ABB ACS 400, User Manual

Page 1: ...User s Manual ACS 400 AC Drives for Speed Control of 3 to 40 Hp 230 Volt and 3 to 50 Hp 460 Volt AC Induction Motors ACS 400 ABB Automation Inc http nicontrols com ...

Page 2: ... automation parts and repairs based in the UK We provide a wide range of automation solutions from sourcing obsolete parts to express repairs and new part upgrades Visit nicontrols com for more information 4 4 0 1 2 5 4 673747 i n f o n i c o n t r o l s c o m w w w n i c o n t r o l s c o m NI N O R T H E R N INDUSTRIAL W W W N I C O N T R O L S C O M Cert No 11848 ISO 9001 2008 ...

Page 3: ...http nicontrols com ...

Page 4: ...Drives for Speed Control of AC Induction Motors User s Manual ACS400 US 04 3AUA489002B5310 R0101 Rev B Effective 01 16 01 Supersedes 2 1 99 Copyright 2001 ABB Automation Inc All Rights Reserved http nicontrols com ...

Page 5: ...http nicontrols com ...

Page 6: ...lay terminals RO1A RO1B RO1C RO2A RO2B RO2C Warning The ACS 400 is not a field repairable unit Never attempt to repair a malfunctioning unit contact the factory or your local Authorized Service Center for replacement Warning The ACS 400 can start up automatically after an input voltage interruption if programmed for Automatic Restart after power outage Warning When the control terminals of two or ...

Page 7: ...iv ACS 400 User s Manual http nicontrols com ...

Page 8: ...oating Network 11 Installation of ACS 400 Conduit Box 12 Cable Connections 14 Control Terminals 15 Motor 16 Connection Examples 17 Replacing the Cover 18 Applying Power 18 Environmental Information 18 Protection Features 19 Motor Overload Protection 20 Drive Overload Protection 20 Specifications 21 Product Conformity 23 Accessories 24 Programming 25 ACS PAN A Control Panel 25 Control Modes 25 Outp...

Page 9: ...35 General 35 Fault Resetting 35 Troubleshooting Guide 40 Motor Will Not Run 41 Motor Stalls during Acceleration 42 Overvoltage Fault Indication 43 Overcurrent Fault Indication 44 Overload Fault Indication 45 Undervoltage Fault Indication 46 External Fault Indication 47 No Operator Display 48 ACS 400 Basic Parameters 49 Application Macros 53 Application Macro Factory 0 54 Application Macro Factory...

Page 10: ...ettings 133 Control Locations 134 Output signal source selection 135 Diagnostic Counters 137 Communication 138 Introduction to Modbus 138 Register Read and Write 138 Register Mapping 139 Exception Codes 140 Function Codes 140 The Control Word and the Status Word 141 References 144 Actual Values 146 Fault and Alarm Status 148 Appendix A 151 Local Control vs Remote Control 151 Local Control 151 Remo...

Page 11: ...r s Manual PID Controller 159 Relay Outputs 160 Adding More I O to ACS 400 160 Setting up NDIO modules 160 Appendix C 161 ACS 400 EMC Instructions 161 Appendix D 167 ACS 400 Dimensional Drawings 167 http nicontrols com ...

Page 12: ...ith this User s Manual Conduit Box Warning Stickers and a separate Installation Guide The Installation Guide gives a summary of the installation instructions described here To help you mark the mounting holes for installation of your ACS 400 a Wall Mounting Template is drawn on the lid of the box Remove the lid from the box and save it Step by step instructions The installation of the ACS 400 has ...

Page 13: ...11 12 CHECK the environment MOUNT the ACS 400 to the wall REMOVE the cover ATTACH a warning sticker in the language of your choice IDENTIFY power and control terminals CHECK voltage supply CHECK I O jumpers J1 and J2 CHECK the motor CONNECT power terminals CONNECT control wires REPLACE the cover TURN the power on See A See B C See D See E F See E I J See G T See L T See E K M See E J See J See N S...

Page 14: ...400 must be installed in a heated indoor controlled environment that is suitable for the selected enclosure Drives are available in either an IP21 NEMA Type 1 or an IP54 NEMA Type 12 enclosure The drive must be protected from airborne dust corrosive gases or liquids and conductive contaminants such as condensation carbon dust and metallic particles The IP54 NEMA Type 12 enclosure provides protecti...

Page 15: ...1 ACS 400 drives is located in Appendix D on page 167 R1 R2 R3 R4 W 4 92 125 4 92 125 7 99 203 7 98 203 W1 3 86 98 3 86 98 6 30 160 6 30 160 H 14 14 359 18 07 459 22 48 571 26 08 662 H1 12 52 318 16 42 417 20 79 528 24 38 619 D 8 24 209 8 71 221 9 77 248 11 07 281 Mass lb kg 12 8 5 8 19 8 9 40 8 18 5 59 5 27 Frame Size IP21 NEMA 1 Dimensions Reference in mm http nicontrols com ...

Page 16: ...red to the IP 21 enclosure but does not require a de rating Figure 3 IP 54 NEMA Type 12 4 enclosures A complete set of dimensional drawings for the NEMA Type 12 4 ACS 400 drives is located in Appendix D on page 167 R1 R2 R3 R4 W 8 43 214 8 43 214 10 09 256 10 09 256 W1 3 86 98 3 86 98 6 30 160 6 30 160 H 17 72 450 21 65 550 25 27 642 29 21 742 H1 12 52 318 16 42 417 20 79 528 24 38 619 D 9 43 240 ...

Page 17: ...d below and 2 in 50 mm around the sides of the unit 1 Using the mounting template mark the position of the mounting holes 2 Drill the holes 3 Screw in four screws or affix nuts and bolts depending on the mounting surface Figure 5 Marking and drilling the mounting holes 3 IP 21 Position the ACS 400 onto the mounting screws or bolts and securely tighten in all four corners Note Lift the ACS 400 by i...

Page 18: ...IP 21 NEMA Type 1 Opening frame size R3 and R4 units See Paragraph T for frame size assignments of type codes 1 Remove the control panel if needed 2 Lift the retaining lever and simultaneously pull the upper front cover slightly 3 Lift the other retaining lever with a screwdriver 4 Open the upper part of the front cover and remove it 5 Press the retaining lever and pull 6 Remove the lower part of ...

Page 19: ...8 ACS 400 User s Manual Figure 10 Opening type IP 54 NEMA Type 12 4 drives IP 54 NEMA Type 12 4 1 Take the screws off 2 Remove the front cover 3 Remove panel if needed http nicontrols com ...

Page 20: ...ve Green LED Red LED X2 Panel connector Warning sticker X6 Connector for X3 RS485 connector X1 I O connection see I Analog input Termination jumper J2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 Warning Dangerous voltage Wait 5 minutes after disconnecting supply before proceeding See User s Manual DDCS communication module U1 V1 W1 U2 V2 W2 I N P U T M O T O R Uc Uc PE PE Additional P...

Page 21: ...2n I2nnd 4 9 6 6 A f1 48 63 Hz f2 0 250Hz Ser no For more information see ACS400 User s Manual 6 LISTED 45Y1 IND CONT EQ For more information see ACS400 User s EXCEPT 230 V I1N I2N AC S 4 0 1 004 3 2 AC Drive Product Type S Standard drive ACS 400 Product Family Input Bridge 0 6 pulse rectifier Enclosure Type 1 Wall mounted Rated Output Power in kVA See ACS 400 rating tables Voltage Rating 3 380 48...

Page 22: ...th grounding screws otherwise you may cause danger or damage the unit Location of the grounding screws is shown in Figure 15 and Figure 16 Note In IT networks do NOT use an RFI filter The input power becomes connected to ground through the filter capacitors In floating networks this may cause danger or damage the unit Figure 15 Removing the grounding screws from frame size R1 and R2 frequency conv...

Page 23: ...your local ABB representative for specific IEC installation instructions Figure 17 US conduit box installation kit Your ACS 400 should include the parts shown above the two 2 halves of the conduit box four 4 screws with captive washers and two 2 self tapping screws A different conduit arrangement containing five screws and two cable clamp brackets is included with the type IP 54 NEMA Type 12 ACS 4...

Page 24: ...e 19 Positioning the conduit box for type IP 21 NEMA Type 1 drives Insert the two screws with captive washers into the appropriate hole on each side of the conduit box on the front side of the drive B Figure 20 Conduit with top two screws installed Insert the two self tapping screws into the two holes on the bottom of the drive C and tighten using a powered driver Take care not to overtighten Tigh...

Page 25: ...V maximum The ACS 400 has an electronic motor protection feature that complies with the requirements of the National Electric Code USA When this feature is selected and properly adjusted additional overload protection is not required unless more than one motor is connected to the drive or unless additional protection is required by applicable safety regulations See parameters 3004 3005 and 3006 Fo...

