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ABB ACH 500 Series Programming Manual

Adjustable frequency ac drives 2 to 400 hp
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ACH 500
ABB Drives
Programming Manual
Including Application Macros
ACH 500 Adjustable Frequency
AC Drives 2 to 400 HP, Series B
ACH 500-05C
EFFECTIVE 11/1/94
SUPERCEDES 6/1/94
$25.00 U.S.
ASEA BROWN BOVERI

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Summary of Contents for ABB ACH 500 Series

  • Page 1 $25.00 U.S. Programming Manual ACH 500 Including Application Macros ACH 500 Adjustable Frequency AC Drives 2 to 400 HP, Series B ACH 500-05C EFFECTIVE 11/1/94 SUPERCEDES 6/1/94 ABB Drives ASEA BROWN BOVERI...
  • Page 2 ACH 500 Adjustable Frequency AC Drives 2 to 400 HP Programming Manual Including Application Macros ACH 500-05C EFFECTIVE: 1994-11-01 SUPERCEDES: 1994-06-01 © 1994 ABB Drives Inc. All Rights Reserved.
  • Page 3 Safety Instructions General Safety Warnings in this manual appear in either of two ways: Instructions • Dangerous voltage warnings, preceded by a Dangerous Voltage symbol, indicate the presence of voltages which may cause death or serious injury. These warnings describe procedures to avoid death or serious injury. •...
  • Page 4 Safety Instructions Warnings, Cautions, and Notes WARNING! Your drive contains dangerous voltages when connected to the line power. Always check that the ACH 500 is safe, after disconnecting the power, by measuring the DC bus voltage and line input voltage. Failure to check voltages could cause death or serious injury.

  • Page 5: Table Of Contents

    Table of Contents Chapter 1 – Introduction How To Use This Manual ............1-1 Intended Audience .
  • Page 6 Table of Contents Application 2 – Floating Point Control ..........5-6 Operation Diagram .

  • Page 7: Chapter 1 - Introduction

    Chapter 1 – Introduction This chapter describes the purpose and contents of this manual, describes the intended audience, explains conventions used in this manual, and lists related publications. How To Use This The purpose of this manual is to provide you with the information necessary to select, modify, and apply Application macros to the operation of your ACH Manual 500 drive.

  • Page 8: Intended Audience

    The audience for this manual has: • Knowledge of standard electrical wiring practices, electronic components, and electrical schematic symbols. • Minimal knowledge of ABB product names and terminology. • No experience or training in installing, operating, or servicing the ACH 500.

  • Page 9: Control Panel Keys

    Chapter 1 – Introduction Control Panel Keys Control Panel keys are flat, labeled, pushbutton keys that allow you to monitor drive functions, select drive parameters, and change drive macros and settings. Table 1-1 illustrates each Control Panel Key as it appears on the Control Panel Keypad.
  • Page 10 Chapter 1 – Introduction This page intentionally left blank. ACH 500 Programming Manual...

  • Page 11: Chapter 2 - Overview Of Ach 500 Programming

    Chapter 2 – Overview of ACH 500 Programming This chapter defines Application macros in terms of parameter settings and describes how to use the menu system of parameters to select and modify the macros. Overview of Application Macros Application Macros Application macros are pre-programmed parameter sets.

  • Page 12: Menu System Of Parameters

    Chapter 2 – Overview of ACH 500 Programming Menu System of The parameters in the ACH 500 are organized via a system of menus. There Parameters are four levels of information, plus a start-up data menu. The four levels are: Operating Data, Main Level, Group Level, and Parameter Level.

