUT 1501 CONTENT 102 137 1 103 1502 CONTENT MIN 0 0 Hz 1503 AO CONTENT MAX 7 1504 0 0 20 0 mA 0 1 mA 1505 MAXIMUM 0 0 20 0 mA 0 1 mA 20 0 mA 1506 FILTER AO 0 10s 0 15 0 15 Group 16 SYSTEM CONTROLS 1601 RUN ENABLE 0 6 1 1602 PARAMETER LOCK 0 2 1 1 OPEN 1604 FAULT RESET SEL 0 7 1 li 1605 LOCAL Lock 0 1 1 0 OPEN 20 LIMITS 2003 CURRENT 0 5 ly 1 66 ly 0 1A 1 5 Iu 2005 OVERVOLT CTRL 0 1 1 1 ENABLE 2006 UNDERVOLT CTRL 0 2 1 1 ENABLE TIME 2007 MINIMUM FREQ 0 250Hz 1Hz 0 Hz 2008 MAXIMUM FREQ 0 250Hz 1Hz Group 21 START STOP 2101 START FUNCTION 1 4 1 1 RAMP 2102 STOP FUNCTION 1 2 1 1 COAST 2103 TORQ BOOST CURR 0 5 ly 1 8 ln 0 1A 1 2 ly 2104 STOP DC INJ TIME 0 250 s 0 1 1s Os 2105 PREMAGN SEL 0 6 1 2106 PREMAGN MAX TIME 0 0 25 0 s 0 1s 2 0s 2107 START INHIBIT 0 1 1 1 ON ACS 400 User s Manual 53 Code Range Resolution Default User S M Group 22 ACCEL DECEL 2201 ACC DEC 1 2 SEL 0 5 1 li viv 2202 ACCELER TIME 1 0 1 1800s 0 1 15 55 2203 DECELER TIME 1 0 1
18. 7 DI4U 5D Same as above except that the digital inputs in use are DI4 and DI5 8 COMM reference is given through serial communication 9 COMM Al1 10 COMM The reference is given through serial communication The analog input 1 signal is combined to the fieldbus reference sum or multiplication For more information see chapter Standard Serial Communication on page 95 ACS 400 User s Manual 63 1104 EXT REF1 MIN Sets the minimum frequency reference for external reference 1 in Hz When analog input signal is at minimum external reference 1 equals to EXT REF1 MIN See Figure 22 on page 65 1105 EXT REF1 MAX Sets the maximum frequency reference for external reference 1 in Hz When analog input signal is at maximum external reference 1 equals to EXT REF1 MAX See Figure 22 on page 65 1106 EXT REF2 SELECT This parameter selects the signal source for external reference 2 The alternatives are the same as with external reference 1 1107 EXT REF2 MIN Sets the minimum reference in When analog input signal is at minimum value external reference 2 equals to EXT REF2 MIN See Figure 22 If the PID Control macro is selected this parameter sets the minimum process reference 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 r
19. ACS 400 User s Manual 33 34 ACS 400 User s Manual Diagnostics The ACS 400 alarms and faults are described in Table 5 and Table 6 respectively The ACS100 PAN control panel displays only the alarm and fault codes The alarm and fault messages are displayed only by the ACS PAN A control panel Alarms AL1 7 arise from button operation The green LED blinks for faults greater than AL7 indicating the ACS 400 cannot follow the control command Table 5 Alarms Code Message Description OPERATION FAILED Parameter upload download failed START ACTIVE Operation not allowed while start is active LOCAL REMOTE Operation not allowed in current control mode Local or Remote BUTTON DISABLED Start Stop Direction or reference from control panel is not followed Possible causes Remote mode parameters disable the buttons see APPENDIX Local mode START STOP button interlocked from digital inputs Local mode Shaft direction is fixed by parameter 1003 DIRECTION PARAMETER LOCK Operation not allowed Parameter 1602 PARAMETER LOCK or 1605 LOCAL LOCK is active FACTORY MACRO Use of factory macro disables operation OVERCURRENT Overcurrent controller active OVERVOLTAGE Overvoltage controller active DC UNDERVOLTAGE Undervoltage controller active DIRECTION LOCK Direction lock See parameter 1003 DIRECTION SERIAL COMM LOSS Serial communication loss
20. ACS 400 User s Manual 111 From any state From any state From any state Emergency Stop Emergency Off Fault OFF3 CW Bit2 0 OFF2 CW Bit1 0 OFF3 OFF2 W Bit4 W Bit3 1 SW Bit5 0 ACTIVE ACTIVE SW Bit4 0 FAULT SW Bit3 1 0 10 CW Bit7 1 From any state OFF1 CW Bit0 0 SWITCH ON POWER OFF INHIBITED SW Bit6 1 1 1 0 Power ON CW Bit0 0 gt A NOT READY TO SWITCH SW Bit0 0 CW Bit3 0 CW xxxx xxxx x110 CW xxxx xxxx x111 gt 320 OPERATION READY TO E SW Bit2 0 INBIBITED SW Bit0 1 C D READY TO OPERATE SW Bit1 1 CW Bit5 0 CW Bit3 1 and ll SW Bit12 1 OPERATION 25 ENABLED Sw Biz CW Bit6 0 A CW Bit5 1 RFG ACCELERATOR ENABLED CW Bit6 1 OPERATING SW Bit8 1 This state transition occurs also if the fault is reset D from any other source e g digital input State Output current CW Control Word f Output frequency SW Status Word RFG Ramp Function Generator Figure 43 The state machine for evaluation of start and stop signals 112 ACS 400 User s Manual Fault and Alarm Status The ACS 400 provides fault and alarm status words that are accessible only from the serial communication link not from the control panel These status words are located in place of parameter group Modbus holding registers 40301 40309
21. COMMANDS COMMANDS 1003 1601 1001 1002 Figure 45 Selecting control location and control source 116 Internal Signal Connections for the Macros EXT REF2 EXT REF1 EXT1 EXT2 CONST SP SELECT SELECT SELECT SELECT REF SEL X 1106 1103 1102 1201 1101 ExT 1013 4 AM EXT l Analog KEYPAD inputs EXT2 Remote 1 2 DAI 2DI 5 po DA Min freq Digital KEYPAD A Max freq inputs Const Crit sp BE speeds Acc Dec REF2 i i REF1 Hz Keypad Ref Loc Rem L 1 Nee ee Start Stop Direction 1 1 Start Stop NOT SEL Local DI1 DI5 EXT N REQUEST T GM Remote FORWARD Direction KEYPAD NOT SEL i DI1 DI5 EXT2 REVERSE b Enabled AENEA DI1 DI5 EXT ANDS EXTA NDS DIRECTION RUN ENABLE 1601 1002 1003 1601 Figure 46 The control signal connections of the ABB Standard Alternate and Premagnetize macros 117 EXT REF2 EXT REF1 EXT1 EXT2 CONST KEYPAD SELECT SELECT SEL SPEED SEL REF SEL 1106 1103 1102 1201 1101 Control iDI2 Terminal erminals AH EXT Analog KEYPAD inputs 2 Remote LAM
22. The maximum input signal runs the drive at maximum reference in the forward direction See Figure 21 See also parameter 1003 DIRECTION Caution Minimum reference for joystick should be 0 3 V 0 6 mA or higher If a 0 10 V signal is used the ACS 400 will operate at maximum reference in the reverse direction if the control signal is lost Set parameter 1301 MINIMUM to a value 0 3 V or higher and parameter 3001 AI MIN FUNCTION to 1 FAULT and the ACS 400 will stop in case the control signal is lost A EXT REF 1 MAX EXT REF 1 MIN gt EXT REF 1 MIN 10 V 20 mA EXT REF 1 MAX Hysteresis 4 96 of Full Scale v 2V 4mA EXT REF 1 MIN 0V 0mA 2 2 96 EXT REF 1 MIN Figure 21 Joystick control Maximum for external reference 1 is set with Parameter 1105 and minimum with Parameter 1104 5 DISU 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 014 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 0130 40 Same as above except that the speed reference is not reset to zero on a Stop command When the 400 is started the motor will ramp up at the selected acceleration rate to the stored reference
23. These registers also contain copies of the Control Word 40001 and Status Word 40004 Registers 40301 40309 are generally read only type however alarm words can be reset by writing zero into the register Table 24 lists the fault and alarm words Table 24 Fault and alarm status words No Name Description 40301 MAIN CONTROL WORD Read only copy of the Control page 108 Word 40001 See 40302 MAIN STATUS WORD Read only copy of the Status Word 40004 See page 110 40305 FAULT WORD 1 Fault information When a fau t is active corresponding bit is set Bit descriptions are given in Table 25 40306 FAULT WORD 2 Fault information When a fau t is active corresponding bit is set Bit descriptions are given in Table 25 40308 ALARM WORD 1 Alarm information When an a arm is active corresponding bit is set Bits remain set until whole alarm word is reset by writing 0 to it See Table 26 40309 ALARM WORD 2 Alarm information When an a arm is active corresponding bit is set Bits remain set until whole alarm word is reset by writing 0 to it See Table 26 Table 25 Bit descriptions for fault words 1 and 2 Bit Fault Word 1 Fault Word 2 Overcurrent Underload DC overvoltage Reserved ACS 400 overtemperature DDCS link Fault current Reserved Output overload DC undervoltage Analo
24. 1 REF1 Hz or Keypad Reference 2 REF2 EXT1 EXT2 Start Stop Direction Start Stop Direction External Reference 1 Hz External Reference 2 Figure 44 Control locations Local Control The control commands are given explicitly from the control panel when the ACS 400 is in local control Parameter 1101 KEYPAD REF SEL is used to select keypad reference which can be either REF1 Hz or REF2 If REF1 Hz is selected the type of reference is frequency and it is given to the ACS 400 in Hz If REF2 is selected the reference is given in percent If PID Control macro is used reference REF2 is fed directly to the PID controller as percentage Otherwise reference REF2 is converted to frequency so that 100 corresponds to MAXIMUM FREQ parameter 2008 115 Remote Control When the ACS 400 is in remote control REM the commands are given primarily through digital and analog inputs although commands can be given also through the control panel or serial communication Parameter 1102 EXT1 EXT2 SELECT selects between the two external control locations EXT1 and EXT2 For ExT1 the source of the Start Stop Direction commands is defined by parameter 1001 EXT1 COMMANDS and the reference source is defined by parameter 1103 EXT REF1 SELECT External reference 1 is always a frequency reference For EXT2 the source of the Start Stop Dir
25. 1800s 0 1 15 55 2204 ACCELER TIME 2 0 1 1800s 0 1 15 605 2205 DECELER TIME 2 0 1 1800s 0 1 15 605 2206 RAMP SHAPE 0 3 1 0 LINEAR Group 25 CRITICAL FREQ 2501 CRIT FREQ SEL 0 1 1 0 OFF 2502 CRIT FREQ 1 LO 0 250 2 1 2 0 Hz 2503 FREQ 1 HI 0 250Hz 1Hz 0 Hz 2504 CRIT FREQ 210 0 250 2 1 2 0 Hz 2505 CRIT FREQ 2 HI 0 250 Hz 1 Hz 0 Hz Group 26 MOTOR CONTROL 2603 COMPENSATION 0 30V 1 10V Y 2604 IR COMP RANGE 0 250 2 1 2 50 Hz v 2605 LOW NOISE 0 1 1 v 2606 V f RATIO 1 2 1 1 LINEAR v 2606 SLIP COMPENSATION 0 150926 1 096 Group 30 FAULT FUNCTIONS 3001 AI MIN FUNCTION 0 3 1 1 FAULT 3002 PANEL LOSS 1 3 1 1 FAULT 3003 EXTERNAL FAULT 0 5 1 0 NOT SEL 3004 MOT THERM PROT 0 2 1 1 FAULT 3005 MOT THERM TIME 256 9999 s 1s 500 s 3006 MOT LOAD CURVE 50 150 6 196 100 3007 ZERO SPEED LOAD 25 150 196 70 96 3008 BREAK POINT 1 250Hz 1Hz 35 Hz 3009 STALL FUNCTION 0 2 1 0 NOT SEL 3010 STALL CURRENT 0 5 lu 1 6671 0 1A 1 2 In 3011 STALL FREQ 0 5 50 Hz 0 1 Hz 20 Hz 3012 STALL TIME 10 400 s 1s 20s 3013 UNDERLOAD FUNC 0 2 1 0 NOT SEL 3014 UNDERLOAD TIME 10 400 s 1s 20s 3015 UNDERLOAD CURVE 1 5 1 1 54 ACS 400 User s Manual Code Name Range Resolution Default User M Group 31 AUTOMATIC RE
26. 7 66 ACS 400 User s Manual Group 13 Analog Inputs Code Description 1301 MINIMUM Relative minimum value of AI1 96 Value corresponds to minimum reference set by parameter 1104 EXT REF1 MIN or 1107 EXT REF2 MIN See Figure 22 on page 65 1302 MAXIMUM Maximum value of Al1 96 Value corresponds to maximum reference set by parameter 1105 EXT REF1 MAX or 1108 EXT REF2 MAX See Figure 22 on page 65 1303 FILTER Al1 Filter time constant for analog input Al1 As the analog input value changes 63 of the change takes place within the time specified by this parameter Note 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 76 A Unfiltered signal 100 63 EN Filtered signal gt t Time constant Figure 23 Filter time constant for analog input 1304 MINIMUM AI2 Minimum value of AI2 96 Value corresponds to minimum reference set by parameter 1104 EXT REF1 MIN or 1107 EXT REF2 MIN 1305 MAXIMUM 12 Maximum value of AI2 96 Value corresponds to maximum reference set by parameter 1105 EXT REF1 MAX or 1108 EXT REF2 MAX 1306 FILTER AI2 Filter time constant for Al2 Refer to parameter 1303 FILTER 11 ACS 400 User s Manual 67 Group 14 Relay Outputs Code Description 1401 RE
27. 9 G Type Code and Model Designation The Type Code Label is attached to the right side of the unit cover on the heat sink ABB Industrial Products Made in USA U1 380 480 V For more information see ACS400 User s Manual LISTED 45Y1 Type ACS401000432 u2 3 0 980 480 V Hin Hnnd 4716 2 6 US Code 63996611 IND CONT EQ I2n I2nnd 4 9 6 6A 1 48 63 Hz C Ser no 1982800001 12 0 250Hz Figure 12 ACS 400 type designation label gt 004 3 5 o A lo jm AC Drive Product Type S Standard industrial drive ACS 400 Product Family Input Bridge 0 6 pulse rectifier Enclosure Type 1 Wall mounted Operator Panel and Description 0 No operator panel no documentation European conduit plate 1 No operator panel US English documentation 4 US conduit plate 6 ACS PAN A operator panel US English documentation US conduit plate Rated Output Power in kVA See ACS 400 rating tables Voltage Rating 1 200 240 V AC 3 380 480 V AC Enclosure Class 2 IP21 NEMA 1 5 IP54 NEMA 12 Figure 13 Type code key A Serial number label is attached on upper part of the chokeplate between mounting holes Type ACS401000432 Code 63996611 Ser no 1982800001 Figure 14 Serial number label 10 ACS 400 User s Manual Installation of ACS 400 Gland Plates or Condu
28. DDCS link baud rate in Mbits s 5002 DDCS NODE NR DDCS link node number 5003 COMM FAULT TIME Communication time out delay This applies both to standard Modbus and DDCS link 5004 COMM FAULT FUNC Communication fault function This applies both to standard Modbus and DDCS link 0 NOT SEL No operation 1 FAULT A fault indication is displayed and the ACS 400 coasts to stop 2 CONST SP 7 A warning indication is displayed and the speed is set according to parameter 1208 CONST SPEED7 LAST SPEED A warning indication is displayed and the speed is set to the level the ACS 400 was last operating at This value is determined by the average speed over the last 10 seconds Caution If you select CONST SPEED 7 or LAST SPEED make sure that it is safe to continue operation if communication is lost 5005 PROTOCOL SEL Defines what communication protocols are used Options 1 DDCS and 3 STD MDB DDCS should be selected only if DDCS communication module is installed 0 NOT SEL No serial communication is active 1 DDCS DDCS serial communication is active 2 STD MODBUS Standard Modbus protocol is active 3 STD MDB DDCS Both standard Modbus and DDCS are active 5006 COMM COMMANDS This parameter controls the commands source protocol selection Although the ACS 400 can communicate simultaneously via several serial communication channels the controlling commands start stop dire
29. POWER 1 100 1 kW 1 kW Y 9910 MOTOR COS PHI 0 50 0 99 0 01 0 83 Group 01 OPERATING DATA 0102 SPEED 0 9999 rpm 1 rpm E 0103 OUTPUT FREQ 0 250 Hz 0 1 Hz 0104 CURRENT 0 1A 0105 TORQUE 1 0106 POWER 0 1 kW 0107 DC BUS VOLTAGE 0 999 9 V 0 1 V 0109 OUTPUT VOLTAGE 0 480 V 0110 5400 TEMP 0 150 C 0 1 C 0111 EXTERNAL REF 1 0 250 Hz 0 1 Hz 0112 EXTERNAL REF 2 0 100 0 1 96 0113 CTRL LOCATION 0 2 1 0114 RUN TIME R 0 00 9999 kh 1h 0115 kWh COUNTER 0 9999 kWh 1 kWh 0116 APPL BLK OUTPUT 0 100 0 1 0117 DI1 DI4 STATUS 0000 1111 1 0118 1 0 100 0 1 0119 jAl2 0 100 0 1 0121 015 amp RELAYS 0000 0111 1 0122 0 20 mA 0 1 mA 0124 ACTUAL VALUE 1 0 100 0 1 0125 ACTUAL VALUE 2 0 100 0 1 5 0126 CONTROL DEV 100 100 0 1 0127 ACTUAL VALUE 0 100 0 1 ACS 400 User s Manual 51 Code Name Range Resolution Default User S M 0128 LAST FAULT 0 26 1 0 0129 PREVIOUS FAULT 0 26 1 0 0130 OLDEST FAULT 0 26 1 0 0131 SERIAL LINK DATA 1 0 255 1 0132 SERIAL LINK DATA 2 0 255 1 0133 SERIAL LINK DATA 0 255 1 0134 PROCESS VAR 1 0 65535 or 1 32768 32767 0135 PROCESS VAR 2 0 65535 or 1 32768 32767 0136 RUN TIME 0 00 99 99 kh 0
30. Selecting Full Parameter Set Normally only the basic parameters are visible When the full Menu is active an asterisk appears in the second row of the panel display Removal and reapplication of power automatically alters the menu to the short parameter set FULL SHORT MENU Press amp hold FULL SHORT MENU 2 MENU MENU Visible if full menu is active 28 ACS 400 User s Manual LED Indicators Red LED Green LED OFF ON Power ON and drive is operating normally OFF BLINKS Alarm is active ON ON Fault is active Drive can be reset from the control panel BLINKS ON Fault is active Turn power off to reset the drive Resetting the Drive from the Control Panel When the red LED of the ACS PAN is on or blinking a fault is active To reset a fault when the red LED is on press the RESET button Caution This may start the drive when in remote control To reset a fault when the red LED is blinking turn the power off Caution Turning the power on again may start the drive immediately The relevant fault code see Diagnostics flashes in the panel display until the fault is reset or the display is cleared You can clear the display without resetting the fault by pressing any button Note If no other button is pressed within 15 seconds and the fault is still active the fault code will be displayed again After a power fail