Page 26: ...frequency reference Resolution 0 1 accuracy 1 6 AGND Analog input circuit common Connected internally to chassis ground through 1 MΩ 7 AO1 Analog output programmable Default 0 20 mA load 500 Ω 0 fnom output frequency 8 AGND Common for DI return signals 9 24 V Auxiliary voltage output 24 V DC 250 mA reference to AGND Short circuit protected 10 DCOM1 Digital input common for DI1 DI2 and DI3 DI Confi...

Page 27: ... V for ACS401 XXXX 3 X and fN either 50 Hz or 60 Hz The motor nominal current must be less than the nominal output current of the ACS 400 See Sections G and T Warning Ensure the motor is compatible for use with the ACS 400 The ACS 400 must be installed by a competent person If in doubt contact your local ABB sales or service office X3 Description 1 Screen 2 B 3 A 4 AGND 5 Screen http nicontrols co...

Page 28: ... DI2 DI3 DI4 DI5 DCOM2 RO1C RO1A RO1B RO2C RO2A RO2B SCR AI1 AGND 10V AI2 AGND AO1 AGND 24V DCOM1 DI1 DI2 DI3 DI4 DI5 DCOM2 RO1C RO1A RO1B RO2C RO2A RO2B J1 Analog inputs ACS 400 ACS 400 J1 Analog inputs DI configuration for NPN connection sink DI configuration for PNP connection source Ground the cable screen on the sourcing end X1 X1 SCR B A AGND SCR SCR B A GND B A GND SCR J2 RS485 interf ACS 4...

Page 29: ... IP21 NEMA Type 1 1 First locate the bottom mounting clips 2 Click the retaining lever to its place 3 Replace the control panel Replacing the front cover for IP54 NEMA Type 12 1 Replace the control panel 2 Replace the front cover 3 Carefully tighten the screws Replacing the front cover to IP 21 NEMA Type 1 units from size ACS401x0163x and up 1 Hook the bottom end fingers of the lower part of the f...

Page 30: ...d 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 A momentary 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 ...

Page 31: ...ds on the extent of the overload Iout IN the output frequency and fnom Times given apply to a cold start S Drive Overload Protection Iout IN Output frequency 1 5 1 0 0 5 0 0 35 Hz Duty cycle t T T 10 min Ambient temperature θamb max is 104 F 40 C 122 F 50 C is permissible if I2 is derated to 90 Iout t Imax I2 T time Imax I2 Duty cycle 1 5 1 4 1 3 1 2 1 1 1 0 0 1 0 2 0 3 0 4 0 5 Heavy Duty rating N...

Page 32: ... 1 36 3 46 2 69 3 89 1 112 2 132 0 Output Voltage U2 V 0 U1 Switching Frequency kHz 4 standard 8 Low Noise Protection Limits Overcurrent peak A 31 4 44 3 69 8 101 2 128 7 142 3 196 0 279 8 367 8 Overvoltage Running Start Inhibit VDC VDC 421 VDC 1 3 UDC Nominal 240 VAC input 1 18 UDC Nominal 240 VAC Undervoltage Running Start Inhibit VDC VDC 182 VDC 0 65 UDC Nominal 208 VAC Input 0 85 UDC Nominal 2...

Page 33: ...vercurrent peak A 20 3 27 5 37 48 64 76 99 125 145 195 Overvoltage Running Start Inhibit VDC VDC 842 corresponds to 624 VAC input 661 in input voltage range 380 415 VAC 765 in input voltage range 440 480 VAC Undervoltage Running Start Inhibit VDC VDC 333 corresponds to 247 VAC input 436 in input voltage range 380 415 VAC 505 in input voltage range 440 480 VAC Overtemperature C F 95 C 203 F Heat Si...

Page 34: ...mplies with North American standard UL508C The ACS 400 400V Series complies with European requirements Low Voltage Directive 73 23 EEC with amendments EMC Directive 89 336 EEC with amendments Corresponding declarations and a list of main standards are available on request Note See ACS 400 EMC instructions An adjustable frequency drive and a Complete Drive Module CDM or a Basic Drive Module BDM as ...

Page 35: ...er s Manual V Accessories ACS 100 140 400 EXT Extension cable kit for use with the control panel ACS400 IF11 3 through ACS400 IF41 3 RFI input filters RS485 232 Adapter DDCS Communication Module http nicontrols com ...

Page 36: ...isplayed the panel frequency reference is set to the current external reference and the drive is stopped When LOCAL KEEP RUN is displayed the current run stop status and the frequency reference are copied from the user I O Start and stop the drive by pressing the START STOP button Change the shaft direction by pressing the REVERSE button parameter 1003 must be set to REQUEST Switch back to remote ...

Page 37: ...tons changes the reference immediately The reference can be modified in local control mode but also in remote control mode if the ACS 400 is programmed for that type of operation Menu Structure ACS 400 has a large number of parameters Of these only the so called basic parameters are initially visible See Selecting Full Parameter Set on page 28 for details on specifying the full parameter set The m...

Page 38: ...ns simultaneously Menu Functions Scroll the Menu for desired menu function then press and hold ENTER down until the display blinks to start the operation Note Parameter copying does not affect all parameters The excluded parameters are 9901 9905 9910 1605 1607 5002 5201 and all Group 51 parameters See ACS 400 Complete Parameter List on page 65 for a description of these parameters Copy Parameters ...

Page 39: ...LED of the ACS PAN A is blinking an alarm is active The relevant alarm message is shown in the panel display Alarms 1 7 arise from button operation and the green LED does not blink for them The alarm and fault messages disappear when MENU ENTER or the arrow buttons on the control panel are pressed The message will reappear after a few seconds if the keypad is not touched and alarm or fault is stil...

Page 40: ...art the drive when in remote control To reset a fault when the red LED is blinking turn the power off Caution Turning the power on again may start the drive immediately Contrast Setting Display contrast can be adjusted any time Increase contrast by pressing and holding the ENTER and UP buttons Decrease contrast by pressing and holding the ENTER and DOWN buttons The buttons must be pressed simultan...

Page 41: ...e is stopped When LCr is displayed the current run stop status and the frequency reference are copied from the user I O Start and stop the drive by pressing the START STOP button Change the shaft direction by pressing the REVERSE button parameter 1003 must be set to REQUEST Switch back to remote control REM by pressing and holding the MENU and ENTER buttons down simultaneously until rE is displaye...

Page 42: ...u Structure ACS 400 has a large number of parameters Of these only the so called basic parameters are initially visible The menu function LG is used to make the full parameter set visible Setting Parameter Value Press ENTER to view the parameter value To set a new value press and hold ENTER until SET is displayed Note SET blinks if the parameter value is altered SET is not displayed if the value c...

Page 43: ... ACS 400 Complete Parameter List on page 65 for a description of these parameters Select between basic and full menu Copy parameters from panel to drive upload Note Drive must be stopped and in local control Parameter 1602 PARAMETER LOCK must be set to 1 OPEN Copy parameters from drive to panel download Note Drive must be stopped and in local control Parameter 1602 PARAMETER LOCK must be set to 1 ...

Page 44: ...e arrow buttons of control panel are pressed The message will reappear after a few seconds if the keypad is not touched and alarm or fault is still active Figure 24 Fault and alarm messages Refer to the Diagnostics on page 35 section for a complete list of alarms and faults Resetting the Drive from the Control Panel To reset a fault when the red LED is on press the START STOP button Caution Resett...

Page 45: ...34 ACS 400 User s Manual http nicontrols com ...

Page 46: ...U ENTER or the arrow buttons of control panel are pressed The message will reappear after a few seconds if the keypad is not touched and the alarm or fault is still active Last three fault codes are stored into parameters 0128 0130 These fault memories can be cleared from the control panel by pressing the UP and DOWN buttons simultaneously while in parameter set mode Fault Resetting Faults that ar...

Page 47: ... direction if fixed by parameter 1003 DIRECTION 14 SERIAL COMM LOSS Serial communication through Standard Modbus Channel is lost Check connections between the external control system and the ACS 400 Refer to parameters 5003 COMM FAULT TIME and 5004 COMM FAULT FUNC 15 MODBUS EXCEPTION Exception response is sent through Standard Modbus channel The bus master may be sending queries which cannot be pr...

Page 48: ... overload condition The ACS 400 output current exceeds the ratings given in Specifications on page 21 of this manual 27 AUTOMATIC RESET ACS 400 is about to perform automatic fault reset operation As a result the drive may start after the reset operation Refer to parameter group 31 AUTOMATIC RESET 28 PID SLEEP PID sleep function is active The drive may accelerate when the PID sleep function is deac...

Page 49: ...ss than MINIMUM AI2 1306 See also parameter 3001 AI MIN FUNCTION 9 MOTOR OVERTEMP Motor overtemperature condition as estimated by the ACS 400 Refer to parameters 3004 3008 10 PANEL LOSS Panel communication loss Control panel is disconnected when the drive is receiving start stop and direction commands from the panel Drive is in local control mode LOC is shown in the control panel display or Drive ...