  • Page 13: Operating Data Parameters

    Chapter 2 – Overview of ACH 500 Programming Using the Start-up Data The Start-up Data Menu provides access to parameters that should be set at Menu start-up, and should not need to be changed. These parameters are Language, Application Macro, and Motor Information. Refer to Chapter 3 – Start-up Data for descriptions of each parameter.
  • Page 14 Chapter 2 – Overview of ACH 500 Programming Main Level The Main Level organizes the parameters into four main functional areas. The ACH 500 has four Mains. Each Main allows you to access Groups within the Main. One of the Mains, Application Parameters, is only accessible when you select an Application macro that requires additional set-up parameters.
  • Page 15 Chapter 2 – Overview of ACH 500 Programming Group Level The Group Level groups the parameters by their functionality. Each Main provides access to several Groups. For example: • CONTROL CONNECTIONS/10 MAIN contains Groups 10.1 – 10.8. • DRIVE PARAMETERS/20 MAIN contains Groups 20.1 – 20.5. •...
  • Page 16 Chapter 2 – Overview of ACH 500 Programming Parameter Level The Parameter Level is the programming level where the parameters are viewed and can be modified. Each Group contains several Parameters. Parameters allow you to change certain specifications or values to meet the needs of your particular application.
  • Page 17 Chapter 2 – Overview of ACH 500 Programming Figure 2-5 shows how to set Parameter 20.1.1 (Minimum Frequency) to 3 Hz starting from Operating Data Parameter 1 (Output Frequency). Note: To accelerate the change of parameter value, press and hold the [Up Arrow] or [Down Arrow] button.
  • Page 18 Chapter 2 – Overview of ACH 500 Programming Application Macros Table 2-1 is an example of HVAC macro parameters that you are most likely to modify if you are using the ACH 500 HVAC macro to control your motor. The HVAC macro default settings appear in the Default column. Table 2-1 HVAC Macro Parameters Main Group...

  • Page 19: Chapter 3 - Start-Up Data

    Chapter 3 – Start-up Data This chapter lists and explains the Start-up Data parameters and describes how to set these parameters. The Start-up Data parameters are a special set of parameters that allow you to set-up the drive and motor information. Start-up Data parameters should only need to be set during start-up and should not need to be changed.

  • Page 20: Parameter Selection

    Chapter 3 – Start-up Data Table 3-1 Start-up Data Parameters Parameter Range/Unit Description A LANGUAGE Available languages Language selection. B APPLICATIONS Application macros Application macro selection. C APPLIC. RESTORE No, Yes Restores parameters to original values. D SUPPLY VOLTAGE Supply voltage Sets the supply voltage.
  • Page 21 Chapter 3 – Start-up Data F MOTOR CURRENT This parameter matches the ACH 500 to the rated motor current, adjustable -FLA between 0 and 1000 amps. The drive uses this parameter for motor overload protection and current (amperage) information displays. If the accuracy of the current display (parameter O.3) is off by more than 10% due to long motor cables (ACS 501 units only), a software calculation can be installed by pressing and holding the [left arrow] until an exclamation point...
  • Page 22 Chapter 3 – Start-up Data This page intentionally left blank. ACH 500 Programming Manual...

  • Page 23: Chapter 4 - Control Operation

    Chapter 4 – Control Operation This chapter describes the Operating Data parameters and how to monitor and select them. It explains Keypad control and External control, and describes the Keypad Reference 1, Keypad PI, and External Reference 1 and 2 parameters.
  • Page 24 Chapter 4 – Control Operation Table 4-1 Operating Data Parameters Parameter Range/Unit Description 1 OUTPUT FREQUENCY Frequency to motor. 2 SPEED rpm/%/no units Calculated speed, either motor RPM, %, or a scaled speed display. Displayed value is based on frequency minus slip. 3 MOTOR CURRENT Motor current, (10% accuracy).

  • Page 25: Parameter Selection

    Chapter 4 – Control Operation Parameter Range/Unit Description 21 APPL BLOCK OUTPUT * PI-Controller output signal. 22 ACTUAL VALUE 1 * Feedback signal for the PI Controller. 23 ACTUAL VALUE 2 * Feedback signal for the PI Controller. 24 LAG MOTORS RUNNING ** 0 –...
  • Page 26 Chapter 4 – Control Operation 4 CALCULATED This parameter displays motor torque in percent of motor rating, as calculated TORQUE by the drive. Press [Up Arrow] to move to the next parameter. 5 CALCULATED POWER This parameter displays motor power in percent of motor rating, as calculated by the drive.
  • Page 27 Chapter 4 – Control Operation 14 EXTERNAL REF 2 This parameter is the external frequency reference from control location R2, displayed in percent. The signal source selection is made with Parameter 10.2.5 (External Ref2 Sel). Press [Up Arrow] to move to the next parameter. 15 RUN TIME This parameter is an elapsed-time indicator.

  • Page 28: Motor Control Values

    Chapter 4 – Control Operation 23 ACTUAL VALUE 2 This parameter is a feedback signal to the PI-Controller, displayed in percent. Press [Up Arrow] to move to the next parameter. 24 LAG MOTRS Number of lag motors running in Pump and Fan control. RUNNING 25 CONTROLLER Output value of the PI-Controller.