31. The function code received in the query is not an allowable FUNCTION action for the slave ACS 400 Unsupported Command 02 ILLEGAL DATA The data address received in the query is not an allowable ADDRESS address for the slave ACS 400 Address outside groups 03 ILLEGAL DATA value contained in the query data field is not an allowable value for the slave ACS 400 Value outside min max limits ACS 400 Parameter is read only ACS 400 Message is too long ACS 400 Parameter write not allowed when start is active ACS 400 Parameter write not allowed when factory macro is selected Function Codes The ACS 400 supports the Modbus function codes given in Table 20 If any other function codes are used ACS 400 returns an exception response with error code 01 illegal function Table 20 Function codes Code Description 03 Read holding registers 06 Preset single register 16 10 Hex Preset multiple registers ACS 400 User s Manual 107 The Control Word Holding register 40001 The Control Word is the principal means for controlling ACS 400 from a fieldbus system It is sent by the fieldbus master station to the drive ACS 400 switches between its states according to the bit coded instructions on the Control Word Note In order to use Control Word the drive must be configured to receive control commands from the serial communication channel Refer to Control Locations on page 100
32. cables B type IP 21 NEMA 1 arives The conduit plate is attached with three screws into threaded holes marked a in Figure 16 and b in Figure 17 12 ACS 400 User s Manual Cable Connections Table 4 Cable Terminal Description Note U1 V1 W1 3 power supply input Do not use 1 supply PE Protective Ground Follow local rules for cable size U2 V2 W2 Power output to motor See S Uc Uc DC bus For optional ACS BRK braking unit X11 to 16 Control Wiring Low voltage control use shielded cable X1 17 to 22 Control Wiring Low voltage or 115VAC X3 RS485 Communications Use shielded cable Follow local codes for cable size To avoid electromagnetic interference use separate conduits for input power wiring motor wiring control and communications wiring and braking unit wiring Keep these four classes of wiring separated in situations where the wiring is not enclosed in conduit Also keep 115VAC control wiring separated from low voltage control wiring and power wiring Use shielded cable for control wiring Use 60 C rated power cable 75 C if ambient temperature exceeds 45 C 113 F Refer to Section S Specifications for current ratings fuse recommendations and the maximum wire size capacities and tightening torques for the terminals The ACS 400 is suitable for use on a circuit capable of delivering not more than 65 000 RMS symmetrical amperes 480 V maximum The ACS 400 has
33. or from EXT1 to ExT2 or vice versa 0 OFF Start inhibit control disabled Drive will start after fault is reset or mode is changed if there is a pending start command 12 Start inhibit control enabled Drive will not start after fault is reset or mode changed ACS 400 User s Manual 73 Group 22 Accel Decel Two acceleration deceleration ramp pairs can be used If both ramp pairs are used selection can be made between these while running 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 0 NOT SEL The first ramp pair is used ACCELER TIME 1 DECELER TIME 1 1 5 DH DI5 Ramp pair selection is done through a digital input DI1 to DI5 Digital input deactivated Ramp pair 1 ACCELER TIME 1 DECELER TIME 1 is used Digital input activated Ramp pair 2 ACCELER TIME 2 DECELER TIME 2 is used 2202 ACCELER TIME 1 Ramp 1 time from zero to maximum frequency 0 MAXIMUM FREQ 2203 DECELER TIME 1 Ramp 1 time from maximum frequency to zero MAXIMUM FREQ 0 2204 ACCELER TIME 2 Ramp 2 time from zero to maximum frequency 0 MAXIMUM FREQ 2205 DECELER TIME 2 Ramp 2 time from maximum frequency to zero MAXIMUM FREQ 0 2206 RAMP SHAPE Acceleration deceleration ramp shape selection LINEAR 1 FAST S CURVE 2 MEDIUM CURVE 3 SLOW S CURVE
34. the load will cause regeneration back into the ACS 400 thus keeping the DC bus charged and preventing an undervoltage trip This will increase power loss ride through on systems with a high inertia 0 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 72 ACS 400 User s Manual Group 21 Start Stop The ACS 400 supports several start and stop modes including flying start and torque boost at start DC current can be injected either before the start command PREMAGN SEL 011 015 or right after the start command PREMAGN SEL CONST DC hold can be used when stopping the drive in ramp mode If stopping by coast mode is selected DC braking can be used Code Description 2101 START FUNCTION Conditions during motor acceleration 1 RAMP Ramp acceleration as defined by the active acceleration time 2202 ACCELER Time1 or 2204 ACCELER Time2 2 FLYING START Flying start Use this setting if the motor is already rotating and the drive will start smoothly at the present frequency Note Flying Start may cause an under rated motor to ramp through its speed range 3 TORQUE BOOST Automatic torque boost might be necessary for loads with high star
35. values 1 and 2 is used as the feedback signal 3 ACT1 ACT2 Sum of actual values 1 and 2 ACT1 ACT2 Product of actual values 1 2 5 1 2 Quotient of actual values 1 and 2 6 MIN A1 A2 Smaller of actual values 1 and 2 7 MAX A1 A2 Greater of actual values 1 and 2 8 sq A1 A2 Square root of difference of actual values 1 and 2 9 sqA1 sqA2 Sum of square roots of actual values 1 and 2 4007 ACT1 INPUT SEL Source for actual value 1 ACT1 1 Al1 Analog input 1 is used as actual value 1 2 AI2 Analog input 2 is used as actual value 1 4008 ACT2 INPUT SEL Source for actual value 2 ACT2 1 Al1 Analog input 1 is used as actual value 2 2 Al2 Analog input 2 is used as actual value 2 ACS 400 User s Manual 87 Code Description 4009 ACT1 MINIMUM Minimum value for actual value 1 1 Refer to Figure 38 and to Group 13 parameters for analog input minimum and maximum settings 4010 ACT1 MAXIMUM Maximum value for actual value 1 ACT1 Refer to Figure 38 and to Group 13 parameters for analog input minimum and maximum settings 4011 ACT2 MINIMUM Minimum value for actual value 2 ACT2 Refer to parameter 4009 4012 ACT2 MAXIMUM Maximum value for actual value 2 ACT2 Refer to parameter 4010 ACTI 96 A ACT1 MAXIMUM ACT1 MINIMUM p Analog input signal Al min Al max AcT
36. 0 3008 BREAK POINT Break point of motor load curve Refer to Figure 30 for an example of a motor load curve See Figure 32 3009 STALL FUNCTION This parameter defines the operation of stall protection The protection is activated if the output current becomes too high compared to output frequency refer to Figure 31 NOT SEL Stall protection not used 1 FAULT When the protection is activated the ACS 400 coasts to stop Fault indication is displayed 2 WARNING warning indication is displayed The indication disappears in half the time set by parameter 3012 STALL TIME lout A Stall region 3010 STALL CURRENT Frequency 3011 STALL FREQ HI Figure 31 Motor stall protection 3010 STALL CURRENT Current limit for stall protection Refer to Figure 31 3011 STALL FREQ HI This parameter sets the frequency value for the stall function Refer to Figure 31 3012 STALL TIME This parameter sets the time value for the stall function 3013 UNDERLOAD FUNCTION Removal of motor load may indicate a process malfunction The protection is activated if The motor torque drops below the load curve selected by parameter 3015 UNDERLOAD CURVE This condition has lasted longer than the time set by parameter 3014 UNDERLOAD TIME Output frequency is higher than 10 96 of the nominal frequency of the motor and higher than 5 Hz 0 NOT SEL Underload protection is not used 1 FAU
37. 01 kh 0137 MWh COUNTER 0 0 999 9 MWh 0 1 MWh Group 10 COMMAND INPUTS 1001 EXT1 COMMANDS 0 10 1 viv 1002 EXT2 COMMANDS 0 10 1 viv 1003 DIRECTION 1 3 1 viv Group 11 REFERENCE SELECT 1101 REF SEL 1 2 1 1 REF1 Hz 1102 1 2 SEL 1 10 1 1103 REF1 SELECT 0 10 1 d viv 1104 EXT REF1 MIN 0 250 Hz 1 Hz 0 Hz 1105 REF1 0 250 Hz 1 Hz T v 1106 REF2 SELECT 0 10 1 viv 1107 EXT REF2 MIN 0 100 1 0 1108 REF2 0 500 1 100 Group 12 CONSTANT SPEEDS 1201 CONST SPEED SEL 0 10 1 viv 1202 CONST speed 1 0 250 Hz 0 1 Hz 5 Hz 1203 CONST speed 2 0 250 Hz 0 1 Hz 10 Hz 1204 CONST speed 3 0 250 Hz 0 1 Hz 15 Hz 1205 CONST speed 4 0 250 Hz 0 1 Hz 20 Hz 1206 CONST speed 5 0 250 Hz 0 1 Hz 25 Hz 1207 CONST speed 6 0 250 Hz 0 1 Hz 40 Hz 1208 CONST speed 7 0 250 Hz 0 1 Hz 50 Hz Group 13 ANALOG INPUTS 1301 Alt 0 100 1 0 1302 AH 0 100 1 100 1303 FILTER Alt 0 10s 0 1s 0 18 1304 MINIMUM AI2 0 100 1 0 1305 MAXIMUM 2 0 100 1 100 52 ACS 400 User s Manual Code Name Range Resolution Default User M 1306 FILTER 2 0 10s 0 18 0 16 Group 14 RELAY OUTPUTS 1401 RELAY OUTPUT 1 0 27 1 3 FAULT 1 1402 RELAY OUTPUT 2 0 27 1 2 RUN 1403 RELAY 1 ON DELAY 0
38. 1 96 A ACT1 MINIMUM MAXIMUM 4 r r Analog input signal Al min Al max Figure 38 Actual value scaling The range of the analog input signal is set by parameters 1301 and 1302 or parameters 1304 and 1305 depending on the analog input used 88 ACS 400 User s Manual Code Description 4013 PID SLEEP DELAY Time delay for the sleep function see Figure 39 If the ACS 400 output frequency is below a set level parameter 4014 SLEEP LEVEL longer than PID SLEEP DELAY ACS 400 is stopped 4014 PID SLEEP LEVEL Level for activation of sleep function see Figure 39 When the ACS 400 output frequency falls below the sleep level the sleep delay counter is started When the ACS 400 output frequency rises above the sleep level the sleep delay counter is reset 4015 WAKE UP LEVEL Level for deactivation of sleep function This parameter sets a process actual value limit for the sleep function see Figure 39 When the actual value falls below the limit the sleep function is interrupted Wake up level Ref x Param 4015 100 Note Wake up level comparison is also inverted when error value is inverted using parameter 4005 ERROR VALUE INV Actual value A WAKE UP LEVEL NZ Frequency Time A tg SLEEP DELAY parameter 4013 SLEEP LEVEL parameter 4014 Time STOP START Figure 39 Sleep function Note The proportional gai
39. 1 Al2 open lt gt 0 from frequency reference Resolution 0 1 accuracy 1 6 AGND Analog input circuit common Connected internally to frame ground through 1 MQ 7 AO1 Analog output programmable Default 0 20 mA load lt 500 lt gt 0 fnom output frequency 8 AGND Common for DI return signals 9 24V Auxiliary voltage output 24 V DC 250 mA reference to AGND Short circuit protected 10 DCOM1 Digital input common for 011 DI2 and To activate a digital input there must be 2 10 V or lt 10 V between that input and DCOM1 The 24 V may be provided by the ACS 400 X1 9 using the connection examples see Section L or by an external 12 24 V source of either polarity DI Configuration Factory 0 Factory 1 from 50 Hz 60 Hz 11 DI 1 Start Close to start Motor will ramp up to Start If DI 2 is closed momentary closing frequency reference Open to stop Motor will of DI 1 starts the ACS 400 coast to stop 12 DI2 Reverse Close to reverse rotation direction Stop Momentary opening stops the ACS 400 13 013 Jog Close to set output frequency to jogging Reverse Close to reverse rotation frequency default 5 Hz direction 14 014 Must be closed for Factory 0 Must be open for Factory 1 15 DI 5 Accel Decel selection ACC1 DEC1 or ACC2 DEC2 16 DCOM2 DCOWM2 digital input common for 014 DI5 17 RO1C Relay output 1 programmable defa
40. 400 in thousands of hours kh 0137 MWh COUNTER Counts the megawatt hours of ACS 400 in operation ACS 400 User s Manual Group 10 Command Inputs Start Stop and Direction commands can be given from the control panel or from two external locations EXT1 EXT2 The selection between the two external locations is made with parameter 1102 EXT1 EXT2 SEL For more information on control locations refer to APPENDIX starting page 115 Code Description 1001 EXT1 COMMANDS Defines the connections and the source of Start Stop Direction commands for External control location 1 ExT1 0 NOT SEL No Start Stop Direction command source for ExT1 is selected 1 01 Two wire Start Stop connected digital input 011 DI1 deactivated Stop DI1 activated Start 2 DI1 2 Two wire Start Stop Direction Start Stop is connected to digital input DI1 as above Direction is connected to digital input 012 012 deactivated Forward 012 activated Reverse To control direction value of parameter 1003 DIRECTION should be REQUEST 3 DITP 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 011 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 se
41. 5 015 42 ACS 400 User s Manual Application Macro Factory 1 This macro is intended for applications where there is no control panel available It provides a general purpose configuration that is typically used in North America Note The value of parameter 9902 is 0 FACTORY DI 4 is connected v3 SCR 1 r2 External Reference 1 0 10 V lt gt 0 60 Hz H LLT 10V Reference voltage 10 VDC s 2 Not used AGND nA 2 Output frequency 0 20 lt gt 0 60 Hz AGND 9 24V 24 VDC a Momentary activation with 012 activated Start gt IDI2 Momentary deactivation Stop DI3 Fwd Rev activate to reverse rotation direction 14 Must be connected 7 ss 015 Ramp pair selection Activate to select ramp pair 2 16 IDDCOM2 17 RO1C Relay ouput 1 programmable Default Fault gt 17 connected to 18 19 RO1B OAK L Relay ouput 2 programmable 2 Ro2B Default Running gt 20 connected to 22 Input signals Output signals V I jumper S1 Start stop and direction An output AO 011 2 3 Frequency 0 10V Analog reference Al1 Relay output 1 Fault Ramp pair 1 2 selection DI5 Relay output 2 Running 0 10V
42. 5 Critical 75 Group 26 Motor Control 76 Group 30 Fault Functions 77 Group 31 Automatic Reset 81 Group 32 5 82 Group 33 Information 83 Group 34 Process 84 Group 40 PID 86 Group 50 90 Group 51 Ext Comm Module 91 Group 52 Standard Modbus 92 Standard Serial 95 OVIEN i4 dye VIE AT Been ek eae 95 Grounding and Termination 97 Activating Modbus 98 Communication settings 99 Control Locations 100 Output signal source selection 102 Diagnostic Counters 104 Communication 105 Introduction to Modbus 105 Register Read and 105 Register Mapping 106 Exception Codes reb P REP E oe 107 Function
43. 6 98 3 86 98 3 86 98 3 86 98 H 17 72 450 21 65 550 25 28 642 29 21 742 H1 12 52 318 16 42 417 20 79 528 24 37 619 H2 12 49 330 16 93 430 21 46 545 25 04 636 D 9 49 241 9 96 253 10 98 279 12 28 312 a 0 217 5 5 0 217 5 5 0 256 6 5 0 256 6 5 b 0 394 10 0 394 10 0 512 13 0 512 13 0 217 5 5 0 217 5 5 0 256 6 5 0 256 6 5 Weight Ib kg 12 76 5 8 19 80 9 0 40 70 18 5 61 60 28 ACS 400 User s Manual 5 C Mounting the ACS 400 on a Wall A Warning Before installing the ACS 400 ensure the input power supply to the drive is off 1 The lid of the packing box provides a Wall Mounting Template Remove the lid from the box 2 The ACS 400 should only be mounted vertically on a smooth solid surface free from heat dampness and condensation Ensure minimum air flow gaps of 8 in 200 mm above and below and 2 in 50 mm around the sides of the unit 1 Using the mounting template mark the position of the mounting holes 2 Drill the holes 3 Screw in four screws or affix nuts and bolts depending on the mounting surface 3 IP 21 Position the ACS 400 onto the fixings and securely tighten in all four corners Note Lift the ACS 400 by its metal chassis IP 54 1 Remove the front cover see Figure 10 2 Remove the rubber plugs by pushing from outside 3 Screw in the screws 4 Replace the rubber plugs Figure 4 a i PL 4 Figure 5 Marking and drilling the mounting hol