Page 50: ... the DDCS option module and the optic fibres Check the status of the fieldbus adapter Refer to appropriate fieldbus adapter manual Check connections between external control system and fieldbus adapter Alternatively check the status of the IO extension modules NDIO required by PFC block Refer also to DDCS Option Module Manual and parameters 5004 5007 20 AI OUT OF RANGE Analog input out of range Ch...

Page 51: ...y occur during start up of your ACS 400 drive motor will not run see page 41 motor stalls during acceleration see page 42 overvoltage fault indication see page 43 overcurrent fault indication see page 44 overload fault indication see page 45 undervoltage fault indication see page 46 external fault indication see page 47 no operator panel display see page 48 http nicontrols com ...

Page 52: ...ACS 400 User s Manual 41 Motor Will Not Run http nicontrols com ...

Page 53: ...42 ACS 400 User s Manual Motor Stalls during Acceleration http nicontrols com ...

Page 54: ...ACS 400 User s Manual 43 Overvoltage Fault Indication http nicontrols com ...

Page 55: ...44 ACS 400 User s Manual Overcurrent Fault Indication http nicontrols com ...

Page 56: ...ACS 400 User s Manual 45 Overload Fault Indication http nicontrols com ...

Page 57: ...46 ACS 400 User s Manual Undervoltage Fault Indication http nicontrols com ...

Page 58: ...ACS 400 User s Manual 47 External Fault Indication http nicontrols com ...

Page 59: ...48 ACS 400 User s Manual No Operator Display http nicontrols com ...

Page 60: ...ation macro Sets parameter values to their default values Refer to CROSSREF for a detailed description of each macro 0 FACTORY 1 ABB STANDARD 2 3 WIRE 3 ALTERNATE 4 MOTOR POT 5 HAND AUTO 6 PID CONTROL 7 PREMAGN 8 PFC CONTROL Default value 0 FACTORY MACRO á 9905 MOTOR NOM VOLT Nominal motor voltage from motor name plate Range of this parameter depends on the type of the ACS 400 Default value 400 V ...

Page 61: ...sing the UP and DOWN buttons simultaneously while in parameter set mode Group 10 COMMAND INPUTS 1003 DIRECTION Rotation direction lock 1 FORWARD 2 REVERSE 3 REQUEST If you select REQUEST the direction is set according to the given direction command Default 3 REQUEST or 1 FORWARD depending on the selected application macro á Group 11 REFERENCE SELECT 1105 EXT REF1 MAX Maximum frequency reference in...

Page 62: ...lues given here are valid only if other analog output configuration parameters have not been modified Description of all parameters is given in ACS 400 Complete Parameter List on page 65 Group 20 LIMITS 2003 MAX CURRENT Maximum output current Range 0 5 IN 1 5 1 7 IN where IN is nominal current of the ACS 400 Default value 1 5 IN 2008 MAXIMUM FREQ Maximum output frequency Range 0 250 Hz Default val...

Page 63: ...ue 5 0 s 2203 DECELER TIME 1 Ramp 1 time from maximum to zero frequency MAXIMUM FREQ 0 Default value 5 0 s 2204 ACCELER TIME 2 Ramp 2 time from zero to maximum frequency 0 MAXIMUM FREQ Default value 60 0 s 2205 DECELER TIME 2 Ramp 2 time from maximum to zero frequency MAXIMUM FREQ 0 Default value 60 0 s Group 26 MOTOR CONTROL 2606 U f RATIO U f below field weakening point 1 LINEAR 2 SQUARE LINEAR ...

Page 64: ...om the panel Parameter Values Selecting an application macro with parameter 9902 APPLIC MACRO will set all other parameters except the group 99 Start up Data parameters the parameter lock 1602 the parameter save 1607 and groups 50 52 serial communication parameters to their default values Default values of certain parameters depend on the selected macro These are listed with the description of eac...

Page 65: ...RUN 1002 EXT 2 COMMANDS 0 NOT SEL 1503 AO CONTENT MAX 60 Hz 1003 DIRECTION 3 REQUEST 1601 RUN ENABLE 0 NOT SEL 1102 EXT1 EXT2 SEL 6 EXT1 1604 FAULT RESET SEL 6 START STOP 1103 EXT REF1 SELECT 1 AI1 2008 MAXIMUM FREQ 60 Hz 1105 EXT REF1 MAX 60 Hz 2105 PREMAGN SEL 0 NOT SEL 1106 EXT REF2 SELECT 0 KEYPAD 2201 ACC DEC 1 2 SEL 5 DI5 1201 CONST SPEED SEL 3 DI3 4001 PID GAIN 1 0 1401 RELAY OUTPUT 1 3 FAU...

Page 66: ...402 RELAY OUTPUT 2 2 RUN 1002 EXT 2 COMMANDS 0 NOT SEL 1503 AO CONTENT MAX 60 Hz 1003 DIRECTION 3 REQUEST 1601 RUN ENABLE 0 NOT SEL 1102 EXT1 EXT2 SEL 6 EXT1 1604 FAULT RESET SEL 6 START STOP 1103 EXT REF1 SELECT 1 AI1 2008 MAXIMUM FREQ 60 Hz 1105 EXT REF1 MAX 60 Hz 2105 PREMAGN SEL 0 NOT SEL 1106 EXT REF2 SELECT 0 KEYPAD 2201 ACC DEC 1 2 SEL 5 DI5 1201 CONST SPEED SEL 0 NOT SEL 4001 PID GAIN 1 0 ...

Page 67: ... RUN 1002 EXT 2 COMMANDS 0 NOT SEL 1503 AO CONTENT MAX 60 Hz 1003 DIRECTION 3 REQUEST 1601 RUN ENABLE 0 NOT SEL 1102 EXT1 EXT2 SEL 6 EXT1 1604 FAULT RESET SEL 0 KEYPAD 1103 EXT REF1 SELECT 1 AI1 2008 MAXIMUM FREQ 60 Hz 1105 EXT REF1 MAX 60 Hz 2105 PREMAGN SEL 0 NOT SEL 1106 EXT REF2 SELECT 0 KEYPAD 2201 ACC DEC 1 2 SEL 5 DI5 1201 CONST SPEED SEL 7 DI3 4 4001 PID GAIN 1 0 1401 RELAY OUTPUT 1 3 FAUL...

Page 68: ...t speed 3 1204 1001 EXT 1 COMMANDS 4 DI1P 2P 3 1402 RELAY OUTPUT 2 2 RUN 1002 EXT 2 COMMANDS 0 NOT SEL 1503 AO CONTENT MAX 60 Hz 1003 DIRECTION 3 REQUEST 1601 RUN ENABLE 0 NOT SEL 1102 EXT1 EXT2 SEL 6 EXT1 1604 FAULT RESET SEL 0 KEYPAD 1103 EXT REF1 SELECT 1 AI1 2008 MAXIMUM FREQ 60 Hz 1105 EXT REF1 MAX 60 Hz 2105 PREMAGN SEL 0 NOT SEL 1106 EXT REF2 SELECT 0 KEYPAD 2201 ACC DEC 1 2 SEL 0 NOT SEL 1...

Page 69: ...DI1F 2R 1402 RELAY OUTPUT 2 2 RUN 1002 EXT 2 COMMANDS 0 NOT SEL 1503 AO CONTENT MAX 60 Hz 1003 DIRECTION 3 REQUEST 1601 RUN ENABLE 0 NOT SEL 1102 EXT1 EXT2 SEL 6 EXT1 1604 FAULT RESET SEL 0 KEYPAD 1103 EXT REF1 SELECT 1 AI1 2008 MAXIMUM FREQ 60 Hz 1105 EXT REF1 MAX 60 Hz 2105 PREMAGN SEL 0 NOT SEL 1106 EXT REF2 SELECT 0 KEYPAD 2201 ACC DEC 1 2 SEL 5 DI5 1201 CONST SPEED SEL 7 DI3 4 4001 PID GAIN 1...

Page 70: ...Y OUTPUT 2 2 RUN 1002 EXT 2 COMMANDS 0 NOT SEL 1503 AO CONTENT MAX 60 Hz 1003 DIRECTION 3 REQUEST 1601 RUN ENABLE 0 NOT SEL 1102 EXT1 EXT2 SEL 6 EXT1 1604 FAULT RESET SEL 0 KEYPAD 1103 EXT REF1 SELECT 6 DI3U 4D 2008 MAXIMUM FREQ 60 Hz 1105 EXT REF1 MAX 60 Hz 2105 PREMAGN SEL 0 NOT SEL 1106 EXT REF2 SELECT 0 KEYPAD 2201 ACC DEC 1 2 SEL 0 NOT SEL 1201 CONST SPEED SEL 5 DI5 4001 PID GAIN 1 0 1401 REL...