  • Page 29: Keypad Control

    Chapter 4 – Control Operation Keypad Control vs. The ACH 500 can be controlled from two external control locations, of which External Control one is the cover-mounted HOA switch and speed pot or from the Control Panel keypad. Figure 4-2 shows all control locations. Figure 4-2 Control Locations Keypad Control (R1 or PI)
  • Page 30 Chapter 4 – Control Operation Figure 4-3 Control Signal Selection How to Set References CONTROL LOCATION KEYPAD R1 KEYPAD PI EXTERNAL KEYPAD REF 1 CRIT FREQUENCIES 20.5.2/20.5.3 KEYPAD PI (REF 2) 20.5.4/20.5.5 20.5.6/20.5.7 20.5.8/20.5.9 PRESET SPEED 1-7 EXTERNAL REF 1 SEL REF 1&2 20.5.10/20.5.11 10.2.2...

  • Page 31: Keypad Reference 1 And Keypad Pi

    Chapter 4 – Control Operation Keypad Reference 1 and Keypad PI Keypad Reference 1 Operating Data Parameter 10 (Keypad Ref 1) is a direct frequency reference. To set the frequency reference, select Parameter 10 (Keypad Ref 1), press [ * ], then press [Up Arrow] or [Down Arrow] keys to increase or decrease the keypad reference.

  • Page 32: External Reference 1 And 2

    Chapter 4 – Control Operation External Reference 1 and 2 External Reference 1 This is the external frequency reference from control location R1 which is used for HAND. The signal source selection is made with Parameter 10.2.2 (External Ref 1 Sel). The factory default is Analog Input 2 (AI2). This is used for the cover-mounted speed pot.

  • Page 33: Chapter 5 - Standard Application Macro Programs

    Chapter 5 – Standard Application Macro Programs This chapter describes the operation and application suitability of four standard Application macros and the User macro. The chapter begins with Table 5-1 which lists the macros, suitable applications for each, what each macro controls, and how to access each macro to modify its parameters.

  • Page 34: Macro Applications And Access

    Chapter 5 – Standard Application Macro Programs Macro Applications and Access Table 5-1 Macro Applications and Access Macro Suitable Applications Controls Select HVAC General HVAC applications, such as supply fans, return fans, and Cover mounted HVAC pumps. HOA switch and speed pot.

  • Page 35: Application 1 - Hvac

    Chapter 5 – Standard Application Macro Programs Application 1 – All drive commands, reference settings, and parameter settings can be HVAC undertaken from the local keypad or through the screw terminals. Select the control device with Parameter 9 (Control Location). Two analog and three relay contact signals are available on Terminal Block X50.

  • Page 36: Hvac Macro External Connections

    Chapter 5 – Standard Application Macro Programs HVAC Macro External Connections Connection Example Figure 5-2 HVAC Macro Connection Example Terminal X50 Function Reference voltage + 10 VDC 10 mA Hand Reference GND 2 AI 1+ Auto Reference* Auto Reference AI 1- AI 2+ Hand Reference* AI 2-...

  • Page 37: Hvac Parameter Settings

    Chapter 5 – Standard Application Macro Programs HVAC Parameter Settings START-UP DATA 20.5 CRIT FREQUENCIES A LANGUAGE ENGLISH 10.5 ANALOG INPUTS 20.5.1 CRIT FREQ SELECT B APPLICATIONS HVAC 10.5.1 MINIMUM AI1 0 V/0 mA 20.5.2 CRIT FREQ 1 LOW 0 Hz C APPLIC.

  • Page 38: Application 2 - Floating Point Control

    Chapter 5 – Standard Application Macro Programs ® Application 2 – HVAC applications using a Dwyer Photohelic or similar instrument to Floating Point Control maintain static pressure. Speed increase and speed decrease contacts are used to control the speed of the ACS 500. Operation Diagram Figure 5-3 Operation Diagram Input...

  • Page 39: Floating Point Control External Connections

    Chapter 5 – Standard Application Macro Programs Floating Point Control External Connections Connection Example Figure 5-4 Connection Example Terminal X50 Function Reference voltage + 10 VDC 10 mA Hand Reference GND 2 AI 1+ Auto Reference* Auto Reference AI 1- AI 2+ Hand Reference* AI 2-...