44. 83 Group 01 OPERATING DATA 0128 LAST FAULT Last recorded fault 0 no fault See Diagnostics starting on page 35 Can be cleared with the control panel by pressing UP and DOWN buttons simultaneously when in parameter set mode Group COMM 10 AND INPUTS 1003 DIRECTION Rotation direction lock 1 FORWARD 2 REVERSE 3 REQUEST Default 3 REQUEST or 1 FORWARD depending on the application macro selected If you select REQUEST the direction is set according to the given direction command Group 11 REFERENCE SELECT 1105 EXT REF1 MAX Maximum frequency reference in Hz Range 0 250 Hz Default value 50 Hz or 60 Hz depending on the application macro selected Group 12 CONSTANT SPEEDS 1202 CONST SPEED 1 Range for all constant speeds 0 250 0 Hz Default value 5 0 Hz 1203 CONST SPEED 2 Default value 10 0 Hz 1204 CONST SPEED 3 Default value 15 0 Hz 38 ACS 400 User s Guide Code Name User Group 13 ANALOG INPUTS 1301 MINIMUM Minimum value of Al1 in per cent Defines relative analog input value where frequency reference reaches minimum value Range 0 100 Default value 0 96 Group 15 ANALOG OUTPUT 1503 AO CONTENT MAX Defines output frequency where analog output reaches 20 mA Default value 50 0 Hz or 60 0 Hz depending on the application macro selecte
45. 85485 a i ACS100 PAN i 8 8 _ 18 ACS PAN i fg i 8 DDCS BIL Option Module Connector p 4 pum lt per i n Drive Window ole d ole olo o a Gu c G Figure 40 Standard serial communication features of the ACS 400 ACS 400 User s Manual 95 Data Flow gt Fieldbus Master PLC Fieldbus Parameter R W Requests Status Word SW gt Actual Values ACT 4 Control Word CW 4 References REF Figure 41 Structure of a fieldbus system 96 ACS 400 User s Manual Grounding and Termination RS485 Bus The RS485 network should not be directly grounded at any point All the devices on the network should be well grounded using their corresponding grounding terminals As always the grounding wires should not form any closed loops and all the devices should be grounded to a common ground The RS485 network must be terminated using 120 resistors at both ends of the network Use jumper J2 to connect or disconnect the termination resistors Termination should not be done on the intermediate stations See Figure 42 for the proper method of termination Terminated Terminated 00000 00000 00000 00000 Figure 42 Termination for the 5485 link warnings The connections should only be made with the
46. ABB Comp AC User s Manual ACS 400 AC Drives for Speed Control of 3 to 50 Hp 2 2 to 37 kW AC Induction Motors EP ER PADDED ACS 400 AC Drives for Speed Control of AC Induction Motors User s Manual ACS400 US 04 3AUA489002B5310 R0101 Rev A Effective 2 1 99 Copyright 1999 ABB Drives amp Power Products All Rights Reserved o h lt gt PPP Warning Only a competent electrician should install the ACS 400 Warning Dangerous voltages are present when input power is connected Wait at least 5 minutes after disconnecting the supply before removing the cover Measure the voltage at DC terminals U U before servicing the unit See Section E Warning Even when the motor is stopped there are dangerous voltages present at Power Circuit terminals U1 V1 W1 and U2 V2 W2 and U U Warning Even when power is removed from the input terminals of the ACS 400 there may be dangerous external voltages at relay terminals RO1A RO1B RO1C RO2A RO2B RO2C Warning The ACS 400 is not a field repairable unit Never attempt to repair a broken unit contact the factory or your local Authorized Service Center for replacement Warning The ACS 400 can start up automatically after an input voltage interruption if programmed for Automatic Restart after power outage Warning When the control terminals of two or more ACS100 140 400 units are connected in parallel the auxiliary voltage for
47. ALUE 1 PID Controller actual value 1 1 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 process controller 0127 PID ACTUAL VALUE Feedback signal for PID controller 0128 LAST FAULT Last recorded fault 0 fault See Diagnostics starting page 35 Can be cleared with the control panel by pressing UP and DOWN buttons simultaneously when in parameter set mode 0129 PREVIOUS FAULT Previous recorded fault See Diagnostics starting page 35 Can be cleared with the control panel by pressing UP and DOWN buttons simultaneously when in parameter set mode 0130 OLDEST FAULT Oldest recorded fault See Diagnostics starting page 35 Can be cleared with the control panel by pressing UP and DOWN buttons simultaneously when in parameter set mode 0131 SERIAL LINK DATA 1 Free data location that can be written from serial link 0132 SERIAL LINK DATA 2 Free data location that can be written from serial link 0133 SERIAL LINK DATA 3 Free data location that can be written from serial link 0134 PROCESS VAR 1 Process variable 1 as selected by parameters in group 34 0135 PROCESS VAR 2 Process variable 2 as selected by parameters in group 34 0136 RUN TIME Shows the total running time of ACS
48. Activate to reverse rotation Fwd Rev 1 014 Constant speed selection 115 inn 5 Constant speed selection 1 RO1C Relay ouput 1 programmable 1 Default fault gt 17 connected to 18 19 RO1B F 20 RO2C 2 RO2A Relay ouput 2 programmable gt RO2B Default running gt 20 connected to 22 Constant speed selection 0 open 1 connected DI4 015 Output 0 0 Reference through 1 0 Constant speed 1 1202 0 1 Constant speed 2 1203 1 1 Constant speed 3 1204 Note Deactivation of stop signal interlocks panel START STOP button in local control mode Application Macro 3 wire parameter values 9905 MOTOR NOM VOLT 480 V 1105 EXT REF1 MAX 60 Hz 9907 MOTOR NOM FREQ 60 Hz 1106 EXT REF2 SELECT 0 KEYPAD 9908 MOTOR NOM SPEED 1720 rpm 1201 CONST SPEED SEL 8 014 5 1001 EXT 1 COMMANDS 4 DI1P 2P 3 1503 AO CONTENT MAX 60 Hz 1002 EXT 2 COMMANDS 0 NOT SEL 1601 RUN ENABLE 0 NOT SEL 1003 DIRECTION 3 REQUES T 1604 FAULT RESET SEL 0 KEYPAD 2008 MAXIMUM FREQ 60 Hz 1102 EXT1 EXT2 SEL 6 EXT1 2105 PREMAGN SEL 0 NOT SEL 1103 EXT REF1 SELECT 1 2201 ACC DEC 1 2 SEL 0 NOT SEL ACS 400 User s Manual Application Macro Alternate This macro offers an I O configuration that uses a sequence of DI control signals to alternate the direction of drive rotation Note The value of parameter 9902 i
49. Filter time constant for AO AO mA 1505 1504 AOcontent 1505 1504 r p AO content Figure 25 Analog output scaling 70 ACS 400 User s Manual Group 16 System Controls Code Description 1601 RUN ENABLE Selects the source of the run enable signal 0 NOT SEL ACS 400 is ready to start without an external run enable signal 1 5 DH 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 400 will coast to stop and not start until the run enable signal resumes 6 COMM The run enable signal is given through serial communication Command Word bit 3 1602 PARAMETER LOCK LOCKED Parameter modification disabled 1 OPEN Panel operations are allowed and parameter modification is enabled 2 NOT SAVED Parameter values can be changed but they are not stored in permanent memory Note This parameter is not affected by macro selection Note Option 0 LOCKED can be selected only in remote mode 1604 FAULT RESET SEL Fault reset source Note Fault reset is always enabled with control panel Note Option 6 START STOP should not be selected when start stop and direction commands are given through serial communication 0 KEYPAD ONLY Fault reset is executed from the control panel keypad 1 5 DM 015 Fault reset is exec
50. Group 01 OPERATING DATA 0133 SER LINK DATA 0 255 Controlling data for the analoque output Group 15 ANALOG OUTPUT 1501 CONTENT 102 137 e g 133 Directs the contents of parameter 133 to the analog output 1503 AO CONTENT MAX 255 Analog output scaling upper limit 20 mA reached when value 255 written to parameter 133 ACS 400 User s Manual 103 Diagnostic Counters Diagnostic counters can be used for debugging the Modbus system Counters will roll over from 65535 to 0 The counter values are stored to permanent memory when power is disconnected Counters can be reset from the control panel by pressing the UP and DOWN buttons simultaneously when in parameter set mode or by writing zero from the serial communication channel 1 Note Parameters 5206 5212 are displayed in hexadecimal format by the control panel Table 17 Code Name Range User Group 52 STANDARD MODBUS 5206 BAD MESSAGES 0 65535 5207 GOOD MESSAGES 0 65535 5208 BUFFER OVERRUNS 0 65535 5209 FRAME ERRORS 0 65535 5210 PARITY ERRORS 0 65535 5211 ERRORS 0 65535 5212 BUSY ERRORS 0 65535 5213 SER FAULT MEM 1 0 3 5214 SER FAULT MEM 1 0 3 5215 SER FAULT MEM 3 0 3 104 ACS 400 User s Manual Communication This chapter describes the Modbus communication for the ACS 400 drive Introduction to Modbus Modbus is a serial asynchronous protocol The Modb
51. H 11 RUSSIAN 9902 APPLIC MACRO Selects application macro Sets parameter values to their default values Refer to Application Macros starting on page 41 for detailed description of each macro FACTORY 1 ABB STANDARD 2 3 WIRE 3 ALTERNATE 4 MOTOR POT 5 HAND AUTO 6 PID CONTROL 7 PREMAGN Default value 0 FACTORY MACRO 9905 MOTOR NOM VOLT Nominal motor voltage from motor nameplate Range of this parameter depends on the type of the ACS 400 Default value for 400 V unit 400 or 480 V depending on application macro selected Default value for 200 V unit 200 or 240 V depending on application macro selected 9906 MOTOR NOM CURR Nominal motor current from motor nameplate Values for this parameter range from 0 5 IN 1 5 Iy where Iy is nominal current of the ACS 400 Default value ly 9907 MOTOR NOM FREQ Nominal motor frequency from motor nameplate Range 0 250 Hz Default 50 Hz or 60 Hz depending on macro selected ACS 400 User s Guide 37 Code Name User 9908 MOTOR NOM SPEED Nominal motor speed from motor nameplate Range 0 3600 rpm Default 1440 or 1720 rpm depending on application macro selected 9909 MOTOR NOM POWER Nominal motor power from nameplate Range 1 100 kW 1 5 125 Hp Default 1 kW 1 5 Hp 9910 MOTOR COS PHI Nominal motor cos phi from nameplate Range 0 50 0 99 Default 0
52. LAY OUTPUT 1 Relay output 1 content Selects which information is indicated with relay output 1 0 NOT SEL Relay is not used and is de energized 1 READY The ACS 400 is ready to function The relay is energized unless no run enable signal is present or a fault exists and supply voltage is within range 2 RUN Relay energized when the ACS 400 is running 3 FAULT 1 Relay energized when power is applied and de energized upon a fault trip 4 FAULT Relay energized when a fault is active 5 ALARM Relay energized when an alarm is active except AL1 AL7 AL15 and AL 27 AL28 6 REVERSED Relay energized when motor rotates in reverse direction 7 SUPRV1 OVER Relay energized when first supervised parameter 3201 exceeds the limit 3203 See Group 32 Supervision starting page 82 8 SUPRV1 UNDER Relay energized when first supervised parameter 3201 drops below the limit 3202 See Group 32 Supervision starting page 82 9 SUPRV2 OVER Relay energized when second supervised parameter 3204 exceeds the limit 3206 See Group 32 Supervision starting page 82 10 SUPRV2 UNDER Relay energized when second supervised parameter 3204 drops below the limit 3205 See Group 32 Supervision starting page 82 11 AT SET POINT Relay energized when output frequency is equal to reference frequency 12 FAULT RST Relay energized when the ACS 400 is in a fault condition and will rese
53. LT When the protection is activated the ACS 400 coasts to stop Fault indication is displayed 2 WARNING warning indication is displayed 3014 UNDERLOAD TIME Time limit for underload protection ACS 400 User s Manual 79 Code Description 3015 UNDERLOAD CURVE This parameter provides five selectable curves shown in Figure 33 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 600 s oo 1 0 0 5 0 lo In Trip time 3 5 3 0 60 s 25 90 s 2 0 180s 3005 fo fark 0 02 04 06 08 10 12 output current In nominal current of the motor fo output frequency break point frequency parameter 3008 BREAK POINT Figure 32 Thermal protection trip times when parameters 3005 MOT THERM TIME 3006 MOT LOAD CURVE and 3007 ZERO SPEED LOAD have default values 100 80 4 70 60 4 50 40 lt 4 30 96 20 4 S 0 T n 2 4 fy Figure 33 Underload curve types Ty nominal torque of the motor fy nominal frequency of the motor 80 ACS 400 User s Manual Group 31 Automatic Reset The automatic reset system can be used for resetting overcurrent overvoltage undervoltage and analog input loss faults automatically Number of allowe
54. NDS 0 NOT SEL 1601 RUN ENABLE 0 NOT SEL 1003 DIRECTION 3 REQUEST 1604 FAULT RESET SEL 0 KEYPAD 2008 MAXIMUM FREQ 50 Hz 1102 EXT1 EXT2 SEL 6 ExT1 2105 PREMAGN SEL 0 NOT SEL 1103 EXT REF1 SELECT 1 2201 ACC DEC 1 2 SEL 5 DI5 44 ACS 400 User s Manual Application Macro 3 wire This macro is intended for those applications wh ere the drive is controlled using momentary push buttons It gives two more preset speeds compared to Factory Macro 1 by using 014 and DI5 Note The default frequency is 60 Hz Note The value of parameter 9902 is 2 3 WIRE Input signals Start stop and direction 011 2 3 Analog reference Al1 Preset speed selection 14 5 Relay Output signals VA jumper S1 0 10 An output AO Frequency fan 0 10V Relay output 1 Fault m output 2 Running v4 SCR 2 External Reference 1 0 10 V lt gt 0 60 Hz n 113 AGND 4 Reference voltage 10 VDC 5 Not used _ AGND AO1 Output frequency 0 20 mA lt gt 0 60 Hz s AGND 9 24V 24 VDC 10 DCOM1 11 DH Momentary activation with DI2 activated Start Momentary deactivation Stop 13
55. O PANEL FULL SHORT MENU 26 ACS 400 User s Manual Setting Parameter Value The parameter set mode is entered by pressing ENTER In set mode the value is underlined The value is altered by using the UP DOWN buttons The modified value is stored by pressing ENTER Modifications can be cancelled and set mode exited by pressing MENU 9901 LANGUAGE 9901 LANGUAGE OT accept and store It ENGLISH ENGLISH 2 o value exit without saving 2 Note In the parameter set mode the cursors blink when the parameter value is altered Note To view the parameter default value while in the parameter set mode press the UP DOWN buttons simultaneously Adjust the Panel Display Contrast Simultaneously depressing the ENTER key and the UP DOWN key will adjust the display contrast ACS 400 User s Guide 27 Menu Functions Use the UP DOWN arrows to scroll through the Menu for the desired menu function then press and hold ENTER down until the display blinks to start the operation Copy Parameters from Drive to Panel upload Press amp hold COPY TO PANEL ENTER COPYING gt Note The drive must be stopped and in local control Parameter 1602 PARAMETER LOCK must be set to 1 OPEN Copy Parameters from Panel to Drive download Press amp hold COPY TO DRIVE COPYING ENTER Note The drive must be stopped and in local control Parameter 1602 PARAMETER LOCK must be set to 1 OPEN
56. PENDIX starting page 115 for description of different control locations 0114 RUN TIME R Shows the total run time of the ACS 400 in thousands of hours Can be reset by pressing UP and DOWN buttons simultaneously when in parameter set mode 0115 kWh COUNTER R Shows the ACS 400 operating hours 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 PID control block This value has significance only when the PID Control macro is used 0117 011 014 STATUS Status of the four digital inputs Status is displayed as binary number If the input is activated the display will indicate 1 If the input is deactivated the display will be 0 ACS100 PAN ACS PAN eee 000001101BIN X DI4 DI2 DI 1 58 ACS 400 User s Manual Code Description 0118 Relative value of analog Input 1 displayed 0119 Al2 Relative value of analog input 2 displayed in 0121 DI5 amp RELAYS Status of digital input 5 and relay outputs 1 indicates that the relay is energized and 0 indicates that the relay is de energized ACS100 PAN ACS PAN I LII 000000101BIN DI5 Relay 2 status Relay 1 status 0122 AO Value of analog output signal in milliamperes 0124 ACTUAL V
57. R NOM FREQ 50 Hz 1106 EXT REF2 SELECT 9908 MOTOR NOM SPEED 1440 rpm 1201 CONST SPEED SEL 1001 EXT 1 COMMANDS 2 011 2 1503 AO CONTENT 1002 ExT 2 COMMANDS 7 015 4 1601 RUN ENABLE L 1003 DIRECTION 3 REQUEST 1604 FAULT RESET SEL KEYPAD 2008 MAXIMUM FREQ 1102 EXT1 EXT2 SEL 3 2105 PREMAGN SEL 1103 EXT REF1 SELECT 1 11 2201 ACC DEC 1 2 SEL 48 ACS 400 User s Manual Application Macro PID Control This macro is intended for use with different closed loop control systems such as pressure and flow control The value of parameter 9902 is 6 PID CTRL Input signals Start stop DI1 5 Analog reference Al1 Actual value 12 Output signals An output AO Frequency Relay output 1 Fault Relay output 2 Running Control location selection 012 Constant speed DI3 Run enable 014 SCR AGND 10V Al2 AGND AO1 AGND 24V Note JB 24 VDC 10 DCOM1 11 DH DI2 DI3 14 DIA 15 1015 31 1s DCOM2 17 RO1C 1 19 RO1B 20 RO2C 21 RO2A 22 RO2B Reference voltage 10 VDC Actual signal 0 20 mA PID Output frequency 0 20 lt gt 0 50 Hz m Relay ouput 1 programmable