Page 71: ... 1604 FAULT RESET SEL 0 KEYPAD 1103 EXT REF1 SELECT 1 AI1 2008 MAXIMUM FREQ 60 Hz 1105 EXT REF1 MAX 60 Hz 2105 PREMAGN SEL 0 NOT SEL 1106 EXT REF2 SELECT 2 AI2 2201 ACC DEC 1 2 SEL 0 NOT SEL 1201 CONST SPEED SEL 0 NOT SEL 4001 PID GAIN 1 0 1401 RELAY OUTPUT 1 3 FAULT 1 4002 PID INTEG TIME 60 s External Reference 1 0 10 V 0 50 Hz Hand Control Reference voltage 10 VDC External reference 2 0 20 mA 0 ...

Page 72: ...2 COMMANDS 6 DI5 1503 AO CONTENT MAX 60 Hz 1003 DIRECTION 1 FORWARD 1601 RUN ENABLE 4 DI4 1102 EXT1 EXT2 SEL 2 DI2 1604 FAULT RESET SEL 0 KEYPAD 1103 EXT REF1 SELECT 1 AI1 2008 MAXIMUM FREQ 60 Hz 1105 EXT REF1 MAX 60 Hz 2105 PREMAGN SEL 0 NOT SEL 1106 EXT REF2 SELECT 1 AI1 2201 ACC DEC 1 2 SEL 0 NOT SEL 1201 CONST SPEED SEL 3 DI3 4001 PID GAIN 1 0 1401 RELAY OUTPUT 1 3 FAULT 1 4002 PID INTEG TIME ...

Page 73: ...OMMANDS 2 DI1 2 1402 RELAY OUTPUT 2 2 RUN 1002 EXT 2 COMMANDS 0 NOT SEL 1503 AO CONTENT MAX 60 Hz 1003 DIRECTION 3 REQUEST 1601 RUN ENABLE 0 NOT SEL 1102 EXT1 EXT2 SEL 6 EXT1 1604 FAULT RESET SEL 0 KEYPAD 1103 EXT REF1 SELECT 1 AI1 2008 MAXIMUM FREQ 60 Hz 1105 EXT REF1 MAX 60 Hz 2105 PREMAGN SEL 5 DI5 1106 EXT REF2 SELECT 0 KEYPAD 2201 ACC DEC 1 2 SEL 0 NOT SEL 1201 CONST SPEED SEL 7 DI3 4 4001 PI...

Page 74: ...EXT1 EXT2 SEL 3 DI3 1604 FAULT RESET SEL 0 KEYPAD 1103 EXT REF1 SELECT 1 AI1 2008 MAXIMUM FREQ 62 Hz 1105 EXT REF1 MAX 62 Hz 2105 PREMAGN SEL 0 NOT SEL 1106 EXT REF2 SELECT 1 AI1 2201 ACC DEC 1 2 SEL 0 NOT SEL 1201 CONST SPEED SEL 0 NOT SEL 4001 PID GAIN 2 5 1401 RELAY OUTPUT 1 29 PFC 4002 PID INTEG TIME 3 s EXT1 Manual or EXT2 PID PFC reference 0 10 V Reference voltage 10 VDC Actual signal 0 20 m...

Page 75: ...64 ACS 400 User s Manual http nicontrols com ...

Page 76: ...TOR NOM FREQ 0 250 Hz 1 Hz 60 Hz á 9908 MOTOR NOM SPEED 0 3600 rpm 1 rpm 1750 rpm á 9909 MOTOR NOM POWER 0 1 134 HP 0 1 HP 3 50 HP Size Dependent á 9910 MOTOR COS PHI MOTOR POWER FACTOR 0 50 0 99 0 01 0 83 á Group 01 OPERATING DATA 0102 SPEED 0 9999 rpm 1 rpm 0103 OUTPUT FREQ 0 250 Hz 0 1 Hz 0104 CURRENT 0 1 A 0105 TORQUE 100 100 0 1 0106 POWER 0 1 kW 0107 DC BUS VOLTAGE 0 999 9 V 0 1 V 0109 OUTPU...

Page 77: ...XT1 EXT2 SEL 1 8 1 á á 1103 EXT REF1 SELECT 0 10 1 á á 1104 EXT REF1 MIN 0 250 Hz 1 Hz 0 Hz 1105 EXT REF1 MAX 0 250 Hz 1 Hz á 1106 EXT REF2 SELECT 0 10 1 á á 1107 EXT REF2 MIN 0 100 1 0 1108 EXT REF2 MAX 0 500 1 100 Group 12 CONSTANT SPEEDS 1201 CONST SPEED SEL 0 10 1 á á 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 ...

Page 78: ... 0 1 s Group 16 SYSTEM CONTROLS 1601 RUN ENABLE 0 6 1 á á 1602 PARAMETER LOCK 0 2 1 1 OPEN 1604 FAULT RESET SEL 0 7 1 á á 1605 LOCAL LOCK 0 1 1 0 OPEN 1607 PARAM SAVE 0 1 1 0 DONE 1608 DISPLAY ALARMS 0 1 1 0 NO Group 20 LIMITS 2003 MAX CURRENT 0 5 IN 1 5 1 7 IN 0 1 A 1 5 IN 2005 OVERVOLT CTRL 0 1 1 1 ENABLE 2006 UNDERVOLT CTRL 0 2 1 1 ENABLE TIME 2007 MINIMUM FREQ 0 250 Hz 1 Hz 0 Hz 2008 MAXIMUM F...

Page 79: ...OW NOISE 0 1 1 0 OFF á 2606 U f RATIO 1 2 1 1 LINEAR á 2607 SLIP COMP RATIO 0 250 1 0 á 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 1 s 500 s 3006 MOT LOAD CURVE 50 150 1 100 3007 ZERO SPEED LOAD 25 150 1 70 3008 BREAK POINT 1 250 Hz 1 Hz 35 Hz 3009 STA...

Page 80: ...HI 0 3204 SUPERV 2 PARAM 102 137 1 103 3205 SUPERV 2 LIM LO 0 3206 SUPERV 2 LIM HI 0 Group 33 INFORMATION 3301 SW VERSION 0 0 0 0 f f f f 3302 TEST DATE yy ww Group 34 PROCESS VARIABLES 3401 DISPLAY SEL 1 2 1 1 STANDARD 3402 P VAR 1 SEL 102 137 1 104 3403 P VAR 1 MULTIP 1 9999 1 1 3404 P VAR 1 DIVISOR 1 9999 1 1 3405 P VAR 1 SCALING 0 3 1 1 3406 P VAR 1 UNIT 0 31 1 1 A 3407 P VAR 2 SEL 102 137 1 1...

Page 81: ... 0 100 0 1 0 4016 PID PARAM SET 1 7 1 6 SET 1 4017 WAKE UP DELAY 0 60 s 0 01 s 0 50 s 4018 SLEEP SELECTION 0 5 1 0 INTERNAL á 4019 SET POINT SEL 1 2 1 2 EXTERNAL 4020 INTERNAL SETPNT 0 0 100 0 0 1 40 Group 41 PID CONTROL 2 4101 PID GAIN 0 1 100 0 1 4102 PID INTEG TIME 0 1 320 s 0 1 s 4103 PID DERIV TIME 0 10 s 0 1s 0 s 4104 PID DERIV FILTER 0 10 s 0 1 s 1 s 4105 ERROR VALUE INV 0 1 1 0 NO 4106 ACT...

Page 82: ...AGES 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 3 0 255 1 Group 81 PFC CONTROL 8103 REFERENCE STEP 1 0 0 100 0 1 0 8104 REFERENCE STEP 2 0 0 100 0 1 0 8105 REFERENCE STEP 3 0 0 100 0 1 0 8109 START FREQ 1 0 0 250 Hz 0 1 H...

Page 83: ...erter at 4 kHz switching frequency 8118 AUTOCHNG INTERV 0 0 336 h 0 1 h 0 0 h NOT SEL 8119 AUTOCHNG LEVEL 0 0 100 0 0 1 50 8120 INTERLOCKS 0 6 1 4 DI4 á 8121 REG BYPASS CTRL 0 1 1 0 NO 8122 PFC START DELAY 0 10 s 0 01 s 0 5 s Code Name Range Resolution Default User S M http nicontrols com ...

Page 84: ...OR NOM FREQ sets the frequency at which output voltage is equal to the MOTOR NOM VOLT The ACS 400 cannot supply the motor with a voltage greater than the input supply voltage See Figure 25 9906 MOTOR NOM CURR Nominal motor current from motor nameplate The allowed range is 0 5 IN 1 5 IN of ACS 400 9907 MOTOR NOM FREQ Nominal motor frequency from motor nameplate field weakening point See Figure 25 9...

Page 85: ...ays the temperature of the ACS 400 heatsink in degrees Fahrenheit 0111 EXTERNAL REF 1 The value of external reference 1 in Hz 0112 EXTERNAL REF 2 The value of external reference 2 in 0113 CTRL LOCATION Displays the active control location Alternatives are 0 LOCAL 1 EXT1 2 EXT2 See Appendix A on page 151 for description of different control locations 0114 RUN TIME R Shows the total running time of ...