  • Page 40: Floating Point Control Parameter Settings

    Chapter 5 – Standard Application Macro Programs Floating Point Control Parameter Settings START-UP DATA 20.5 CRIT FREQUENCIES 10.5 ANALOG INPUTS 20.5.1 CRIT FREQ SELECT A LANGUAGE ENGLISH 10.5.1 MINIMUM AI1 0 V/0 mA 20.5.2 CRIT FREQ 1 LOW 0 Hz B APPLICATIONS HVAC FLOAT PT.

  • Page 41: Application 3 - Hvac-Pi

    Chapter 5 – Standard Application Macro Programs Application 3 – Start/Stop from two different places, Control Location selection, Run Enable HVAC-PI selection, one Preset Speed selection, Reference setting and actual value feedback through screw terminal inputs. Reference setting also possible internally with the keypad.

  • Page 42: Hvac-Pi External Connections

    Chapter 5 – Standard Application Macro Programs HVAC-PI External Process Control = Auto Connections Direct Speed Control = Manual Connection Example Figure 5-6 Connection Example Terminal X50 Function Reference voltage + 10 VDC 10 mA Hand Reference GND 2 AI 1+ Actual 1 Auto Feedback...

  • Page 43: Hvac-Pi Parameter Settings

    Chapter 5 – Standard Application Macro Programs HVAC-PI Parameter Settings START-UP DATA 10.7 ANALOG OUTPUTS 30.1.12 UNDERLOAD TIME 600s 10.7.1 ANALOG OUTPUT 1 OUT FREQ 30.1.13 UNDERLOAD CURVE A LANGUAGE ENGLISH 10.7.2 SCALE AO1 100% 30.2 AUTOMATIC RESET B APPLICATIONS PI-CONTROL 10.7.3 MINIMUM AO1 0 mA...

  • Page 44: Application 4 - Pump And Fan

    Chapter 5 – Standard Application Macro Programs Application 4 – The main application areas of Pump and Fan Control (PFC) are pumping and Pump and Fan ventilation systems where speed regulation of a drive motor and automatic start/stop of a maximum of three constant speed motors are beneficial. PFC can easily be connected to a custom made automatic motor alternation system for controlled changing of drive motors.

  • Page 45: Pump And Fan External Connections

    Chapter 5 – Standard Application Macro Programs Pump and Fan External Connections Connection Example Figure 5-8 Connection Example Terminal X50 Function Reference Voltage 10 VDC Manual Speed Reference) 10 mA GND 2 AI 1+ Actual Signal (ACT1) AI 1- 0 V - 10 V or 0 mA - 20 mA* AI 2+ Reference Signal Transducer...

  • Page 46: Pump And Fan Parameter Settings

    Chapter 5 – Standard Application Macro Programs Pump and Fan Parameter Settings 10.6 RELAY OUTPUTS 30.1.9 STALL CURRENT .75 x I START-UP DATA 10.6.1 RELAY RO1 OUTPUT PFC AUTOM 30.1.10 STALL TIME/FREQ 20s/25 Hz 10.6.2 RELAY RO2 OUTPUT PFC AUTOM 30.1.11 UNDERLOAD FUNC A LANGUAGE ENGLISH...

  • Page 47: Ach 500 Parameter Menus

    Chapter 6 – Parameters ACH 500 Parameter This chapter explains the function of each parameter in the ACH 500, and the Menus valid selections for each parameter. Figure 6-1 shows the process of accessing the ACH 500 Parameter Menus. Figure 6-1 Parameter Menu Selection 40.2 PUMP &...

  • Page 48: Main 10 Control Connections

    Chapter 6 – Parameters Main 10 Control Connections Group 10.1 These parameter values can only be altered with the ACH 500 stopped. The Start/Stop/Direction Range/Unit column in Table 6-1 shows parameter values. The text following the table explains parameter values in detail. Table 6-1 Group 10.1 Parameter...
  • Page 49 Chapter 6 – Parameters DI1P,2P,3P Start forward, start reverse, and stop. Start and direction commands are given simultaneously with two separate momentary push-buttons. The stop push-button is normally closed, and connected to DI3. The start forward push-button is normally open, and connected to DI1.