58. SET 3101 NR OF TRIALS 0 5 1 0 3102 TRIAL TIME 1 0 180 0s 0 15 305 3103 DELAY TIME 0 0 3 0s 0 15 05 3104 OVERCURRENT 0 1 1 0 DISABLE 3105 AR OVERVOLTAGE 0 1 1 0 DISABLE 3106 AR UNDERVOLTAGE 0 1 1 0 DISABLE 3107 AR AI MIN 0 1 1 0 DISABLE Group 32 SUPERVISION 3201 SUPERV 1 102 137 1 103 3202 SUPERV 1 LIM LO 0 65535 0 3203 SUPERV 1 LIM HI 0 65535 0 3204 SUPERV 2 PARAM 102 137 1 103 3205 SUPERV 2 LIM LO 0 65535 0 3206 SUPERV 2 LIM HI 0 65535 0 Group 33 INFORMATION 3301 SW VERSION 0 0 0 0 f f f f 3302 TEST DATE yy ww Group 34 PROCESS VARIABLES 3401 DISPLAY SEL 1 2 1 1 STANDARD 3402 P VAR 1 SEL 102 137 1 104 3403 VAR 1 MULTIP 1 9999 1 1 3404 VAR 1 DIVISOR 1 9999 1 1 3405 VAR 1 SCALING 0 3 1 1 3406 P VAR 1 UNIT 0 31 1 1 A 3407 VAR 2 SEL 102 137 1 103 3408 VAR 2 MULTIP 1 9999 1 1 3409 VAR 2 DIVISOR 1 9999 1 1 3410 P VAR 2 SCALING 0 3 1 1 34011 P VAR 2 UNIT 0 31 1 3 Hz ACS 400 User s Manual 55 Code Name Range Resolution Default User S M Group 40 PID CONTROL 4001 PID GAIN 0 1 100 0 1 1 0 4002 INTEG TIME 0 1 320 s 0 15 605 4003 PID DERIV TIME 0 10s 0 1s 0s 4004 PID DERIV FILTER 0 10s 0 1s 1s 4005 ERROR VALUE IN
59. Start inhibit V DC 436 in input voltage range 380 415 VAC 505 in input voltage range 440 480 VAC Overtemperature C 95 heat sink Max cable length m 100 200 200 200 few 4 kHz Power stages are designed for the continuous loywp current These values are valid when the altitude is less than 3300 ft 1000 m ASL See R Low noise setting programmable with optional control panel For ambient operating temperature 0 40 C derate Py and 1 to 80 Maximum cable lengths listed are based on capacitive coupling between motor wires and from motor wires to ground It may also be necessary to consider motor insulation requirements related to drive output dv dt ACS 400 User s Manual 21 400 V series 3 Input 380V 480V 10 50 60 Hz Max wire sizes and screw torque of connectors Power terminals mm 10 AWG6 stranded 16 AWG4 35 AWG2 stranded Torque 1 3 1 5 Nm stranded Torque 3 2 3 7 Nm Torque 1 5 1 8 Nm Control terminals 0 5 1 5 AWG22 AWG16 Torque 0 4 Nm Line fuse 3 7 10 10 16 16 35 50 ACS401 Power losses Power circuit Control circuit RK Follow local rules for cable size see I Shielded motor cable is recommended Fuse type UL class CC or T Use 60 C rated power cable 75 C if Tamb above 45 C T Product Conformity The ACS 400 complies with European requirements Low Volt
60. V 0 1 1 0 NO 4006 ACTUAL VAL SEL 1 9 1 1 1 Y 4007 1 INPUT SEL 1 2 1 2 2 4008 2 INPUT SEL 1 2 1 2 Al2 v 4009 ACT MINIMUM 0 1000 196 0 4010 MAXIMUM 0 1000 1 100 4011 2 MINIMUM 0 1000 1 0 4012 2 MAXIMUM 0 1000 1 100 4013 PID SLEEP DELAY 0 0 3600 s 0 1 15 605 4014 SLEEP LEVEL 0 0 120 Hz 0 1 Hz 0 Hz 4015 WAKE UP LEVEL 0 0 100 0 1 96 0 Group 50 COMMUNICATION 5001 DDCs BIT RATE 1 2 4 8 1 v 5002 DDCS NODE NR 1 254 1 1 v 5003 COMM FAULT TIME 0 1 60s 0 15 1s 5004 COMM FAULT FUNC 0 3 1 0 NOT SEL 5005 PROTOCOL SEL 0 3 1 0 NOT SEL v 5006 COMMANDS 0 2 1 0 NOT SEL v Group 51 EXT COMM MODULE 5101 FIELDBUSPAR1 15 5115 Group 52 STANDARD MODBUS 5201 STATION ID 1 247 1 1 5202 COM SPEED 3 6 12 24 48 96 192 96 9600 bits s 5203 PARITY 0 2 1 0 NONE 5206 BAD MESSAGES 0 FFFF 1 5207 GOOD MESSAGES 0 FFFF 1 5208 BUFFER OVERRUNS 0 FFFF 1 5209 FRAME ERRORS 0 FFFF 1 5210 PARITY ERRORS 0 FFFF 1 5211 CRC ERRORS 0 FFFF 1 5212 BUSY ERRORS 0 FFFF 1 5213 SER FAULT MEM 1 0 255 1 5214 SER FAULT MEM 2 0 255 1 5215 SER FAULT MEM 0 255 1 56 ACS 400 User s Manual Group 99 Start up Data Note Start up Data parameters are used for setting up the ACS 400 Code Description 9901 LANGUAGE Language selection
61. V Visible Shaft direction is forward reverse Drive is running and at set point FWD REV Blinking rapidly Drive is accelerating decelerating FWD REV Blinking slowly Drive is stopped ACS 400 User s Manual 31 Output Display When power is applied to the control panel it 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 1 2 ourPUT Loc NT Loc LI Hz n 5 OUTPUT Loc OUTPUT Menu Structure ACS 400 has a large number of parameters Of these only the basic parameters are initially visible The menu function LG is used to make the full parameter set visible See Select between basic and full menu on page 33 OUTPUT display Parameter groups Parameters 103 lou TPuT Setting Parameter Value Press ENTER to view the parameter value To set a new value press and hold ENTER until SET is displayed 2200 TED Note SET blinks if the parameter value is altered SET is not displayed if the value cannot be altered Note To view th
62. age Directive 73 23 EEC with amendments EMC Directive 89 336 EEC with amendments Corresponding declarations and a list of main standards are available on request Note See ACS 400 EMC instructions An adjustable frequency drive and a Complete Drive Module CDM or a Basic Drive Module BDM as defined in IEC 61800 2 is not considered as a safety related device mentioned in the Machinery Directive and related harmonized standards The CDM BDM adjustable frequency drive can be considered as a part of safety device if the specific function of the CDM BDM adjustable frequency drive fulfills the requirements of the particular safety standard The specific function of the CDM BDM adjustable frequency drive and the related safety standard is mentioned in documentation of the equipment 22 ACS 400 User s Manual U Accessories ACS 100 PAN Control panel for use with the ACS 100 ACS 140 ACS 400 ACS PAN A Control panel for use with the ACS 400 ACS 100 EXT Extension cable kit for use with the control panel 5400 11 3 through ACS400 IF41 3 RFI input filters ACS BRK Braking units RS485 232 Adapter DDCS Communication Module ACS 400 is supported by Drive Ware Contact your local ABB sales office for details ACS 400 User s Manual 23 24 ACS 400 User s Manual PROGRAMMING ACS PAN A Control Panel The ACS PAN A is an alphanumeric control panel with a backlit LCD display and multiple languages The
63. alarm MODBUS EXCEPTION Modbus exception response is sent through serial communication LOSS Analog input 1 loss Analog input 1 value is less than MINIMUM 1 1301 See parameter 3001 Al lt MIN FUNCTION Al2 LOSS Analog input 2 loss Analog input 2 value is less than MINIMUM AI2 1306 See parameter 3001 Al lt MIN FUNCTION PANEL LOSS Panel loss Panel is disconnected when Start Stop Dir or reference is coming from panel See parameter 3002 and APPENDIX ACS400 OVERTEMP Hardware overtemperature at 95 of the trip limit MOTOR OVERTEMP Motor overtemperature at 95 of the trip limit UNDERLOAD Motor underload alarm MOTOR STALL Stall alarm DDCS COMM LOSS DDCS link loss alarm Reserved MANUAL OFF Reference is not followed 1605 LOCAL LOCK 1 OUTPUT OVERLOAD If the load is not reduced the drive will soon trip due to OUTPUT OVERLOAD fault FL5 AUTOMATIC RESET The drive has stopped due to a fault but will attempt to restart automatically See parameter Group 31 PID SLEEP ACTIVE The PID sleep feature has stopped the drive The drive will restart automatically if the PID wake up conditions are satisfied ACS 400 User s Manual 35 Table 6 Faults Message OVERCURRENT Description Overcurrent Possible mechanical problem Acceleration and or deceleration times may be too short Power supply disturbanc
64. ales or service office ACS 400 User s Manual 15 L Connection Examples DI configuration for NPN connection sink DI configuration for PNP connection source ACS 400 ACS 400 SCR H SCR foros AGND AGND SL 4 10V M A 4 10V pp mA s Al2 ao AP AGND Lo M AGND h 1 S 6 Guinesoaningent AOT AGND AGND 24V o 24V 10 DCOM1 m 10 DCOM1 11 DH u DH 12 DI2 12 DI2 13 DIS 13 DI3 14 014 14 DIA 15 DI5 15 DI5 DCOM2 16 DCOM2 17 1 17 RO1C 18 RO1A o 18 RO1A 0 19 RO1B r 19 RO1B fr 20 RO2C 20 2 21 RO2A 1 1 21 2 N 22 RO2B 22 RO2B J1 Analog inputs J1 Analog inputs x x 0 10 V An x Ant 0 10 V XX 12 0 4 20 mA 5 il Al2 0 10 V DN X eq RS485 Multidrop application Other Modbus Devices ACS 400 SCR SCR J2 B N RS485 interf CEA B A
65. an electronic motor protection feature that complies with the requirements of the National Electric Code USA When this feature is selected and properly adjusted additional overload protection is not required unless more than one motor is connected to the drive or unless additional protection is required by applicable safety regulations See parameters 3004 3005 and 3006 Note For CE installation requirements see ABB publication CE US 02 CE Council Directives and Variable Speed Drives Contact your local ABB representative for specific IEC installation instructions ACS 400 User s Manual 13 J Control Terminals Main I O terminal X1 The analog input signal is selected with V I jumper J1 Al open V and Al connected 1 X1 Identification Description 1 SCR Terminal for signal cable screen Connected internally to frame ground 2 Al1 Analog input channel 1 programmable Default 0 10 V Rj 200 J1 Al1 open lt gt 0 from frequency reference 0 20 mA R 500 1 closed lt gt 0 from frequency reference Resolution 0 1 accuracy 1 AGND Analog input circuit common Connected internally to frame ground through 1 MQ 10V 10 V 10 mA reference voltage output for analog input potentiometer accuracy 2 12 Analog input channel 2 programmable Default 0 20 mA R 500 J1 Al2 closed lt gt 0 from frequency reference 0 10 V Rj 200 J
66. ariable for the output display of the ACS PAN control panel Process variable 1 Frequency reference 1 STANDARD Panel displays standard variables 2 PROCESS VAR Panel displays process variables See Figure 36 OUTPUT Process variable 2 Figure 36 ACS PAN output display when process variable display is selected 3402 P VAR 1 SEL Selection of process variable 1 Number of any parameter within Group 1 OPERATING DATA 3403 P VAR 1 MULTIP Process variable 1 multiplier 3404 P VAR 1 DIVISOR Process variable 1 divider 3405 P VAR 1 SCALING Decimal point location of process variable 1 when displayed Refer to Figure 37 Value Display 0 125 1 12 5 2 1 25 3 0 125 Figure 37 Display with different decimal point locations when calculated value is 125 3406 P VAR 1 UNIT Process variable unit 0 NO 4 96 8 kh 122mV 16 F 20 m3 s 24 gpm 28 Mgd 12A 5 s 9 C 13 kW 17 Hp 21 dm s 25 psi 29 inHg 2 V 6 h 10 kHz 14 W 18 MWh 22 bar 26 cFm 30 2 3 Hz 7 11 _ 15 kWh 19 23 kPa 27 31 84 ACS 400 User s Manual Code Description 3407 P VAR 2 SEL Selection of process variable 2 Number of any parameter within the group 1 OPERATING DATA 3408 P VAR 2 MULTIP Process variable 2 multiplier 3409 P VAR 2 DIVISOR Process variable 2 divider 3410 P VAR 2 SCALING Decimal point location of process variabl
67. control panel can be connected to and detached from the drive at any time The panel can be used to copy parameters to other ACS 400 drives with the same software version Parameter 3301 Run indicator haft direction Control modes Shaft directi UP DOWN Display modes TPUTIMENUILOC REMIRUN MENU ENTER Green LED Red LED e RESET START STOP LO RESET E LOC REM REVERSE Control Modes The first time the drive is powered up it is controlled from the Control Terminal Strip X1 remote control REM The ACS 400 is controlled from the control panel when the drive is in local control LOC Switch to local control LOC by pressing and holding the LOC REM button until first LOCAL CONTROL or LOCAL KEEP RUN is displayed Ifthe button is released while LOCAL CONTROL is displayed the panel frequency reference is set to the current external reference and the drive is stopped When LOCAL KEEP RUN is displayed the current run stop status and the frequency reference are copied from the user I O Start and stop the drive by pressing the START STOP button Change direction by pressing the REVERSE button Parameter 1003 must be set to REQUEST Switch back to remote control REM by pressing and holding the LOC REM button until REMOTE CONTROL is displayed Direction RUN gt Drive is running and at set point RUN Shaft direction is forward gt or rever
68. ction and reference can be received only from a single communication channel selectable by this parameter 0 NOT SEL Controlling commands are not received via serial communication 1 STD MODBUS Controlling commands can be received through Channel 1 standard Modbus protocol 2 DDCS Controlling commands can be received through the DDCS link 90 ACS 400 User s Manual Group 51 Ext Comm Module Parameters of this group need to be adjusted when a DDCS option module is installed Refer to option module documentation for more information regarding these parameters Code Description 5101 FIELDBUSPAR 1 Parameter 1 of communication module in DDCS link Value reflects the type of connected DDCS option module Table 11 List of module types Value Module type 0 No module connected 1 NPBA Profibus 2 NMBA Modbus 3 NIBA Interbus S 4 NCSA CS31 bus 5 NCAN CANopen 6 NDNA DeviceNet 7 NLON LONWORKS 8 NMBP Modbus 9 Others 5102 FIELDBUSPAR 2 FIELDBUSPAR 15 5115 Refer to option module documentation for more information on these parameters ACS 400 User s Manual 91 Group 52 Standard Modbus The ACS 400 can be connected to a Modbus fieldbus system Parameters of this group are used to set up station number communication speed and parity Parameters 5206 5215 are diagnostic counters that can be used to debug the fieldbus system Refer to Stan
69. ction Information Group 52 STANDARD MODBUS 5201 STATION NUMBER 1 247 1 Slave number for ACS 400 in Modbus network 5202 COMM SPEED 300 19200 bps 9600 bits s Communication speed 5203 PARITY NONE EVEN ODD NONE Parity and stop bit setting Group 50 COMMUNICATION 5003 COMM FAULT TIME 0 1 60 0 s 1 0s Time limit for communication loss detection 5004 COMM FAULT FUNC NOT SEL FAULT NOT SEL Operation in case CONST SP 7 communication with the LAST SPEED master device is lost 5005 PROTOCOL SEL NOT SEL DDCS STD NOT SEL Communication protocols MODBUS STD selection MDB DDCS Normally must be set to STD MODBUS ACS 400 User s Manual 99 Control Locations The ACS 400 drive can receive control information from multiple sources including digital I O analog I O keypad and Modbus fieldbus To control the ACS 400 via the serial communication channel 1 Modbus fieldbus it must be programmed to accept control commands and or frequency references from this channel To accept control from serial communications ACS 400 must be in remote control The necessary parameters and their usage are listed in Table 14 Before any control commands can be given through serial communication channel 1 parameter 5006 COMM COMMANDS value must be set to STD MODBUS Further information on all the parameters and their alternative settings can be found under ACS 400 Complete Parameter List on page 51 Table 14 Parameters for con
70. d The ACS 400 has the following LED alarm and fault indicators For location of LEDs see section E or if ACS PAN A control panel is connected see the instructions on page 25 Red LED off Green LED blinking ABNORMAL CONDITION ABNORMAL CONDITION ACS 400 cannot fully follow control commands Blinking lasts 15 seconds POSSIBLE CAUSES Acceleration or deceleration ramp is too fast in relation to load torque requirement Amomentary power interruption Red LED on Green LED on FAULT ACTION Apply a stop signal to reset fault Apply a start signal to restart the drive NOTE If the drive fails to start check that the input voltage is within the tolerance range POSSIBLE CAUSES Transient overcurrent Over undervoltage Overtemperature CHECK the supply line for disturbances the drive for mechanical problems that might cause overcurrent that the heat sink is clean Red LED blinking Green LED on FAULT ACTION Turn the power off Wait for the LED s to turn off Turn the power back on Caution This action may start the drive POSSIBLE CAUSE Output ground fault Short circuit DC bus ripple too large CHECK the insulation in the motor circuit Note Whenever the ACS 400 detects a fault condition the fault relay activates The motor stops and the ACS 400 will wait to be reset If the fault still persis