Page 86: ...eously when in parameter set mode 0129 PREVIOUS FAULT Previous recorded fault See Diagnostics on page 35 Can be cleared with the control panel by pressing UP and DOWN buttons simultaneously when in parameter set mode 0130 OLDEST FAULT Oldest recorded fault See Diagnostics on page 35 Can be cleared with the control panel by pressing UP and DOWN buttons simultaneously when in parameter set mode 0131...

Page 87: ...tion the value of parameter 1003 DIRECTION should be REQUEST 5 DI1P 2P 3P Start Forward Start Reverse and Stop Start and Direction commands are given simultaneously with two separate momentary push buttons the P stands for pulse The Stop push button is normally closed and connected to digital input DI3 The Start Forward and Start Reverse push buttons are normally open and connected to digital inpu...

Page 88: ...ontrol 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 http nicontrols com ...

Page 89: ... 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 DI5 External control location 1 or 2 is selected according to the state of the selected digital input DI1 DI5 where deactivated EXT1 and activated EXT2 6 EXT1 External control location 1 EXT1 is selected The control signal sources f...

Page 90: ...ference 1 is set with Parameter 1105 and minimum with Parameter 1104 5 DI3U 4D R Speed reference is given through digital inputs as motor potentiometer control Digital input DI3 increases the speed the U stands for up and digital input DI4 decreases the speed the D stands for down R indicates that the reference will be reset to zero when a Stop command is given The rate of change of the reference ...

Page 91: ...l reference 1 in Hz When the analog input signal is at minimum external reference 1 is equal to EXT REF1 MIN See Figure 27 on page 80 1105 EXT REF1 MAX Sets the maximum frequency reference for external reference 1 in Hz When the analog input signal is at maximum external reference 1 is equal to EXT REF1 MAX See Figure 27 on page 80 1106 EXT REF2 SELECT This parameter selects the signal source for ...

Page 92: ... selected with two digital inputs Constant Speed selection with digital inputs DI1 2 Table 8 Constant Speed selection with digital inputs DI1 2 0 DI deactivated 1 DI activated 7 DI3 4 Three Constant Speeds 1 3 are selected with two digital inputs as in DI1 2 8 DI4 5 Three Constant Speeds 1 3 are selected with two digital inputs as in DI1 2 9 DI1 2 3 Seven Constant Speeds 1 7 are selected with thre...

Page 93: ... EXT REF1 MAX or 1108 EXT REF2 MAX See Figure 27 on page 80 1303 FILTER AI1 Filter time constant for analog input AI1 As the analog input value changes 63 of the change takes place within the time specified by this parameter Note Even if you select 0 s for the filter time constant the signal is still filtered with a time constant of 25 ms due to the signal interface hardware This cannot be changed...

Page 94: ... page 100 9 SUPRV2 OVER Relay energized when second supervised parameter 3204 exceeds the limit 3206 See Group 32 Supervision on page 100 10 SUPRV2 UNDER Relay energized when second supervised parameter 3204 drops below the limit 3205 See Group 32 Supervision on page 100 11 AT SET POINT Relay energized when output frequency is equal to reference frequency 12 FAULT RST Relay energized when the ACS ...

Page 95: ... PFC control Pump Fan Control This option should be selected only when PFC control macro is used 30 AUTOCHANGE Relay is energized when PFC autochange operation is performed This option should be selected only when PFC control macro is used 31 STARTED Relay is energized when drive receives start command even if Run Enable signal is not present Relay is de energized when stop command is received or ...

Page 96: ...current is inversely proportional to the value of the observed parameter Figure 30 Analog output scaling 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 MI...

Page 97: ...t stored in permanent memory Note This parameter is not affected by macro selection Note Parameter writes through Standard Modbus or DDCS channels are not affected by this parameter 1604 FAULT RESET SEL Fault reset source Note Fault reset is always possible with control panel Note Option 6 START STOP should not be selected when start stop and direction commands are given through serial communicati...

Page 98: ... memory Instead this parameter must be used 0 DONE 1 SAVE Note Parameter modifications done from the control panel are normally stored immediately to permanent memory However if 1602 PARAMETER LOCK is set to 2 NOT SAVED modifications done from the control panel are saved only if this parameter 1607 is used 1608 DISPLAY ALARMS Controls the visibility of some of the alarms see Diagnostics on page 35...

Page 99: ...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 output frequency the inertia of the load will cause regeneration back into the ACS 400 thus keeping the DC bus charged and ...

Page 100: ...eeds 20 Hz or when output frequency is equal to reference See also parameter 2103 TORQ BOOST CURR 4 FLY BOOST Activates both the flying start and torque boost Note If torque boost is used the switching frequency is always 4 kHz In this case parameter 2605 LOW NOISE is ignored 2102 STOP FUNCTION Conditions during motor deceleration 1 COAST Motor coasts to stop 2 RAMP Ramp deceleration as defined by...

Page 101: ...al takes place or when switching from EXT1 to EXT2 takes place or when switching from EXT2 to EXT1 takes place 0 OFF Start inhibit control disabled Drive will start after fault is reset Run Enable is activated or mode is changed while there is a pending start command 1 ON Start inhibit control enabled Drive will not start after fault is reset Run Enable is activated or mode is changed In order to ...

Page 102: ...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 f...

Page 103: ...nd CRIT FREQ 2 HI 52 Hz Figure 32 Example of critical frequencies setting in a fan system with bad vibrations at frequency ranges 18 Hz to 23 Hz and 46 Hz to 52 Hz Code Description 2501 CRIT FREQ SEL Critical frequencies activation 0 OFF 1 ON 2502 CRIT FREQ 1 LO Critical frequency 1 start Note If LOW HI no critical frequency lock out will happen 2503 CRIT FREQ 1 HI Critical frequency 1 end 2504 CR...

Page 104: ...g is used the maximum loadability of the ACS 400 is I2 at 30 C ambient temperature or 0 8 I2 at 40 C 2606 U f RATIO U f ratio below field weakening point 1 LINEAR 2 SQUARE Linear is preferred for constant torque applications Square for centrifugal pump and fan applications Square is more silent for most operating frequencies 2607 SLIP COMP RATIO A squirrel cage motor will slip under load The slip ...

Page 105: ...warning indication is displayed and the speed is set to the level at which the ACS 400 was last operating This value is determined by the average speed over the last 10 seconds Caution If you select CONST SPEED 7 or LAST SPEED make sure that it is safe to continue operation in case the analog input signal is lost 3002 PANEL LOSS Operation in case of control panel loss fault 1 FAULT A fault indicat...

Page 106: ...quirements 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 Figure 34 Motor thermal time 3006 MOT LOAD CURVE Moto...

Page 107: ...on 3010 STALL CURRENT Current limit for stall protection Refer to Figure 36 3011 STALL FREQ HI This parameter sets the frequency value for the stall function Refer to Figure 36 3012 STALL TIME This parameter sets the time value for the stall function 3013 UNDERLOAD FUNCTION Removal of motor load may indicate a process malfunction The protection is activated if The motor torque drops below the load...

Page 108: ... reach maximum at the motor rated frequency set by parameter 9907 MOTOR NOM FREQ 3017 GROUND FAULT This parameter defines operation in case of ground fault is detected in the motor or in the motor cable 1 FAULT A fault indication is displayed and the ACS 400 coasts to stop 2 NO The fault indicator is suppressed and the ACS 400 continues operation normally 3022 AI1 FLT LIMIT Fault level for analog ...

Page 109: ...98 ACS 400 User s Manual Figure 38 Underload curve types TM nominal torque of the motor ƒN nominal frequency of the motor http nicontrols com ...

Page 110: ...arameter 1604 FAULT RESET SEL 3102 TRIAL TIME The time within which a limited number of fault autoresets is allowed The allowed number of faults per this time period is given with parameter 3101 NR OF TRIALS 3103 DELAY TIME This parameter sets the time that the ACS 400 will wait after a fault occurs before attempting to reset If set to zero the ACS 400 will reset immediately 3104 AR OVERCURRENT 0 ...

Page 111: ...ing Data group Group 01 3202 SUPERV 1 LIM LO First supervision limit low Display of this parameter depends on the selected supervised parameter 3201 3203 SUPERV 1 LIM HI First supervision limit high Display of this parameter depends on the selected supervised parameter 3201 3204 SUPERV 2 PARAM Second supervised parameter number of the Operating Data group Group 01 3205 SUPERV 2 LIM LO Second super...

Page 112: ... Parameter 1401 RELAY OUTPUT 1 1402 RELAY OUTPUT 2 value is SUPRV2 OVER B Parameter 1401 RELAY OUTPUT 1 1402 RELAY OUTPUT 2 value is SUPRV2 UNDER OVER or SUPRV1 UNDER or SUPRV1 Note Case LOW HIGH represents a normal hysteresis Case A Is for monitoring when if the supervised signal exceeds a given limit Case B Is for monitoring when if the supervised signal falls below a given limit http nicontrols...

Page 113: ...TPUT 1 1402 RELAY OUTPUT 2 value is SUPRV1 UNDER or SUPRV2 UNDER Note Case LOW HIGH represents a special hysteresis with two separate supervision limits Depending on whether the supervised signal has gone below value HIGH 3203 or above value LOW 3202 determines which limit is being used Initially HIGH is used until the signal goes above value LOW After this the limit used is LOW until the signal g...

Page 114: ...ACS 400 User s Manual 103 Group 33 Information Code Description 3301 SW VERSION Software version 3302 TEST DATE Displays the test date of the ACS 400 yy ww http nicontrols com ...

Page 115: ...s variables See Figure 42 Figure 42 ACS PAN output display when process variable display is selected 3402 P VAR 1 SEL Selection of process variable 1 Number of any parameter of the group 1 OPERATING DATA 3403 P VAR 1 MULTIP Process variable 1 multiplier 3404 P VAR 1 DIVISOR Process variable 1 divider 3405 P VAR 1 SCALING Decimal point location of process variable 1 when displayed Refer to Figure 4...

Page 116: ...04 P VAR 1 DIVISOR 1000 Since variable 0103 OUTPUT FREQ is displayed with 0 1 Hz resolution it is internally scaled so that value 10 represents 1 Hz Therefore 3405 P VAR 1 SCALING 1 must be selected 3407 P VAR 2 SEL Selection of process variable 2 Number of any parameter of the group 1 OPERATING DATA 3408 P VAR 2 MULTIP Process variable 2 multiplier 3409 P VAR 2 DIVISOR Process variable 2 divider ...

Page 117: ... activated and deactivated through a digital input CROSSREF shows the connections of internal signals when the PID Control macro is selected Code Description 4001 PID GAIN This parameter defines the gain of the PID Controller The setting range is 0 1 100 If you select 1 a 10 change in error value causes the PID Controller output to change by 10 4002 PID INTEG TIME PID controller integration time D...

Page 118: ...ctual value 2 is selected by parameter 4008 1 ACT1 Actual value 1 is used as the feedback signal 2 ACT1 ACT2 Difference of actual values 1 and 2 is used as the feedback signal 3 ACT1 ACT2 Sum of actual values 1 and 2 4 ACT1 ACT2 Product of actual values 1 and 2 5 ACT1 ACT2 Quotient of actual values 1 and 2 6 MIN A1 A2 Smaller of actual values 1 and 2 7 MAX A1 A2 Greater of actual values 1 and 2 8 ...

Page 119: ...aximum 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 Figure 44 Actual value scaling The range of the analog input signal is set by parameters 1301 and 1302 or parameters 1304 and 1305 depending on the analog input used Code Description ACT1 Analog input signal ACT1 MINIMUM AI ...

Page 120: ... 48 Inverted error value parameter 4005 1 Applied wake up level is according to the following formula Limit parameter 1108 parameter 4015 parameter 1108 setpoint parameter 1108 parameter 1107 When the actual value is higher than or equal to this value the sleep function is de activated See Figure 47 and Figure 49 4016 PID PARAM SET PID parameter set selection When set 1 is selected parameters 4001...

Page 121: ... remote mode REM is shown on control panel display Process reference to PID controller can also be given from the control panel in local mode LOC is shown on control panel display if the panel reference is given as percentage i e value of parameter 1101 KEYPAD REF SEL 2 REF2 4020 INTERNAL SETPNT Sets a constant process reference for the PID controller PID controller follows this reference if param...

Page 122: ...Example of how applied wake up level floats with the set point here parameter 4015 WAKE UP LEVEL equals to 60 PID control inverted case NON INVERTED ERROR VALUE WAKE UP LEVEL 1108 EXT REF2 MAX SETPOINT 4015 APPLIED WAKE UP LEVEL 1107 EXT REF2 MIN 100 75 0 INVERTED ERROR VALUE 1108 EXT REF2 MAX APPLIED WAKE UP LEVEL SETPOINT 1107 EXT REF 2 MIN 4015 WAKE UP LEVEL 0 60 100 http nicontrols com ...

Page 123: ... operation with non inverted error value Figure 49 Wake up level operation with inverted error value APPLIED WAKE UP LEVEL TIME ACT VALUE TIME EXPIRES SLEEP DEACTIVATED APPLIED WAKE UP LEVEL TIME EXPIRES ACT VALUE SLEEP DEACTIVATED http nicontrols com ...

Page 124: ... 2 Parameters of this group belong to PID parameter set 2 The operation of parameters 4101 4112 4119 4120 is analogous with set 1 parameters 4001 4012 4019 4020 PID parameter set 2 can be selected by parameter 4016 PID PARAM SET http nicontrols com ...

Page 125: ...the speed is set to the level at which the ACS 400 was last operating This value is determined by the average speed over the last 10 seconds Caution If you select CONST SPEED 7 or LAST SPEED make sure that it is safe to continue operation in case communication is lost 5005 PROTOCOL SEL Defines what communication protocols are used Options 1 DDCS and 3 STD MDB DDCS should be selected only if a DDCS...

Page 126: ...on the DDCS link and is capable of controlling the digital inputs and outputs of the extension module Note Value 2 IO EXTENSION should be used only when the PFC Pump Fan Control macro is selected 5008 DDCS LINK CTRL Controls the light intensity in the DDCS link The higher the value the higher the intensity 5009 DDCS HW CONFIG HW configuration of the DDCS link 0 STAR Star configuration DDCS regener...

Page 127: ...DBUSPAR 1 Parameter 1 of communication module on the DDCS link Value reflects the type of the connected communication module 5102 5115 FIELDBUSPAR 2 FIELDBUSPAR 15 Refer to communication module documentation for more information on these parameters 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 ...

Page 128: ...ne every time the ACS 400 finds any kind of communication error During normal operation this counter rarely increases 5207 GOOD MESSAGES This diagnostics counter increases by one every time a valid Modbus message has been received by the ACS 400 During normal operation this counter is increasing constantly 5208 BUFFER OVERRUNS Longest possible message length for the ACS 400 is 32 bytes If a messag...

Page 129: ...iagnostic counter increases by one every time the ACS 400 receives a character from the bus while it is still processing the previous message There might be two stations with the same station number Ambient noise levels may be too high 5213 SER FAULT MEM 1 Last Modbus exception code sent 5214 SER FAULT MEM 2 Previous Modbus exception code sent 5215 SER FAULT MEM 3 Oldest Modbus exception code sent...

Page 130: ...09 START FREQ 1 Sets a frequency limit See Figure 50 on page 120 When ACS 400 output frequency exceeds value 8109 START FREQ 1 1 Hz and no auxiliary motors are running the Start Delay counter is started When the time set with parameter 8115 AUX MOT START D is elapsed and if the output frequency is still above value 8109 START FREQ 1 1 Hz the first auxiliary motor is started After the first auxilia...

Page 131: ...Q 2 8113 LOW FREQ 2 Note Low Frequency 2 should be within limits 2007 MINIMUM FREQ 1 and 8109 START FREQ 2 8114 LOW FREQ 3 Sets a frequency limit see Figure 50 When the ACS 400 s output frequency falls below a value 8114 LOW FREQ 3 1 Hz and three auxiliary motors are running a Stop Delay counter is started When the time set with parameter 8116 AUX MOT STOP D is elapsed and if the output frequency ...

Page 132: ...AUTOCHNG INTERV Sets the interval for the Autochange function The time is counted only when the ACS 400 Start signal is on See parameter 8119 AUTOCHNG LEVEL for information on the operation of the Autochange 0 0 NOT SEL This setting switches off the Autochange function Note The ACS 400 always coasts to stop when autochange is performed Warning If the Autochange function is used the Interlocks must...

Page 133: ...led motor is switched off if the motor is running If other motors are running they will not be interrupted 4 The contactor of the new speed controlled motor is switched on The autochange switchgear connects this motor to the ACS 400 5 Time set with parameter 8122 PFC START DELAY is waited 6 Speed controlled motor starts If a constant speed motor was stopped in Step 3 one more motor is connected di...

Page 134: ... the digital inputs are reserved for the interlock signals according to the following table Code Description Interlock signals No of aux motors param 8117 ACS 400 digital inputs NDIO module 1 NDIO module 2 0 DI1 Motor 1 DI2 DI5 free Not used Not used 1 DI1 Motor 1 DI2 Motor 2 DI3 DI5 free 2 DI1 Motor 1 DI2 Motor 2 DI3 Motor 3 DI4 DI5 free 3 DI1 Motor 1 DI2 Motor 2 DI3 Motor 3 DI4 Motor 4 DI5 free ...

Page 135: ...ital inputs NDIO module 1 NDIO module 2 0 DI1 DI2 free DI3 Motor 1 DI4 DI5 free Not used Not used 1 DI1 DI2 free DI3 Motor 1 DI4 Motor 2 DI5 free 2 DI1 DI2 free DI3 Motor 1 DI4 Motor 2 DI5 Motor 3 3 DI1 DI2 free DI3 Motor 1 DI4 Motor 2 DI5 Motor 3 DI1 Motor 4 DI2 Unused Not used Interlock signals No of aux motors param 8117 ACS 400 digital inputs NDIO module 1 NDIO module 2 0 DI1 DI3 free DI4 Moto...