71. d Note Analog output content is programmable Values given here are valid only if other analog output configuration parameters have not been modified Description of all parameters is given in ACS 400 Complete Parameter List starting on page 51 Group 20 LIMITS 2003 MAX CURRENT Maximum output current Range 0 5 Iy 1 66 ly where Iy is nominal current of the ACS 400 Default value 1 5 In 2008 MAXIMUM FREQ Maximum output frequency Range 0 250 Hz Default value 50 Hz or 60 Hz depending on the application macro selected The table continues on the next page ACS 400 User s Guide 39 Code Name User 5 Group 21 START STOP 2102 STOP FUNCTION Conditions during motor stopping 1 COAST Motor coasts to stop 2 RAMP Ramp deceleration as defined by parameter 2203 DECELER TIME 1 or 2205 DECELER TIME 2 Default value 1 COAST Group 22 ACCELER DECELER 2202 ACCELER TIME 1 Ramp 1 time from zero to maximum frequency 0 MAXIMUM FREQ Range is 0 1 1800 s Default value 5 0 s 2203 DECELER TIME 1 Ramp 1 time from maximum to zero frequency MAXIMUM FREQ 0 Range is 0 1 1800 s Default value 5 0 s 2204 ACCELER TIME 2 Ramp 2 time from zero to maximum frequency 0 MAXIMUM FREQ Range is 0 1 1800 s Default value 60 0 s 2205 DECELER TIME 2 Ramp 2 time from maximum to zero frequency MAXIMUM FREQ 0
72. d automatic reset operations within a certain time is selectable Warning If parameter 3107 AR AI MIN is enabled the drive may restart even after a long stop when the analog input signal is restored Ensure that the use of this feature will not cause physical injury and or damage equipment Code Description 3101 NR OF TRIALS Sets the number of allowed autoresets within a certain time The time is defined with parameter 3102 TRIAL TIME The ACS 400 prevents additional autoresets and remains stopped until a successful reset is performed from the control panel or from a place selected by parameter 1604 FAULT RESET SEL 3102 TRIAL TIME The time within which a limited number of fault autoresets is allowed The allowed number of faults per this time period is given with parameter 3101 NR OF TRIALS 3103 DELAY TIME This parameter sets the time that the ACS 400 will wait after a fault occurs before attempting to reset If set to zero the ACS 400 will reset immediately 3104 AR OVERCURRENT DISABLE 1 ENABLE If 1 is selected the fault motor overcurrent is reset automatically after the delay set by parameter 3103 and the ACS 400 resumes normal operation 3105 AR OVERVOLTAGE DISABLE 1 ENABLE If 1 is selected the fault DC bus overvoltage is reset automatically after the delay set by parameter 3103 and the ACS 400 resumes normal operation 3106 AR UNDERVOLTAGE DISABLE 1 ENABLE If 1 is s
73. d 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 60 ACS 400 User s Manual 1002 EXT2 COMMANDS Defines the connections and the source of Start Stop and Direction commands for external control location 2 EXT2 Refer to parameter 1001 EXT1 COMMANDS above 1003 DIRECTION 1 FORWARD 2 REVERSE 3 REQUEST Rotation direction lock This parameter allows you to fix the direction of rotation of the motor to forward or reverse If you select 3 REQUEST the direction is set according to the given direction command ACS 400 User s Manual 61 Group 11 Reference Select Reference commands can be given from the control panel or from two external locations The selection between the two external locations is made with parameter 1102 EXT1 EXT2 SEL For more information on control locations refer to APPENDIX starting page 115 Code Description 1101 KEYPAD REF SEL Selection of active control panel reference in local control mode 1 REF1 Hz Control panel reference is given i
74. dard Serial Communication on page 95 for more information Code Description 5201 STATION ID Sets the slave number for the ACS 400 in Modbus network Range 1 247 Note Modifications take effect only on the next power up 5202 COM SPEED Defines the communication speed of the ACS 400 in bits per second bps 3 300 bps 48 4800 bps 6 600 bps 96 9600 bps 12 1200 bps 192 19200 bps 24 2400 bps Note Modifications take effect only on the next power up 5203 PARITY Defines the parity to be used with the Modbus communication Parameter also defines the number of stop bits With Modbus communication the number of stop bits is 2 with no parity bit and 1 with even or odd parity 0 NONE 1 EVEN 2 ODD Note Modifications take effect only on the next power up 5206 BAD MESSAGES This diagnostics counter increases by one every time the ACS 400 finds any kind of communication error During normal operation this counter hardly ever increases 5207 GOOD MESSAGES This diagnostics counter increases by one every time a valid Modbus message has been received by the ACS 140 During normal operation this counter is increasing constantly 5208 BUFFER OVERRUNS Longest possible message length for the ACS 400 is 32 bytes If a message exceeding 32 bytes is received this diagnostic counter increases by one every time a character is received and cannot be placed in the buffer 5209 FRAME ERRORS Thi
75. drive disconnected from the power source ACS 400 User s Manual 97 Activating Modbus protocol The factory setting for Channel 1 is not enabled To enable standard Modbus protocol for Channel 1 set parameter 5005 PROTOCOL SEL to 2 STD MODBUS After this parameter change the ACS400 is ready to communicate via Channel 1 using the default communication settings given in Table 12 making parameter read and write possible The following sections describe how to configure the ACS400 for more sophisticated communication and control Table 12 Default communication settings of the Channel 1 Station number 1 Communication speed 9600 bps Parity bit none Stop bits two 98 ACS 400 User s Manual Communication settings Communication settings define the communication speed parity checking number of stop bits and fault functions These settings for Channel 1 are defined using parameters in groups 50 COMMUNICATION and 52 STANDARD MODBUS Default communication settings for Channel 1 are listed in Table 12 To be able to communicate with the master device the ACS 400 must use the same communication speed and parity settings as the master Further information on all parameters and their alternative settings is given in under ACS 400 Complete Parameter List on page 51 Table 13 Communication parameters Code Name Range Default User Fun
76. e EXT REF2 MAX See Figure 22 If the PID Contro I any other macro than PID Control is selected this parameter sets the maximum frequency reference This value is given as percentage of maximum frequency erence in When analog input signal is at maximum external reference 2 equals to macro is selected this parameter sets the maximum process reference 64 ACS 400 User s Manual EXT REF A EXT REF MAX EXT REF MIN Analog input signal EXT REF A EXT REF MIN EXT REF 4 3 p Analog input signal Figure 22 Setting EXT REF MINIMUM and EXT REF MAXIMUM The range of the analog input signal is set by parameters 1301 and 1302 or parameters 1304 and 1305 depending on the analog input used Example For 4 to 20 mA input set 1301 20 and 1302 100 ACS 400 User s Manual 65 Group 12 Constant Speeds The ACS 400 has 7 programmable constant speeds ranging from 0 to 250 Hz Negative speed values cannot be given for constant speeds Constant speed selections are ignored if the drive is in local mode or if the process PID reference is followed see PID Control Macro Note Parameter 1208 CONST SPEED 7 acts as a fault speed which can be activated if the control signal is lost Refer to parameter 3001 Al lt MIN FUNCTION and parameter 3002 PANEL LOSS Code Description 1201 CONST SPEED SEL This parameter defines which digital inputs are used
77. e 2 when displayed 3411 P VAR 2 UNIT Process variable 2 unit See parameter 3406 Example Assume that a two pole motor is directly connected to a roll of 0 1 m diameter and the line Speed is to be displayed in m s The following settings are then needed 3401 DISPLAY SEL 2 PROCESS VAR 3402 P VAR 1 SEL 0103 OUTPUT FREQ 3406 P VAR 1 UNIT 19 m s For a 2 pole motor 1 Hz output equals 1 rev s equals PI 0 1m s line speed or approximately 0 314 m s is output freq 314 1000 line speed m s Select 3403 P VAR 1 MULTIP 314 3404 P VAR 1 DIVISOR 1000 Since variable 0103 OUTPUT FREQ is displayed with 0 1 Hz resolution it is internally scaled so that value 10 represents 1 Hz Therefore Parameter 3405 P VAR 1 SCALING must be set to 1 ACS 400 User s Manual 85 Group 40 PID Control The PID Control Macro allows the ACS 400 to take a reference signal setpoint and an actual signal feedback and automatically adjust the speed of the drive to match the actual signal to the reference The control signal block diagram is show in figure 34 on page 118 of the Appendix 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 Limited by parameter 2008 MAXIMUM FREQ 4002 PID INTEG TIME PID controller inte
78. e exception of bit 10 REMOTE which is not used by the ACS 400 108 ACS 400 User s Manual References References are 16 bit words containing a sign bit and a 15 bit integer A negative reference indicating reversed direction of rotation is formed by calculating the two s complement from the corresponding positive reference Reference 1 Holding Register 40002 Reference 1 can be used as the frequency reference REF1 for the ACS 400 Scaling 20000 ExT REF1 MAX Hz parameter 1105 Scaling Parameter 1104 EXT REF1 MIN is not used The signal source of external reference 1 REF1 must be set to COMM and external control location 1 EXT1 must be activated Refer to parameters 1103 EXT REF 1 SELECT and 1102 EXT1 EXT2 SEL Reference 2 Holding Register 40003 Reference 2 can be used as the frequency reference REF2 for the ACS 400 Scaling 10000 2 ExT REF2 MAX 96 parameter 1108 Scaling Parameter 1107 EXT REF2 MIN is not used The signal source of external reference 2 REF2 must be set to COMM and External control location 2 EXT2 must be activated Refer to parameters 1106 EXT REF 2 SELECT and 1102 EXT1 EXT2 SEL Fieldbus Reference Selection and Correction Fieldbus reference is selected by setting a Reference selection parameter 1103 EXT REF1 SELECT or 1106 EXT REF2 SELECT to COMM COMM AI1 or COMM AI1 The latter two enable correction of the fieldbus reference using Analog input AI ACS 400 User s Manual 109 T
79. e for 63 temperature rise This is the time within which the motor temperature reaches 63 of the final temperature rise Figure 29 shows motor thermal time definition If thermal protection according to UL requirements for NEMA class motors is desired use this rule of thumb MOTOR THERM TIME equals 35 times t6 t6 in seconds is the time that the motor can safely operate at six times its rated current given by the motor manufacturer The thermal time for a Class 10 trip curve is 350 s for a Class 20 trip curve 700 s and for a Class 30 trip curve 1050 s Motor load A Temp Rise gt t 100 2 72 6396 lE Mot therm time Figure 29 Motor thermal time 3006 MOT LOAD CURVE Motor current maximum limit MOTOR LOAD CURVE sets the maximum allowable operating load of the motor When set to 100 the maximum allowable load is equal to the value of Start up Data parameter 9906 MOTOR NOM CURRENT The load curve level should be adjusted if the ambient temperature differs from the nominal value Output current relative to 9906 MOTOR NOM CURR 4 150 3006 MOT LOAD CURVE 100 a 3007 ZERO SPEED LOAD 50 i Frequency 3008 BREAK POINT Figure 30 Motor load curve 78 ACS 400 User s Manual 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 3
80. e parameter default value press the UP DOWN buttons simultaneously 32 ACS 400 User s Manual Menu Functions Scroll through the Parameter groups for the desired menu function Press and hold ENTER until the display blinks to start the function Note The ACS100 PAN upload and download functions are not operational with ACS 400 Relatively small permanent memory of the ACS100 PAN cannot store all the ACS 400 parameter values Select between basic and full menu Press and hold a RS ENTER LL ENU 1 Visible if Full menu is active Resetting the Drive from the Control Panel When the red LED of the ACS 400 is on or blinking a fault is active To reset a fault when the red LED is on press the START STOP button Caution This may start the drive when in remote control To reset a fault when the red LED is blinking turn the power off Caution Turning the power on again may start the drive immediately The relevant fault code see Diagnostics flashes in the panel display until the fault is reset or the display is cleared You can clear the display without resetting the fault by pressing any button The word FAULT will be displayed Note If no other button is pressed within 15 seconds and the fault is still active the fault code will be displayed again After a power failure the drive will revert to the same control mode LOC or REM as before the power failure
81. ection Examples Please note the following in the examples below All the digital inputs are connected using negative NPN logic The signal type of analog input is selected with V I jumper J1 Frequency reference is provided with Vl Jumper voltage signal 0 10 V open X X current signal 0 20 mA connected If the frequency reference is provided with a voltage signal from both Al1 and AI2 keep the jump ers positioned according to the picture below ACS 400 User s Manual 41 Application Macro Factory 0 This macro is intended for applications where there is no control panel available It provides a general purpose I O configuration that is typically used in Europe Note The value of parameter 9902 is 0 FACTORY 014 is not connected Input signals Output signals V I jumper S1 Start stop and direction 011 2 An output AO Frequency 0 10 V Analog reference 11 Relay output 1 Fault 0 10 V Constant speed 1 DI3 Relay output 2 Running Ramp pair 1 2 selection DI5 c SCR cht All External Reference 1 0 10 V lt gt 0 50 Hz 1 1 AGND C HU 10V Reference voltage 10 VDC s 2 Not used m s AGND __ nA 7 Output
82. ection commands is defined by parameter 1002 EXT2 COMMANDS and the reference source is defined by parameter 1106 EXT REF2 SELECT External reference 2 can be a frequency reference or a process reference depending on the application macro selected In remote control constant speed operation can be programmed by parameter 1201 CONST SPEED SEL Digital inputs can be used to select between the external frequency reference and seven configurable constant speeds 1202 CONST SPEED 1 1208 CONST SPEED 7 EXT REF2 EXT REF1 EXT EXT2 CONST SP KEYPAD SELECT SELECT SELECT SELECT REF SEL Control 1106 1103 noe 1201 1101 Terminals 1 1 1 AM 2 DM 5 EXT1 Analog KEYPAD 2 inputs Al2 1 Al1 2 011 5 DI DI5 Min freq Remote Max freq Digital KEYPAD ee Applic Local inputs i PID Const Crit speed DI1 015 Speeds i Acc Dec 1 1 j 1 1 i REF2 i 1 1 1 REF1 Hz Keypad i 1 1 Ref Loc Rem L 4 gt Rm Start Stop NOT SEL Local DH DI5 EXT AS REQUEST A KEYPAD Remote x Direction NOT SEL FORWARD i Di Dis EXT REVERSE Enabled i A D DI5 EXT EXT2 DIRECTION RUN ENABLE
83. eep function 1402 RE LAY OUTPUT 2 Re jay output 2 content Refer to parameter 1401 RELAY OUTPUT 1 1403 RE Sw LAY 1 ON DELAY itch on delay for relay 1 Selected controlling signal 1404 RE Sw LAY 1 OFF DELAY Sl 1405 RE Sw itch off delay for relay 1 LAY 2 ON DELAY Ak 809 itch on delay for relay 2 Relay status 1406 RE Sw LAY 2 OFF DELAY 1403 ON DELAY 1404 OFF DELAY itch off delay for relay 2 Figure 24 ACS 400 User s Manual 69 Group 15 Analog Output Analog output is used to output the value of any parameter of the Operating Data group Group 1 as a current signal Output current minimum and maximum values are configurable as are the allowed minimum and maximum values for the observed parameter If analog output content maximum value parameter 1503 is set to less than minimum value parameter 1502 output current is inversely proportional to the value of the observed parameter Code Description 1501 AO CONTENT Content for analog output Number of any parameter of the Operating Data group Group 01 1502 AO CONTENT MIN Analog output content minimum Display depends on parameter 1501 1503 AO CONTENT MAX Analog output content maximum Display depends on parameter 1501 1504 MINIMUM AO Minimum output current 1505 MAXIMUM AO Maximum output current 1506 AO FILTER