Page 136: ...it PFC logic detects if a motor is switched off The logic does not try to start the switched off motor the next available motor is started instead 2 A contact of the motor thermal relay or another protective device in the motor circuit must be wired to the Interlock input PFC logic detects if the thermal relay is activated The motor is stopped Code Description Interlock signals No of aux motors pa...

Page 137: ...nterlocks of a PFC system with two motors There is a thermal relay in the supply circuit of M2 Code Description 3 3 K2 1 M 3 M2 On Off K1 M 3 DI4 DI5 24 V On Off ACS 400 RO1C 230 VAC 230 VAC RO1A RO1B RO2C RO2A RO2B M1 AGND DCOM2 http nicontrols com ...

Page 138: ... value signal instead of the output of the PID regulator Figure 53 Regulator bypass control The capacity of the pumping station outlet flow follows the measured inlet flow Figure 54 The relation between the control signal and the frequency of the controlled motor in a three motor system Code Description M 3 M 3 M 3 3 3 3 3 3 Mains 3 3 ACS 400 Sewage Measured Inlet Flow Reference for the Pumping St...

Page 139: ...mal PFC operation starts Auxiliary motors are started Caution There should always be PFC Start Delay set if the motors are equipped with star delta starters The PFC Start Delay must be set longer than the time setting of the star delta starter After the motor is switched on by the relay output of the ACS 400 there must be enough time for the star delta starter to first switch to star connection an...

Page 140: ...S 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 DriveWindow PC tool Optional serial communication features The ACS 400 can also be connected to a number of other fieldbuses using special fieldbus adapter modules These adapters are connected using a...

Page 141: ...CS 400 User s Manual Figure 56 Structure of a fieldbus system Fieldbus Fieldbus Master PLC Control Word CW References REF Status Word SW Actual Values ACT Data Flow Parameter R W Requests http nicontrols com ...

Page 142: ... loops and all the devices should be earthed to a common ground The RS485 network must be terminated using 120 Ω resistors at both ends of the network Use DIP switch to connect or disconnect the termination resistors The termination should not be done on the intermediate stations on the network as shown in Figure 57 Figure 57 Termination for the RS485 link The connections may only be made with the...

Page 143: ...ia Channel 1 using the default communication settings given in Table 13 making parameter read and write possible The following sections describe how to configure the ACS 400 for more sophisticated communication and control Table 13 Default communication settings of Channel 1 Note Protocol must be reactivated after the communication settings are changed Station number Communication speed Parity bit...

Page 144: ...rameter List on page 65 Table 14 Communication parameters Code Parameter Name Alternative Settings Default Setting Function Information Group 52 STANDARD MODBUS 5201 STATION NUMBER 1 247 1 Slave number for ACS 400 in Modbus network 5202 COMM SPEED 3 300 bps 192 19200 bps 96 9600 bits s Communication speed 5203 PARITY 0 NONE 1 EVEN 2 ODD 0 NONE Parity and stop bit setting Group 50 COMMUNICATION 500...

Page 145: ...d Modbus Function Information Group 50 COMMUNICATION 5006 COMM COMMAND 0 NOT SEL 1 STD MODBUS 2 DDCS 1 STD MODBUS Defines the serial communication channel for the controlling commands start stop direction and reference Must be set to 1 STD MODBUS Group 10 COMMAND INPUTS 1001 EXT1 COMMANDS 0 NOT SEL 1 DI1 10 COMM 10 COMM Enables the Control Word except bit 11 when EXT1 is selected as control locati...

Page 146: ...any value 0 99 to parameter 131 causes the relay output 1 to deactivate Refer to Table 17 for information on analog output control Table 16 Relay output control 1106 EXT REF2 SELECT 0 KEYPAD 1 AI1 8 COMM 9 COMM AI1 10 COMM AI1 8 COMM 9 COMM AI1 or 10 COMM AI1 Fieldbus reference 2 is used when EXT2 is selected as control location See section References below for information on the alternative setti...

Page 147: ...V 1 LIM HI 0 255 e g 100 Upper supervision limit for supervised parameter 1 3204 SUPERV 2 PARAM 102 137 e g 132 SERIAL LINK DATA 2 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 3206 SUPERV 2 LIM HI 0 255 e g 100 Upper supervision limit for supervised parameter 2 Code Parameter Name ...

Page 148: ...ultaneously when in parameter set mode or by writing a zero from serial communication channel 1 Note Parameters 5206 5212 are displayed in hexadecimal format by the control panel Table 18 Code Name Range User Group 52 STANDARD MODBUS 5206 BAD MESSAGES 0 65535 5207 GOOD MESSAGES 0 65535 5208 BUFFER OVERRUNS 0 65535 5209 FRAME ERRORS 0 65535 5210 PARITY ERRORS 0 65535 5211 CRC ERRORS 0 65535 5212 BU...

Page 149: ...an be read from an external device and an external device can modify the register values by writing to them There are no setup parameters for mapping the data to the 4xxxx register The mapping is predefined and corresponds directly to the ACS 400 parameter grouping All parameters are available for both reading and writing The parameter writes are verified for correct value and for valid register a...

Page 150: ...the group Table 19 Parameter mapping 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 4GGPP GG PP 40001 40006 00 Drive control registers 01 Control word 02 Reference 1 03 Reference 2 04 Status word 05 Ac...

Page 151: ...s not an allowable action for the slave ACS 400 Unsupported Command 02 ILLEGAL DATA ADDRESS The data address received in the query is not an allowable address for the slave ACS 400 Address outside groups 03 ILLEGAL DATA VALUE A value contained in the query data field is not an allowable value for the slave ACS 400 Value outside min tax limits ACS 400 Parameter is read only ACS 400 Message is too l...

Page 152: ...on of Control Word bit 10 REMOTE_CMD which is not used by the ACS 400 Table 22 The Control Word See also the state machine in Figure 58 on page 147 Bit Value Description 0 1 Enter READY TO OPERATE 0 Emergency OFF Ramp to stop according to parameter 2203 DECELER TIME 1 Enter OFF1 ACTIVE proceed to READY TO SWITCH ON unless other interlocks OFF2 OFF3 are active 1 1 Continue operation OFF2 inactive 0...

Page 153: ...gh serial communication parameter 1001 Control Word Value Description Step 1 CW 0000 0000 0000 0110 When this value is written the drive state changes to READY TO SWITCH ON Step 2 Wait at least 100 ms before proceeding Step 3 CW 0000 0000 0000 0111 When this value is written the drive state changes to READY TO OPERATE Step 4 CW 0000 0000 0000 1111 When this value is written the drive starts but wi...

Page 154: ...No alarm 8 1 OPERATING Actual value equals reference value is within tolerance limits 0 Actual value differs from reference value is outside tolerance limits 9 1 Drive control location REMOTE 0 Drive control location LOCAL 10 1 The value of first supervised parameter equals to or is greater than supervision limit Refer to Group 32 Supervision 0 The value of first supervised parameter is below supe...

Page 155: ...bus references are scaled as follows Reference 1 20000 EXT REF1 MAX Hz parameter 1105 Scaling Parameter 1104 EXT REF1 MIN is not used Reference 2 10000 EXT REF2 MAX parameter 1108 Scaling Parameter 1107 EXT REF2 MIN is not used Fieldbus Reference Fieldbus reference is selected by setting a reference selection parameter 1103 EXT REF1 SELECT or 1106 EXT REF2 SELECT to COMM COMM AI1 or COMM AI1 The l...

Page 156: ...orresponding to 25 of full scale and voltage at AI1 is 3 V corresponding to 30 of full scale 1 If setting COMM AI1 is used then the corrected fieldbus reference is 25 30 50 5 or 2 5 Hz 2 If setting COMM AI1 is used then the corrected fieldbus reference is 25 30 50 15 or 7 5 Hz 2 1 50 AI1 100 50 100 FIELDBUS REFERENCE REF c o m m A I comm AI http nicontrols com ...

Page 157: ...ctual values are 16 bit words containing a sign bit and a 15 bit integer A negative value is given as two s complement of the corresponding positive value Actual Value 1 Holding Register 40005 Actual output frequency Scaling 5000 50 Hz Actual Value 2 Holding Register 40006 Actual output current Scaling 10 1 A http nicontrols com ...

Page 158: ...O SWITCH ON OPERATION INHIBITED READY TO SWITCH ON READY TO OPERATE OPERATION ENABLED C D From any state Emergency Off OFF2 CW Bit1 0 SW Bit4 0 OFF2 ACTIVE From any state Fault SW Bit3 1 FAULT CW Bit7 1 SW Bit5 0 Emergency Stop OFF3 CW Bit2 0 SW Bit12 1 RFG ACCELERATOR ENABLED CW Bit5 1 CW Bit6 0 C CW Bit6 1 SW Bit8 1 D A D OPERATING OFF3 ACTIVE This state transition also occurs if the fault is re...