84. elected the fault DC bus undervoltage is reset automatically after the delay set by parameter 3103 DELAY TIME and the ACS 400 resumes normal operation 3107 AR Al lt MIN DISABLE 1 ENABLE If 1 is selected the fault analog input signal under minimum level is reset automatically after the delay set by parameter 3103 DELAY TIME x Automatic reset Trial time CS eS X lime Now Figure 34 Operation of automatic reset function In this example if the fault occurs at the moment Now it is automatically reset if parameter 3101 NR OF TRIALS value is greater than or equal to 4 ACS 400 User s Manual 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 within the Operating Data group Group 1 can be supervised Relays can be configured to be energized when the values of supervised parameters are either too low or too high Code Description 3201 SUPERV 1 PARAM First supervised parameter number within the Operating Data group Group 01 3202 SUPERV 1 LIMLO 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 within the Op
85. erating Data group Group 01 3205 SUPERV 2 LIMLO Second supervision limit low Display of this parameter depends on selected supervised parameter 3204 3206 SUPERV 2 LIM HI Second supervision limit high Display of this parameter depends on selected supervised parameter 3204 Value of supervised parameter hi 3203 lo 3202 Energized 1 De energized 0 Energized 1 De energized 0 A Parameter 1401 RELAY OUTPUT 1 1402 RELAY OUTPUT 2 value is SUPRV1 OVER or SUPRV2 OVER B Parameter 1401 RELAY OUTPUT 1 1402 RELAY OUTPUT 2 value is SUPRV1 UNDER or SUPRV2 UNDER Figure 35 Operating data supervision using relay outputs 82 ACS 400 User s Manual Group 33 Information Code Description 3301 SW VERSION Software version 3302 TEST DATE Displays the test date of the ACS 400 yy ww ACS 400 User s Manual 83 Group 34 Process Variables Parameters within this group can be used to create custom process variables Values of process variables can be seen in parameters 0134 PROCESS VAR 1 and 0135 PROCESS VAR 2 AND optionally in the ACS PAN output display Value is calculated by taking given parameter from the operating data group Group 1 and multiplying and dividing it with given coefficients The unit and number of decimal digits is configurable See example below Code Description 3401 DISPLAY SEL Selects displayed v
86. ernate parameter values 9905 MOTOR NOM VOLT 400 V 1105 EXT REF1 MAX 50 Hz 9907 MOTOR NOM FREQ 50 Hz 1106 EXT REF2 SELECT 0 KEYPAD 9908 MOTOR NOM SPEED 1440 rpm 1201 CONST SPEED SEL 7 013 4 1001 EXT 1 COMMANDS 9 DI1F 2R 1503 AO CONTENT MAX 50 Hz 1002 EXT 2 COMMANDS 0 NOT SEL 1601 RUN ENABLE 0 NOT SEL 1003 DIRECTION 3 REQUEST 1604 FAULT RESET SEL 0 KEYPAD 2008 MAXIMUM FREQ 50 Hz 1102 EXT1 EXT2 SEL 6 ExT1 2105 PREMAGN SEL 0 NOT SEL 1103 EXT REF1 SELECT 1 11 2201 ACC DEC 1 2 SEL 5 015 46 ACS 400 User s Manual Application Macro Motor Potentiometer This macro provides a cost effective interface for PLCs that vary the speed of the drive using only digital signals Note The value of parameter 9902 is 4 MOTOR POT Input signals Output signals Start stop and direction An output AO Frequency 011 2 Reference 013 Relay output 1 Fault Reference down 014 Relay output 2 Running Preset speed selection DI5 1 SCR 2 External Reference 1 0 10 V AGND 4 10V Reference voltage 10 VDC s Not used AGND MA 1 Output frequency 0 20 mA lt gt 0 50 Hz AGND 24V 24 VDC PE x pro Start Stop Activate to start LL 1 Forward Reverse Activate to re
87. es DC OVERVOLTAGE DC overvoltage Input voltage too high Deceleration time may be too short ACS400 OVERTEMP ACS 400 overtemperature Ambient temperature too high Severe overload SHORT CIRCUIT Fault current Short circuit Power supply disturbances OUTPUT OVERLOAD Output overload DC UNDERVOLTAGE DC undervoltage ANALOG INPUT 1 Analog input 1 fault Analog input 1 value is less than MINIMUM 1301 See also parameter 3001 Al lt MIN FUNCTION ANALOG INPUT 2 Analog input 2 fault Analog input 2 value is less than MINIMUM AI2 1304 See also parameter 3001 Al lt MIN FUNCTION MOTOR OVERTEMP Motor overtemperature See parameters 3004 3008 PANEL LOSS Panel loss Panel is disconnected when Start Stop Dir or reference is coming from panel See parameter 3002 and APPENDIX Note If FL10 is active when the power is turned off the ACS 400 will start in remote control REM when the power is turned back on PARAMETERING Parameters inconsistent Possible fault situations MINIMUM gt MAXIMUM parameters 1301 and 1302 MINIMUM AI2 MAXIMUM AI2 parameters 1304 and 1305 MINIMUM FREQ MAXIMUM FREQ parameters 2007 and 2008 MOTOR STALL Motor stall See parameter 3009 STALL FUNCTION SERIAL COMM LOSS Serial communication loss EXTERNAL FAULT SIGNAL External fault is active See parameter 3008 EXTERNAL FAULT
88. es Figure 7 Mounting type IP54 drives ACS 400 User s Manual D Removing the Cover Opening frame size R1 and R2 units See Paragraph S for frame size assignments of type codes ANS 1 Remove the control panel 2 n the control panel slot there is a small hole Press the retaining lever inside the hole 3 Remove the cover Figure 8 Opening the frame size R1 and R2 drives of type IP 21 NEMA 1 Opening frame size R3 and R4 units See Paragraph S for frame size assignments of type codes 1 Remove the control panel if needed 5 Press the retaining lever and pull 2 Liftthe retaining lever and simultaneously pull the 6 Remove the lower part of the front cover upper front cover slightly 3 Lift the other retaining lever e g with a screwdriver 4 Open the upper part of the front cover and remove it Figure 9 Opening the frame size R3 and R4 size drives of type IP 21 NEMA 1 ACS 400 User s Manual IP 54 NEMA 12 1 Take the screws off 2 Remove the front cover 3 Remove panel if needed Figure 10 Opening type IP 54 NEMA 12 drives ACS 400 User s Manual E Terminal Interface Green LED
89. eter values 9905 MOTOR NOM VOLT 400 V 1105 EXT REF1 MAX 50Hz 9907 MOTOR NOM FREQ 50Hz 1106 EXT REF2 SELECT 0 KEYPAD 9908 MOTOR NOM SPEED 1440 rpm 1201 CONST SPEED SEL 7 013 4 1001 ExT 1 COMMANDS 2 011 2 1503 AO CONTENT 50 Hz 1002 EXT 2 COMMANDS 0 NOT SEL 1601 RUN ENABLE 0 NOT SEL 1003 DIRECTION 3 REQUEST 1604 FAULT RESET SEL 0 KEYPAD 2008 MAXIMUM FREQ 50 Hz 1102 EXT1 EXT2 SEL 6 ExT1 2105 PREMAGN SEL 5 DI5 1103 EXT REF1 SELECT 1 KEYPAD 2201 ACC DEC 1 2 SEL 0 NOT SEL 50 ACS 400 User s Manual ACS 400 Complete Parameter List Initially only the basic parameters shaded grey in Table 7 are visible See Selecting Full Parameter Set on page 28 for menu function to select full parameter set S Parameters can be modified only when the drive is stopped Default value depends on the selected macro Table 7 Full parameter set Code Name Range Resolution Default User S M Group 99 START UP DATA 9901 LANGUAGE 0 12 1 0 ENGLISH UK 9902 APPLIC MACRO 0 7 1 FACTORY v 9905 MOTOR NOM VOLT 200 208 220 230 240 ig v 380 400 415 440 460 480 V 9906 MOTOR NOM CURR 0 5 ly 1 5 0 1A 1 0 ln v 9907 MOTOR NOM FREQ 0 250Hz 1Hz 9908 MOTOR NOM SPEED 0 3600 rpm 1 rpm viv 9909 MOTOR NOM
90. for ACS PAN A control panel 0 ENGLISH UK 3 ITALIAN 6 DUTCH 9 FINNISH 12 reserved 1 ENGLISH US 4 SPANISH 7 FRENCH 10 SWEDISH 2 GERMAN 5 PORTUGUESE 8 DANISH 11 RUSSIAN Note The ACS 100 PAN does not support Language selection 9902 APPLIC MACRO Application macro selection This parameter is used to select the Application Macro which will configure the 400 for a particular application Refer to Application Macros starting page 41 for a list and description of available Application Macros 0 FACTORY 2 3 WIRE 4 MOTOR POT 6 PID CONTROL 1 ABB STANDARD 3 ALTERNATE 5 HAND AUTO 7 PREMAGN 9905 MOTOR NOM VOLT Nominal motor voltage from motor nameplate This parameter sets the maximum output voltage supplied to motor by ACS 400 MOTOR NOM FREQ sets the frequency at which output voltage is equal to the MOTOR NOM VOLT The ACS 400 cannot supply the motor with a voltage greater than the input voltage See Figure 20 9906 MOTOR NOM CURR Nominal motor current from nameplate The allowed range is 0 5 1 5 ly of ACS 400 9907 MOTOR NOM FREQ Nominal motor frequency from nameplate field weakening point See Figure 20 9908 MOTOR NOM SPEED Nominal motor speed from nameplate 9909 MOTOR NOM POWER Nominal motor power from nameplate 9910 MOTOR COS PHI Nominal motor cos phi from nameplate Output voltage MOTOR NOM VOLT ce ee cee B Output frequency MOTOR NOM FREQ Figure 20 Outpu
91. frequency 0 20 mA lt gt 0 50 Hz s AGND 9 24V 24 VDC o DCOM1 F Start Stop Activate to start ACS400 DI2 Fwd Rev Activate to reverse rotation direction DIS Constant Speed 1 Default 5 Hz 14 DIA Leave unconnected 15 DIS Ramp pair selection Activate to select ramp pair 2 16 IDDCOM2 RO1C Relay ouput 1 programmable ROTA Default Fault gt 17 connected to 18 19 RO1B f 2 RO2C Relay ouput 2 programmable 21 ROZA Default Running gt 20 connected to 22 22 Note DI 4 is used to configure ACS 400 It is read only once when power is connected When DI 4 is open 0 the following applies All parameters marked are determined by the DI4 input Motor nominal values 400 V and 50 Hz and 1440 rpm Input and output signals are scaled according to 50 Hz Maximum frequency is 50 Hz Factory 0 parameter values 9905 MOTOR NOM VOLT 400 V 1105 EXT REF1 MAX 50Hz 9907 MOTOR NOM FREQ 50Hz 1106 EXT REF2 SELECT 0 KEYPAD 9908 MOTOR NOM SPEED 1440 rpm 1201 CONST SPEED SEL 013 1001 EXT 1 COMMANDS 2 DI1 2 1503 AO CONTENT MAX 50 Hz 1002 EXT 2 COMMANDS 0 NOT SEL 1601 RUN ENABLE 0 NOT SEL 1003 DIRECTION 3 1102 EXT1 EXT2 SEL 6 1103 EXT REF1 SELECT 1 REQUEST 1604 FAULT RESET SEL 6 START STOP 1 2008 MAXIMUM FREQ 50 Hz 2105 PREMAGN SEL 0 NOT SEL 2201 ACC DEC 1 2 SEL
92. g input 1 fault Analog input 2 fault COIN OO a PB wo MD oO Motor overtemperature Hardware error Panel loss eo Parameters inconsistent ET En DC bus ripple too large E N Motor stall ET e Serial communication loss E A External fault ET oa Output ground fault ACS 400 User s Manual 113 Table 26 ALARM WORD 1 bit descriptions Bit ALARM WORD 1 Overcurrent controller alarm Overvoltage controller alarm Undervoltage controller alarm Direction lock alarm Serial communication loss Modbus exception generated locally Analog input 1 loss Analog input 2 loss COIN OD a BP oO Panel loss o ACS 400 overtemperature eo Motor overtemperature ET En Underload E N Motor stall alarm ET e DDCS link E A Reserved ET oa Reserved 114 ACS 400 User s Manual APPENDIX Local Control vs Remote Control The ACS 400 can be controlled from two remote control locations or from the control panel Figure 44 below shows the ACS 400 control locations The selection between local control LOC and remote control REM can be done by pushing the MENU and ENTER buttons simultaneously when the ACS100 PAN is used and by pushing the LOC REM button when ACS PAN is used Start Stop Direction Keypad Reference
93. gration 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 96 change is achieved in 1 s VY PID integration time 4003 PID DERIV TIME PID controller derivation time If the process error value changes linearly D part adds a constant value into the PID controller output The derivative is filtered with a 1 pole filter The time constant of the filter is defined by parameter 4004 PID DERIV FILTER Process Error Value 100 Gain Se 2 27 PID derivation time 4004 PID DERIV FILTER Time constant for the filter of D part By increasing the filter time constant it is possible to smooth 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 86 ACS 400 User s Manual Code Description 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 1 Actual value 1 is used as the feedback signal 2 ACT1 ACT2 Difference of actual
94. he Status Word Holding Register 40004 The Status Word is a read only word containing information of the ACS 400 status The contents of Status Word is presented in the following table The text in italics refers to the states in Figure 43 Table 22 The Status Word Bit Value Description 0 READY TO SWITCH ON NOT READY TO SWITCH ON READY TO OPERATE OPERATION ENABLED 1 0 1 0 OFF1 ACTIVE 1 0 Not ready OPERATION INHIBITED 3 0 1 FAULT No fault OFF2 inactive OFF2 ACTIVE inactive OFF3 ACTIVE SWITCH ON INHIBITED Any alarm except AL1 AL7 AL15 AL27 and AL28 No alarm oj 2 j oj 2 o 2 o 2 o OPERATING Actual value equals reference value is within tolerance limits Actual value differs from reference value is outside tolerance limits Drive control location REMOTE Drive control location LOCAL The value of first supervised parameter equals to or is greater than supervision limit Refer to Group 32 Supervision The value of first supervised parameter is below supervision limit External control location 2 ExT2 selected External control location 1 EXT1 selected Run Enable signal received Oo o No Run Enable signal received 13 to 15 Unused 110 ACS 400 User s Manual Actual Values Actual values are read only values containing i
95. imize this delay The value of parameter 9902 is 7 PREMAGN Input signals Output signals Jumper S1 Start stop and direction An output AO Frequency DI1 2 0 10 V Analog reference 11 Relay output 1 Fault 0 10V Preset speed selection DI3 4 Relay output 2 Running Premagnetize DI5 vwa SCR cht D External Reference 1 0 10 V lt gt 0 50 Hz 3 1 1 4_ 10 Reference voltage 10 VDC s_ Al2 Not used 6 AO1 Output frequency 0 20 mA lt gt 0 50 Hz s AGND 24V 24 VDC 10 DCOM1 DH Start Stop Active to start ACS 400 2 DI2 Fwd Rev Activate to reverse rotation th DIB Constant Speed selection 7 11 Constant Speed selection 7 45 1015 Premagnetize Activate to start premagnetising 16 2 RO1C Relay ouput 1 programmable 18 Default Fault gt 17 connected to 18 19 RO1B f 20 RO2C Relay ouput 2 programmable 21 RO2A Default Running gt 20 connected to 22 22 Constant speed selection 0 open 1 connected DI3 014 Output Reference through Al1 Constant speed 1 1202 Constant speed 2 1203 Constant speed 3 1204 o 2 o 2 o o Premagnetize param
96. it Plates A package containing three screws and two gland plates and or one conduit plate is included with the ACS 400 Figure 15 Gland plate for power cables A and for control cables B The conduit plate is a single piece with two blank spaces for punching holes for power and control conduits The conduit plate does not have cable clamps A package containing five screws and two cable clamp brackets is included with the type IP 54 NEMA 12 ACS 400 drives These are required only for IEC installations Gland plates are used for IEC installations and conduit plates are used for US installations Contact your local ABB representative for additional information regarding IEC installations To open the front cover see Removing the Cover on page 7 Figure 16 Removing the front cover ACS 400 User s Manual 11 Connect the gland plate for power cables with one screw The threaded hole for the screw is located in the middle of the heat sink at the bottom end see Figure 17 point marked with a IP 21 NEMA 1 KS Figure 17 Installing the gland plate for power cables A type IP 21 NEMA 1 drives The gland plate for control cables B is attached with two screws into threaded holes marked b in Figure 18 This gland plate is located on top of the power cable gland plate marked A IP 21 NEMA 1 Figure 18 Installing the gland plate for control
97. mensions of units with IP 21 NEMA 1 enclosures Frame Size IP21 NEMA 1 Dimension Reference See Paragraph S for frame size assignments of type codes in mm R1 R2 R3 R4 w 4 92 125 4 92 125 7 99 203 7 99 203 w1 3 86 98 3 86 98 3 86 98 3 86 98 H 12 99 330 16 93 430 21 46 545 25 04 636 H1 12 52 318 16 42 417 20 79 528 24 37 619 H2 11 81 300 15 75 400 19 69 500 23 62 600 D 8 23 209 8 70 221 9 72 247 11 02 280 a 0 217 5 5 0 217 5 5 0 256 6 5 0 256 6 5 b 0 394 10 0 394 10 0 512 13 0 512 13 c 0 217 5 5 0 217 5 5 0 256 6 5 0 256 6 5 Mass Ib kg 12 76 5 8 19 80 9 0 40 70 18 5 59 40 27 4 ACS 400 User s Manual Units with IP 54 NEMA 12 Enclosures The IP 54 NEMA 12 protection class has a different outer plastic cover The IP 54 NEMA 12 enclosure uses the same internal plastic shell as the IP21 enclosure but an internal fan is added to improve cooling This structure increases the dimensions compared to the IP 21 enclosure but does not require a de rating H1 FRONT 2 2d Figure 54 12 enclosures Table 2 Dimensions of units with IP 54 NEMA 12 enclosures Frame Size IP54 NEMA 12 Dimension Reference See Paragraph S for frame size assignments of type codes in mm R1 R2 R3 R4 8 46 215 8 46 215 10 12 257 10 12 257 w1 3 8