Page 159: ...D 1 Fault information When a fault is active the corresponding bit is set Bit descriptions are given in Table 27 306 FAULT WORD 2 Fault information When a fault is active the corresponding bit is set Bit descriptions are given in Table 27 308 ALARM WORD 1 Alarm information When an alarm is active the corresponding bit is set Bits remain set until the whole alarm word is reset by writing 0 to it Se...

Page 160: ...m Overload alarm 1 Overvoltage controller alarm Autoreset alarm 2 Undervoltage controller alarm PID sleep alarm 3 Direction lock alarm PFC autochange alarm 4 Serial communication loss PFC interlock alarm 5 Modbus exception Reserved 6 Analog input 1 loss 7 Analog input 2 loss 8 Panel loss 9 ACS 400 overtemperature 10 Motor overtemperature 11 Underload 12 Motor stall alarm 13 DDCS link 14 Reserved 1...

Page 161: ...150 ACS 400 User s Manual http nicontrols com ...

Page 162: ... in local control Parameter 1101 KEYPAD REF SEL is used to select keypad reference which can be either REF1 Hz or REF2 If REF1 Hz is selected the type of reference is frequency and it is given to the ACS 400 in Hz If REF2 is selected the reference is given in per cent If PID Control macro or PCF macro is used reference REF2 is fed directly to the PID controller as percentage Otherwise reference RE...

Page 163: ...ce is defined by parameter 1103 EXT REF1 SELECT External reference 1 is always a frequency reference For EXT2 the source of the Start Stop Direction commands is defined by parameter 1002 EXT2 COMMANDS and the reference source is defined by parameter 1106 EXT REF2 SELECT External reference 2 can be a frequency reference or a process reference depending on the application macro selected In remote co...

Page 164: ...02 DIRECTION 1003 RUN ENABLE 1601 Control Terminals Analogue inputs AI1 AI2 Digital inputs DI1 DI5 AI1 2 DI1 5 Remote KEYPAD Local AI1 2 DI1 5 KEYPAD EXT1 EXT2 Applic PID DI1 DI5 Const Speeds Remote Local Min freq Max freq Crit speed Acc Dec REF2 REF1 Hz Start Stop Direction Enabled DI1 DI5 REQUEST FORWARD REVERSE Local Remote EXT1 EXT2 NOT SEL DI1 DI5 KEYPAD NOT SEL DI1 DI5 KEYPAD Keypad Ref Loc ...

Page 165: ...02 CONST SP SELECT 1201 AI1 EXT1 EXT2 KEYPAD AI1 2 DI1 5 Remote KEYPAD Local Remote Local DI3 4 Const speeds Min freq Max freq Crit sp Acc Dec KEYPAD REF SEL 1101 Digital inputs DI1 DI5 Keypad Ref Loc Rem REF2 REF1 Hz Start Stop Direction NOT SEL DI1 DI5 KEYPAD NOT SEL DI1 DI5 KEYPAD EXT1 EXT2 Local Remote REQUEST FORWARD REVERSE Start Stop Direction Enabled DI1 DI5 RUN ENABLE DIRECTION EXT2 COMMA...

Page 166: ... Local Const speeds Min freq Max freq Crit sp Acc Dec KEYPAD REF SEL 1101 Digital inputs DI1 DI5 Keypad Ref Loc Rem REF2 REF1 Hz Start Stop Direction NOT SEL DI1 KEYPAD NOT SEL KEYPAD EXT1 EXT2 Local Remote REQUEST FORWARD REVERSE Start Stop Direction RUN ENABLE DIRECTION EXT2 COMMANDS 1002 EXT1 COMMANDS 1001 DI2 DI3 1003 1601 AI1 AI2 AI1 AI2 ACT2 ACT1 ACTUAL VAL SEL 4006 ACTUAL1 INPUT SEL 4007 AC...

Page 167: ...156 ACS 400 User s Manual http nicontrols com ...

Page 168: ...d off and starts the other pump instead The PFC macro makes automatic pump alternation possible Thus each pump can be run with an equal duty time For more information on the alternation system and the other useful features such as Sleep function Constant reference value Reference steps and Regulator by pass see parameter group 40 41 and 81 parameter descriptions As default when PFC macro is select...

Page 169: ...Act Value Process Ref Value DI5 Interlock 2 DI4 Interlock 1 RO2 RO1 M 3 24 V d c Input Power PI ACS 400 Pump 1 Regulated speed Pump 2 Constant speed 230 V a c M 3 Mains Supply 3 24 V supply Pump 2 On Off Pump 1 On Off Process Act Value Process Ref Value DI5 Interlock 2 DI4 Interlock 1 RO2 RO1 M 3 Input Power PI ACS 400 230VAC M 3 Mains Supply 3 24 V supply Pump 2 On Off Pump 1 On Off 230VAC Altern...

Page 170: ...D parameter sets selectable through a digital input PID controller parameters are in groups 40 and 41 Control Terminals Analogue inputs EXT REF2 SELECT 1106 EXT REF1 SELECT 1103 EXT1 EXT2 SEL 1102 CONST SPEED SEL 1201 AI1 EXT1 EXT2 KEYPAD AI1 Remote KEYPAD Local Remote Local Const speeds Min freq Max freq Crit sp Acc Dec KEYPAD REF SEL 1101 Digital inputs DI1 DI5 Keypad Ref Loc Rem REF2 REF1 Hz St...

Page 171: ...ule is needed to use DDCS There can be either one or two NDIO modules on the DDCS link Each NDIO module contains two digital inputs and two relay outputs Setting up NDIO modules Refer to the Installation and Start up Guide of the NDIO module for installation instructions After installation the communication between the ACS 400 and NDIO modules is set up as follows Set the module node numbers using...

Page 172: ...omestic purposes Second Environment includes establishments other than those directly connected to a low voltage power supply network which supplies buildings used for domestic purposes With ACS 400 no RFI filter is needed in Second Environment C Tick Marking A C tick mark is attached to the ACS 400 frequency converters to verify that the unit follows the provisions of the Australian Statuary Rule...

Page 173: ...tance from the sides of the converter is at least 20 cm to avoid excessive radiation to the mains cable In the case of shielded cable twist the cable screen wires together into a bundle not longer than five times its width and connect to the PE terminal of the converter Or PE terminal of input filter if present Motor Cable The motor cable must be a symmetrical three conductor cable with a concentr...

Page 174: ...or At the motor end the motor cable screen must be earthed 360 degrees with an EMC cable gland e g ZEMREX SCG Screened cable glands or the screen wires must be twisted together into a bundle not longer than five times its width and connected to the PE terminal of the motor Symmetrical shielded cable three phase conductors and a concentric or otherwise symmetrically constructed PE conductor and a s...

Page 175: ...hielded twisted multipair cable on the right The analogue and digital input signals should be run in separate screened cables Relay controlled signals providing their voltage does not exceed 48 V can be run in the same cables as digital input signals It is recommended that the relay controlled signals be run as twisted pairs Never mix 24 VDC and 115 230 VAC signals in the same cable Note When the ...

Page 176: ...ecified in EN61800 3 EN50081 1 provided that maximum motor cable length is 30 m and switching frequency 4 kHz Line Current Harmonics The current harmonic levels under rated load conditions are available on request Distribution Networks Isolated from Earth Input filters designed for ACS 400 cannot be used in an isolated or high impedance earthed industrial distribution networks Converter Type Filte...

Page 177: ...166 ACS 400 User s Manual http nicontrols com ...

Page 178: ...ACS 400 User s Manual 167 Appendix D ACS 400 Dimensional Drawings ACS 400 NEMA Type 1 Enclosure R1 Frame Size http nicontrols com ...

Page 179: ...168 ACS 400 User s Manual ACS 400 NEMA Type 1 Enclosure R2 Frame Size http nicontrols com ...

Page 180: ...ACS 400 User s Manual 169 ACS 400 NEMA Type 1 Enclosure R3 Frame Size http nicontrols com ...

Page 181: ...170 ACS 400 User s Manual ACS 400 NEMA Type 1 Enclosure R4 Frame Size http nicontrols com ...

Page 182: ...ACS 400 User s Manual 171 ACS 400 NEMA Type 12 4 Enclosure R1 Frame Size http nicontrols com ...

Page 183: ...172 ACS 400 User s Manual ACS 400 NEMA 12 4 Enclosure R2 Frame Size http nicontrols com ...

Page 184: ...ACS 400 User s Manual 173 ACS 400 NEMA Type 12 4 R3 Frame Size http nicontrols com ...

Page 185: ...174 ACS 400 User s Manual ACS 400 NEMA Type 12 4 R4 Frame Size http nicontrols com ...

Page 186: ...http nicontrols com ...

Page 187: ...9002B5310 R0101 Rev B Effective 01 16 01 Supercedes 2 1 99 ABB Automation Inc Drives Power Products Group 16250 W Glendale Drive New Berlin WI 53151 Telephone 262 785 8378 800 243 4384 Fax 262 780 5135 http nicontrols com ...