98. n Hz 2 REF2 96 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 DI1 D15 External control location 1 or 2 is selected according to the state of the selected digital input DI1 015 where deactivated EXT1 and activated EXT2 6 ExT1 External control location 1 ExT1 is selected The control signal sources for EXT1 are defined with parameter 1001 Start Stop Direction commands and parameter 1103 reference 7 2 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 62 ACS 400 User s Manual 1103 EXT REF1 SELECT This parameter selects the signal source of external reference 1 0 KEYPAD Reference is given from the control panel 1 Al1 Reference is given through analog input 1 2 Al2 Reference is given through analog input 2 3 Al1 JOYST 4 Al2 JOYST Reference is given through analog input 1 or 2 accordingly configured for a joystick The minimum input signal runs the drive at maximum reference in the reverse direction
99. n and integration time values are used to adjust the responsiveness of the system A low value for proportional gain and a high value for integral time ensures stable operation but provides sluggish response Too large of a proportional gain value or too short of an integral time can cause the system to become unstable To start set Parameter 4001 PID Gain to 0 3 Set Parameter 4002 Integration Time to 20 seconds Start the system and see if it reaches the set point quickly while maintaining stable operation If not increase PID Gain 4001 until the actual signal or drive speed oscillates constantly It may be necessary to start and stop the drive to induce this oscillation Reduce PID Gain 4001 until the oscillation stops Set the value to 0 4 to 0 6 times this value Decrease the Integration Time 4002 until the feedback signal or drive speed oscillates constantly It may be necessary to start and stop the drive to induce this oscillation Increase Integration Time 4002 until the oscillation stops Set the value to 1 15 to 1 5 times this value If the feedback signal contains high frequency noise increase the value of Parameter 4004 Derivative Filter until the noise is filtered from the signal ACS 400 User s Manual 89 Group 50 Communication Parameters of this group define some general communication settings Parameters 5001 5002 are used only if DDCS option card is installed Code Description 5001 DDCS BIT RATE
100. nformation on the operation of the drive Actual values are 16 bit words containing sign bit and a 15 bit integer A negative value is given as two s complement of the corresponding positive value Actual Value 1 Holding Register 40005 Actual output frequency Scaling 5000 2 50 Hz Actual Value 2 Holding Register 40006 Actual output current Scaling 10 2 1 A Example The following example shows how to use the Control Word to start the drive When the power is connected the state machine state is NOT READY TO SWITCH ON Table 23 Using the Control Word Control Word Value Description Step 1 CW 0000 0000 0000 0110 bit 15 bit 0 When this value is written state machine state changes to READY TO SWITCH ON Step 2 CW 0000 0000 0000 0111 When this value is written state machine state change S to READY TO OPERATE Step 3 CW 0000 0000 0000 1111 When this value is written the drive starts but will not accelerate State machine state changes to OPERATION ENABLED Step 4 CW 0000 0000 0001 1111 When this value is written the ramp function generator RFG output is released State machine state changes to RFG ACCELERATOR ENABLED Step 5 CW 0000 0000 0011 1111 When this value is written the ramp function generator RFG input is released Drive will accelerate to the given reference State machine state changes to OPERATING
101. ntrol panel loss fault 1 FAULT fault indication is displayed and the ACS 400 coasts to stop 2 CONST SP 7 warning indication is displayed and the speed is set according to parameter 1208 CONST SPEED7 3 LAST SPEED warning indication is displayed and the speed is set to the level the ACS 400 was last operating at This value is determined by the average speed over the last 10 seconds Caution If you select CONST SPEED 7 or LAST SPEED make sure that it is safe to continue operation in case panel is lost 3003 EXTERNAL FAULT External fault input selection NOT SEL External fault signal is not used 1 5 DI1 D15 This selection defines the digital input used for an external fault signal If an external fault occurs i e digital input is deactivated the ACS 400 is stopped and the motor coasts to stop and fault indication is displayed ACS 400 User s Manual 77 Code Description 3004 MOT THERM PROT Motor overtemperature function This parameter defines the operation of the motor thermal protection function which protects the motor from overheating 0 NOT SEL 1 FAULT Displays a warning indication at 95 of the nominal value Displays a fault indication when the motor temperature reaches 100 level The ACS 400 coasts to stop 2 WARNING A warning indication is displayed when the motor temperature reaches 95 of the nominal value 3005 MOT THERM TIME Tim
102. o help you mark the mounting holes for installation of your ACS 400 a Wall Mounting Template is drawn on the lid of the box Tear the lid off and save it Step by step instructions The installation of the ACS 400 has been broken down in a number of steps that are listed on page 2 The steps must be carried out in the order shown At the right of each step reference is made to one or more Reference Sections on the following pages of this User s Manual These sections give detailed information needed for the correct installation of the unit A Warning Before you begin read all of the Safety instructions ACS 400 User s Manual 1 Ceo gt G 4 CHECK the environment 2 C MOUNT the ACS 400 to the wall C REMOVE the cover 4 C _ ATTACH a warning sticker in the language of your choice 5 C IDENTIFY power and control terminals 6 C CHECK voltage supply 7 C CHECK the motor C CHECK I O jumpers J1 and J2 C CONNECT power terminals 4 CONNECT control wires o C REPLACE the cover 12 C TURN the power on Figure 1 Step by step instructions for installing the ACS 400 The references after each step refer to one or more of the Reference Sections on the following pages in this manual gt Uu co 42 o m T See 1 See G S m c r 40 m See E I J L 40
103. oe Standard Function Information 9 Modbus Group 01 OPERATING DATA 0131 SER LINK DATA 1 0 255 Controlling data for the relay outputs 0132 SER LINK DATA 2 0 255 Group 14 RELAY OUTPUTS 1401 RELAY OUTPUT 1 NOT SEL e g SUPERV1 Relay output 1 function OVER With the given setting the relay 1 is SUPRV1 OVER activated when supervised parameter 1 ISUPRV1 UNDER given by parameter 3201 is above the ISUPRV2 OVER limit given by parameter 3203 ISUPRV2 UNDER UNDERLOAD 1402 RELAY OUTPUT 2 As above e g SUPERV1 Relay output 2 function OVER See above Group 32 SUPERVISION 3201 SUPERV 1 PARAM 102 137 e g 131 Number of supervised parameter 1 Any parameter of the group 1 OPERATING DATA 3202 SUPERV 1 LIM LO 0 255 e g 100 Lower supervision limit for supervised parameter 1 3203 SUPERV 1 LIM HI 0 255 e g 100 Upper supervision limit for supervised parameter 1 3204 SUPERV 2 PARAM 102 137 e g 132 Number of supervised parameter 1 Any parameter of the group 1 OPERATING DATA 3205 SUPERV 2 LIM LO 0 255 e g 100 Lower supervision limit for supervised parameter 2 102 ACS 400 User s Manual Setting for Code Parameter Name Paar esas Standard Function Information 9 Modbus 3206 SUPERV 2 LIM HI 0 255 e g 100 Upper supervision limit for supervised parameter 2 Table 16 Analog output control n Setting for Code Parameter Name SWE Standard Function Information 9 Modbus
104. oint Figure 28 Operation of IR compensation 76 ACS 400 User s Manual Group 30 Fault Functions The ACS 400 can be configured to respond to certain abnormal external conditions analog input fault external fault signal and panel loss In these cases the drive can either continue operation at current speed or at a set constant speed while showing an alarm ignore the condition or trip on a fault and stop Motor thermal protection parameters 3004 3008 provide a means of adjusting the motor load curve For example limiting the load near zero speed might be necessary if the motor does not have an externally powered 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 minimum limit NOT SEL No operation 1 FAULT fault indication is displayed and the ACS 400 coasts to stop 2 CONST SP 7 A warning indication is displayed and the speed is set according to parameter 1208 CONST SPEED7 3 LAST SPEED warning indication is displayed and the speed is set to the level the ACS 400 was last operating at This value is determined by the average speed over the last 10 seconds Caution If you select CONST SPEED 7 or LAST SPEED make sure that it is safe to continue operation in case analog input signal is lost 3002 PANEL LOSS Operation in case of co
105. on 2603 COMPENSATION Table 10 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 Hp 5 10 20 25 50 overheating Refer to Table 10 IRcomp V 21 18 15 12 10 2604 IR COMP RANGE IR compensation range Defines frequency after which IR compensation is 0 V 2605 LOW NOISE Motor acoustical noise option OFF standard switching frequency 4 kHz 12 Low noise switching frequency 8 kHz Note When the low noise setting is used the maximum overload of the ACS 400 is I at 30 C ambient temperature or 0 9 I at 40 C 2606 V f RATIO V f ratio below field weakening point 1 LINEAR 2 SQUARE Linear is used for constant torque applications and Square for centrifugal pump and fan applications Square is quieter for most operating frequencies 2607 SLIP COMP Slip Compensation increases frequency slightly as motor load increases so that speed remains constant within 1 296 even though slip increases from 0 to 3 as load increases from 0 to 100 The amount of frequency boost is equal to the product of 9908 MOTOR MOTOR NOM SPEED POLES X 0105 TORQUE 2607 SLIP COMP 120 100 100 9907 MOTOR NOM FREQ Over compensation is possible by adjusting Parameter 2607 to greater than 100 U A IR compensation IR compensation range EE gt f Hz Field weakening p
106. ormation either from the Modbus fieldbus or the control can be distributed between the fieldbus and other available control locations e g digital analog inputs and the drive control panel The ACS 400 has two serial communication channels or ports Channel 0 and Channel 1 Channel 1 is the standard Modbus fieldbus connection Communication settings of Channel 1 can be configured by the user To control the ACS 400 via Modbus the ACS 400 must be programmed to accept control commands and or frequency references from Channel 1 Channel 0 is reserved for drive control panels ACS PAN and ACS100 PAN and for the Drive Window PC tool Optional serial communication features The ACS400 can also be connected to number of other fieldbuses using special fieldbus adapter modules These adapters are connected using an optical DDCS link DDCS Distributed Drives Control System For more information on these options contact your local ABB sales office ACS 400 is Channel 1 Channel 0 Connector X3 I Modbus fieldbus
107. ries 4 2 3 Three wire Start Stop Direction Start Stop connected as with 2 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 DI1P 2P 3P Start Forward Start Reverse and Stop Start and Direction commands are given simultaneously with two separate momentary push buttons the P stands for pulse The Stop push button is normally closed and connected to digital input DI3 The Start Forward and Start Reverse push buttons are normally open and connected to digital inputs DI1 and DI2 respectively Multiple Start push buttons are connected in parallel and multiple Stop push buttons are connected in series To control direction value of parameter 1003 DIRECTION should be REQUEST 6 015 Two wire Start Stop connected to digital input 015 015 deactivated Stop 015 activated Start 7 015 4 Two wire Start Stop Direction Start Stop is connected to digital input 015 Direction is connected to digital input 014 014 deactivated Forward and 014 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 comman
108. s 3 ALTERNATE Input signals Output signals jumper S1 Start stop and direction An output AO Frequency DI1 2 0 10 Analog reference 11 Relay output 1 Fault 0 10 Preset speed selection DI3 4 Relay output 2 Running Ramp pair 1 2 selection DI5 SCR HH 2 External Reference 1 0 10 V lt gt 0 50 Hz m AGND 4 410 Reference voltage 10 VDC 5_ Al2 Not used AGND nA AO1 Output frequency 0 20 mA lt gt 0 50 Hz s AGND 9 24V 24 VDC 10 DCOM1 11 DH Start fwd If DI1 state is the same as DI2 drive stops m re 1012 Start reverse Hs DIB Constant Speed selection 141 DIA Constant Speed selection 7 ss DIS Ramp pair selection Activate to select ramp pair 2 16 IDDCOM2 17 RO1C Relay ouput 1 programmable 18 Default Fault gt 17 connected to 18 19 ROIB 20 RO2C Relay ouput 2 programmable 2 RO2A Default Running gt 20 connected to 22 22 RO2B Constant speed selection 0 open 1 connected DI3 DIA Output Reference through Al1 Constant speed 1 1202 Constant speed 2 1203 Constant speed 3 1204 oj 2 o a ojo Application macro Alt
109. s diagnostic counter increases by one every time when a character with a framing error is received from the bus Communication speed settings of the devices connected in the bus differ Ambient noise levels may be too high 5210 PARITY ERRORS This diagnostic counter increases by one every time when a character with a parity error is received from the bus Parity settings of the devices connected in the bus differ Ambient noise levels may be too high 92 ACS 400 User s Manual Code Description 5211 CRC ERRORS This diagnostic counter increases by one every time when a message with a CRC error is received Ambient noise levels may be too high CRC calculation is not performed correctly 5212 BUSY ERRORS In Modbus network only one device can transmit at any given time This diagnostic counter increases by one every time the ACS 400 receives a character from the bus while it is still processing the previous message 5213 SER FAULT MEM 1 Last Modbus exception code sent 5214 SER FAULT MEM 2 Previous Modbus exception code sent 5215 SER FAULT MEM 3 Oldest Modbus exception code sent ACS 400 User s Manual 93 94 ACS 400 User s Manual Standard Serial Communication Overview The ACS 400 can be connected to an external control system using the standard Modbus fieldbus connection The ACS 400 can receive all of its control inf
110. se lt RUN gt or lt RUN Arrow head blinking rapidly Drive running but not at set point gt or Arrow head blinking slowly Drive is stopped ACS 400 User s Guide 25 Output Display When the control panel is powered up it displays a selection of actual values as in Figure 19 Whenever the MENU button is pressed and held the control panel resumes this OUTPUT display Output current Torque Reference frequency 0 0A 0 50 0Hz Cursors are visible when reference can be modified Actual output frequency OUTPUT Figure 19 Output display variables The frequency reference can be modified using UP DOWN buttons when it is underlined Pressing UP or DOWN buttons changes the output immediately The reference can be modified in local control mode or in remote control mode depending on programming Menu Structure The ACS 400 has a large number of parameters Of these only the basic parameters are initially visible See Selecting Full Parameter Set on page 28 for details on specifying the full parameter set The menu consists of parameter groups and menu functions OUTPUT display Menu Parameters 00 0 50 0 Hz ve 99 START UP DATA 9901 LANGUAGE 0 0 Hz ENGLISH OUTPUT D 01 OPERATING DATA 5 9902 APPLIC MACRO 10 COMMAND INPUTS 9905 MOTOR NOM VOLT 4011 ACT MINIMUM 51 EXT COMM MODULE 4012 ACT2 MINIMUM 52 STANDARD MODBUS COPY TO DRIVE COPY T
111. t after the programmed autoreset delay refer to parameter 3103 DELAY TIME 13 FLT ALARM Relay is energized if any fault alarm occurs except AL1 AL7 15 and AL 27 28 14 EXT CONTROL Relay is energized if external control is selected 15 REF 2 SEL Relay is energized if EXT2 is selected 16 CONST FREQ Relay is energized when a constant speed is selected 17 REF LOSS Relay is energized when reference or active control place is lost 18 OVERCURRENT Relay is energized when overcurrent alarm or fault appears 19 OVERVOLTAGE Relay is energized when overvoltage alarm or fault appears 20 ACS400 TEMP Relay is energized when ACS 400 overtemperature alarm or fault exists Parameter 1401 continues on the next page 68 ACS 400 User s Manual Code Description 21 Re 22 Re 23 Re 24 Re 25 Re 26 Re 27 Re 28 Re ACS OVERLOAD is energized when ACS 400 overload alarm or fault exists UNDERVOLTAGE is energized when undervoltage alarm or fault exists Loss is energized when 1 signal is lost Al2 Loss is energized when 12 signal is lost MOT OVER TEMP is energized when motor overtemperature alarm or fault exists STALL lay is energized when stall alarm or fault exists UNDERLOAD is energized when underload alarm or fault exists PID SLEEP lay is energized when the drive is stopped by the PID sl
112. t voltage as a function of output frequency ACS 400 User s Manual 57 Group 01 Operating Data This group contains drive operating data including actual signals and fault memories Actual Signal values are measured or calculated by the drive and they cannot be set by the user Fault memories can be cleared by the user from the control panel Code Description 0102 SPEED Displays the calculated speed of the motor rpm 0103 OUTPUT FREQ Displays the frequency Hz applied to the motor Also shown in OUTPUT display 0104 CURRENT Displays the motor current as measured by the ACS 400 The same value that is shown by the OUTPUT display mode 0105 TORQUE Output torque Calculated value of torque on motor shaft in of motor nominal torque 0106 POWER Displays the measured motor power in kW Note ACS100 PAN will not display the unit kW 0107 DC BUS VOLTAGE Displays the DC bus voltage as measured by the ACS 400 The voltage is displayed in Volts DC 0109 OUTPUT VOLTAGE Displays the voltage applied to the motor 0110 ACS 400 TEMP Displays the temperature of the ACS 400 heatsink in degrees centigrade 0111 EXT REF 1 The value of external reference 1 in Hz 0112 EXT REF 2 The value of external reference 2 in 96 0113 CTRL LOCATION Displays the active control location Alternatives are 0 LOCAL 1 1 2 EXT2 See AP
113. these control connections must be taken from a single source which can either be one of the units or an external supply Warning The heat sink may reach a high temperature See Section R Note For more technical information contact the factory or your local ABB sales representative ACS 400 User s Manual iii ACS 400 User s Manual Table of Contents i seed eae ee Col iii Installation 55 Re 1 Reference Sections 3 Installation 3 Dimensions 4 Mounting the ACS 400 ona 6 Removing the Cover 7 Terminal Interface 9 Attaching a Warning 9 Type Code and Model Designation 10 Installation of ACS 400 Gland Plates or Conduit Plates 11 Cable 13 Control 14 MOLOT deii eer tera ied eru felit lec ated uen 15 Connection Examples 16 Replacing the Cover 17 ApplyingiPOwer eee a aris ee en are 17 Environmental
114. ting torque Torque boost is only applied at start Boost 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 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 parameter 2101 START FUNCTION 2104 STOP DC INJ TIME DC injection time after modulation has stopped If 2102 STOP FUNCTION is 1 COAST ACS 400 uses DC braking If 2102 STOP FUNCTION is 2 RAMP ACS 400 uses DC hold after ramp Note Excessive DC injection time may cause the motor to overheat 2105 PREMAGN SEL Options 1 5 select source for premagnetizing command Option 6 selects start with DC hold NOT SEL Premagnetizing not used 1 5 011 015 Premagnetizing command is received through digital input 6 CONST Constant premagnetizing time after start command Time is defined by parameter 2106 PREMAGN MAX TIME 2106 PREMAGN MAX TIME Maximum premagnetizing time 2107 START INHIBIT Start inhibit control Start inhibit means a pending start command is ignored when fault is reset or mode change takes place Mode changes are from local to remote
115. tion COMM 1 on the alternative settings 1 1 Group 16 SYSTEM CONTROLS 1601 RUN ENABLE NOT SEL COMM Selects the source of the run enable DI1 DI5 signal COMM 1604 FAULT RESET SEL KEYPAD ONLY COMM Fault reset source pi HS Note Fault reset is always possible START STOP COMM with conrol panel ACS 400 User s Manual 101 Output signal source selection It is possible to control both the relay outputs 1 and 2 as well as the analog output from the serial communication channel 1 Relay outputs can be controlled in the following way Step 1 Configure the ACS 400 to supervise the value of any of the parameters 131 133 using parameters in group 32 SUPERVISION Step 2 Configure a relay output 1 or 2 to respond to the status of one of the supervised parameter The selected relay can now be turned on or off by writing to supervised parameter 131 133 some value that is either above or below the given supervision limits Refer to Table 15 for more information on required parameter settings With the given settings writing any value 100 255 to parameter 131 SER LINK DATA 1 causes the relay output 1 to activate Writing any value 0 99 to parameter 131 causes the relay output 1 to deactivate Refer to Table 16 for information on analog output control Table 15 Relay output control Setting for Code Parameter Name S
116. to select Constant Speeds 0 NOT SEL Constant speed function disabled 1 5 DH DI5 Constant Speed 1 is selected with digital inputs 011 015 Digital input activated Constant Speed 1 activated 1 Lone Speeds 1 3 are selected with two digital inputs Constant Speed selection with digital inputs DI1 2 Table 8 Constant Speed selection with digital inputs DI1 2 DI 1 DI 2 Function 0 No constant speed 0 Constant speed 1 1202 1 Constant speed 2 1203 1 Constant speed 3 1204 Oj O 0 DI deactivated 1 DI activated 7 013 4 Three Constant Speeds 1 3 are selected with two digital inputs as in 011 2 8 014 5 Three Constant Speeds 1 3 selected with two digital inputs as 011 2 Speeds 1 7 are selected with three digital inputs Table 9 Constant Speed selection with digital inputs 011 2 3 DI1 DI2 DI 3 Function 0 0 0 No constant speed Constant speed 1 1202 Constant speed 2 1203 Constant speed 3 1204 Constant speed 4 1205 Constant speed 5 1206 Constant speed 6 1207 Constant speed 7 1208 O oj o o of 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 1208 CONST SPEED 1 CONST SPEED 7 Constant speeds 1
117. trol command source selection Setting for Code Parameter Name ELE Standard Function Information Settings Modbus Group 50 COMMUNICATION 5006 COMM COMMANDS NOT SEL STD MODBUS Defines the source for serial STD MODBUS communication commands in general DDCS Group 10 COMMAND INPUTS 1001 EXT1 COMMANDS NOT SEL COMM Enables the Control Word except bit 11 011 when EXT1 is selected as control 2 location COMM 1002 EXT2 COMMANDS NOT SEL COMM Enables the Control Word except bit 11 011 when 2 is selected as control ee location COMM 1003 DIRECTION FORWARD REQUEST Enables rotation direction control as REVERSE defined by parameters 1001 and 1002 REQUEST Group 11 REFERENCE SELECT 1102 1 2 SEL bi COMM Enables external control location EXT 1 iu EXT2 selection by Control Word bit 11 COMM 1103 REF1 SELECT KEYPAD COMM Fieldbus reference 1 is used when EXT1 1 is selected as control location See or section References below for information COMM 1 on the alternative settings 1 COMM AH 100 ACS 400 User s Manual Setting for Code Parameter Name Sreang Standard Function Information 9 Modbus 1106 EXT REF2 SELECT KEYPAD COMM Fieldbus reference 2 is used when EXT2 1 is selected as control location See lef or section References below for informa
118. ts and no external cause has been identified contact your local ABB sales or service office 18 ACS 400 User s Manual Q Motor Overload Protection If the motor current lout exceeds nominal current ly of the motor for a prolonged period the ACS 400 automatically protects the motor from overheating by tripping The trip time depends on the extent of the overload lout In the output frequency and fon Times given apply to a cold start lout N 0 gt Output frequency 0 35 Hz R Drive Overload Protection lout UA Duty cycle t T lo x T lt 10 min gt time Imax lo N 1 5 Heavy Duty rating Ambient temperature Oamp max is 104 F 40 C 1 4 122 F 50 C is permissible 1 3 if l5 is derated to 90 12 Normal Duty rating 1 1 1 0 gt Duty cycle 0 14 0 2 0 3 0 4 0 5 ACS 400 User s Manual 19 S Specifications 200 V series 3 Input V4 208V 240V 10 50 60 Hz ACS401 Frame size Nominal ratings See G Unit Nominal motor Pn Normal Duty Output current A 11 6 15 3 a e current loNNDmax Nominal motor Heavy Duty CLT CC CE ss Max output current loNmax E PETTY Switching kHz 4 Standard frequency 8 Low noise Protection limits See P ea a Deane a 5
119. ult fault gt 17 connected to 18 12 250 V AC 30 V DC 10 mA 2A 18 RO1A 19 RO1B 20 RO2C Relay output 2 programmable default running gt 20 connected to 22 21 RO2A 12 250 V AC 30 V DC 10 mA 2A ay 22 RO2B Digital input impedance 1 5 ka Use multi strand 0 5 1 5 mm 20 16 AWG wire Note DI 4 is read only when powered up Factory macro 0 and 1 Note For safety reasons the fault relay signals a fault when the ACS 400 is powered down 14 ACS 400 User s Manual Note DI 4 and 5 are electrically isolated from 011 2 and 3 To utilize DI4 and 5 a jumper must be connected See section L for details Note Terminals 3 6 and 8 are at the same potential RS485 terminal X3 Description Screen B J2 RS4 Termin interf Not termin Pd A AGND oj Screen K Motor X X closed Check for motor compatibility The motor must be a three phase induction motor with Vy from 200 to 240 V for ACS401 XXXX 1 X or 380 to 480 V for ACS401 XXXX 3 X and fy either 50 Hz or 60 Hz The motor nominal current ly must be less than the nominal output current of the ACS 400 1 See Sections G and S A Warning Ensure the motor is compatible for use with the ACS 400 The ACS 400 must be installed by a competent person If in doubt contact your local ABB s
120. umper S1 Start stop DI1 5 and An output AO Frequency D12 4 aus 0 10 Two an references Al1 AI2 Relay output 1 Fault K X 0 4 20 mA Control location selection 013 Relay output 2 Running Pal Pet SCR coh 2 External Reference 1 0 10 V lt gt 0 50 Hz Hand Control AGND LL HL Dp H0V Reference voltage 10 VDC 8 5 2 External reference 2 0 20 mA lt gt 0 50 Hz Auto Control 7 AO1 Output frequency 0 20 mA lt gt 0 50 Hz m e AGND 24V 24 VDC T DCOM1 a DI Start Stop Activate to start ACS 400 Hand DI2 Forward Reverse Activate to reverse rotation direction Hand L 411 DIB EXT1 EXT2 Selection Activate to select auto control 14 DI4 Forward Reverse Auto t 005 Start Stop Activate to start ACS 400 Auto 16 2 17 RO1C Relay ouput 1 programmable Default Fault gt 17 connected to 18 19 RO1B 20 RO2C Relay ouput 2 programmable 21 2 Default Running gt 20 connected to 22 22 d Note Parameter 2107 Start Inhibit must be disabled off to permit simultaneous closure of DI3 and DI5 Hand Auto parameter values 9905 MOTOR NOM VOLT 400 V 1105 EXT REF1 MAX 9907 MOTO
121. ure the drive will revert to the same control mode LOC or REM as before the power failure ACS 400 User s Guide 29 30 ACS 400 User s Manual ACS100 PAN Control Panel The control panel can be connected to and detached from the drive at any time The ACS100 PAN panel cannot be used to copy parameters between two ACS400 drives Control modes Sd Units Active fault indicator eH pipes FANIT SUTBUTPAR VENKEWDREV Shaft direction Display modes START STOP MENU REVERSE ENTER UP DOWN Control Modes The first time the drive is powered up it is controlled from the Control Terminal strip remote control REM The ACS 400 is controlled from the control panel when the drive is in local control LOC Switch to local control LOC by pressing and holding the MENU and ENTER buttons down simultaneously until first Loc or later LCr is displayed If the buttons released while Loc is displayed the panel frequency reference is set to the current external reference and the drive is stopped When LCr is displayed the current run stop status and the frequency reference are copied from the user I O Start and stop the drive by pressing the START STOP button Change 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 Direction FWD RE
122. us protocol does not specify the physical interface Typical physical interface is RS485 Modbus is designed for integration with Modicon PLCs or other automation devices and the services closely correspond to the PLC architecture The ACS 400 drive looks like a Modicon PLC on the network If detailed information regarding the Modicon Modbus protocol is required contact your local ABB sales office for a copy of Modbus Protocol Guide Register Read and Write The ACS 400 has all drive parameter control and status information mapped into a 4xxxx register area This holding register area can be read from an external device and an external device can modify the register values by writing to them There are no setup parameters for mapping the data to the 4xxxx register The mapping is pre defined and corresponds directly to the ACS 400 parameter grouping All parameters are available for both reading and writing The parameter writes are verified for correct value and for valid register addresses Some parameters never allow writes including Group 1 actual values some allow only zero write including Group 1 fault memories some parameters allow write only when the drive is stopped including Group 99 setup variables and some can be modified at any time including e g Group 22 acceleration and deceleration ramp times ACS 400 User s Manual 105 Register Mapping The drive parameters are mapped to the 4xxxx area so that
123. uted from a digital input Reset is activated by deactivating the input 6 START STOP Fault reset is activated by Stop command 7 COMM Fault reset is executed through serial communication 1605 LOCAL LOCK Local lock When LOCAL LOCK is active 1 LOCKED local panel is disabled OPEN Control location can be changed from control panel 1 LOCKED Local panel control disabled Note Option 1 LOCKED can be selected only in remote mode ACS 400 User s Manual 71 Group 20 Limits Code Description 2003 MAX CURRENT Maximum output current The maximum output current that the ACS 400 will supply to the motor The default value is 1 5 ly 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 Caution If a braking chopper and a braking resistor are connected to the ACS 400 this parameter value must be set to 0 to ensure proper operation of the chopper 0 DISABLE 1 ENABLE 2006 UNDERVOLT CTRL DC undervoltage controller enable If the DC bus voltage drops due to loss of input power the undervoltage controller will decrease the motor speed in order to keep the DC bus voltage above the lower limit By decreasing the motor speed the inertia of
124. verse rotation direction DI3 Reference up Activate to increase reference IL 4 14 014 Reference down Activate to decrease reference DI5 Constant speed 1 16 IDDCOM2 17 RO1C Relay ouput 1 programmable RO1A Default Fault gt 17 connected to 18 19 RO1B 202 RO2C Relay ouput 2 programmable 2 RO2A Default Running gt 20 connected to 22 22 RO2B Note If both and DI 4 are active or inactive reference is kept fixed Reference is stored during stop or power down condition Analog reference is not followed when motor potentiometer is selected Motor potentiometer parameter values 9905 MOTOR NOM VOLT 400 V 1105 EXT REF1 MAX 50Hz 9907 MOTOR NOM FREQ 50 Hz 1106 EXT REF2 SELECT 0 KEYPAD 9908 MOTOR NOM SPEED 1440 rpm 1201 CONST SPEED SEL 5 015 1001 ExT 1 COMMANDS 2 011 2 1503 AO CONTENT MAX 50Hz 1002 ExT 2 COMMANDS 0 NOT SEL 1601 RUN ENABLE 0 NOT SEL 1003 DIRECTION 3 REQUEST 1604 FAULT RESET SEL 0 KEYPAD 2008 MAXIMUM FREQ 50Hz 1102 EXT1 EXT2 SEL 6 ExT1 2105 PREMAGN SEL 0 NOT SEL 1103 ExT REF1 SELECT 6 DI3U 4D 2201 ACC DEC 1 2 SEL 0 NOT SEL ACS 400 User s Manual 47 Application Macro Hand Auto This macro offers an I O configuration that is typically used for fan or pump applications Note The value of parameter 9902 is 5 HAND AUTO Input signals Output signals J

ABB Comp-AC User's Manual ACS 400 AC Drives for Speed

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