  • Page 50: Group 10.2 Ext Reference Select

    Chapter 6 – Parameters Group 10.2 Ext These parameter values can be altered with the ACH 500 running, except Reference Select those marked with (O). The Range/Unit column in Table 6-2 shows parameter values. The text following the table explains parameter values in detail. Table 6-2 Group 10.2 Parameter...
  • Page 51 Chapter 6 – Parameters AI1/JOYST Reference from analog input 1 configured for a joystick. Analog input minimum signal is full speed reverse, and analog input maximum signal is full speed forward. The mid point between minimum and maximum is zero speed. CAUTION: Minimum reference for joystick must be 0.3 V/0.6 mA or greater.
  • Page 52 Chapter 6 – Parameters 4 EXT REF1 MAXIMUM 0 Hz – 500 Hz (ACH 501) 0 Hz – 120 Hz (ACH 502) This parameter sets the frequency corresponding to the maximum reference. When Parameter 20.1.2 (Maximum Frequency) is changed, this parameter is automatically set to the same value.

  • Page 53: Group 10.3 Preset Speeds

    Chapter 6 – Parameters 9 EXT REF2 MAXIMUM 0 Hz – 500 Hz (ACH 501) 0 Hz – 120 Hz (ACH 502) This parameter sets the frequency corresponding to the maximum reference. When Parameter 20.1.2 (Maximum Frequency) is changed, this parameter is automatically set to the same value.
  • Page 54 Chapter 6 – Parameters 1 PRESET SPEED SEL This parameter defines which Digital Inputs are used to select Preset Speeds. NOT SEL DI1 – DI6 Preset speed number 1 selected by the Digital Input. 24 V DC = Preset Speed activated.

  • Page 55: Group 10.4 System Contr Inputs

    Chapter 6 – Parameters DI4,5,6 Refer to DI1,2,3. Group 10.4 System These parameter values can only be altered with the ACH 500 stopped. The Contr Inputs Range/Unit column in Table 6-6 shows parameter values. The text following the table explains parameter values in detail. Table 6-6 Group 10.4 Parameter...

  • Page 56: Group 10.5 Analog Inputs

    Chapter 6 – Parameters Group 10.5 These parameter values can be altered with the ACH 500 running. The Range/ Analog Inputs Unit column in Table 6-7 shows parameter values. The text following the table explains parameter values in detail. Table 6-7 Group 10.5 Parameter Range/Unit...
  • Page 57 Chapter 6 – Parameters 3 RC FILTER ON AI1 Filter time constant for Analog Input 1. As the Analog Input value changes, 63 percent of the change takes place within the time period given by this parameter. If you select the minimum value 0.01s, the signal is not filtered.

  • Page 58: Group 10.6 Relay Outputs

    Chapter 6 – Parameters Group 10.6 These parameter values can only be altered when the ACH 500 is not running. Relay Outputs The text following Table 6-8 explains parameter values in detail. Table 6-8 Group 10.6 Parameter Range/Unit Description 1 RELAY RO1 OUTPUT Relay Output 1 content.
  • Page 59 Chapter 6 – Parameters EXT. CTRL External control selected. REF 2 SEL Reference 2 selected. PRESET SPD A Preset Speed (1 – 7) selected. DC BUS LIM Voltage regulator is activated. FREQ1 LIM Output frequency has exceeded the Supervision Limit 1. Refer to Parameter 30.3.1 (Output Freq 1 Func).

  • Page 60: Group 10.7 Analog Outputs

    Chapter 6 – Parameters Group 10.7 Analog These parameter values can be altered with the ACH 500 running, except Outputs those marked with (O). The Range/Unit column in Table 6-9 shows parameter values. The text following the table explains parameter values in detail. Table 6-9 Group 10.7 Parameter...
  • Page 61 Chapter 6 – Parameters V/DC BUS DC bus voltage. 20 mA = 100% of Nominal DC Bus Voltage (V x 1.35). MOTOR VOLT Motor voltage. 20 mA = Supply Voltage. REFERENCE Active reference that the ACH 500 is currently following. 20 mA = 100% of the active reference.

  • Page 62: Group 10.8 Ext Communication

    Chapter 6 – Parameters Group 10.8 Ext For external communication parameter settings, refer to the Remote Panel Communication Manual (SAGS700PAN-04) or the DMT 500 PC Manual (DMT500PC-US-04) for information on the GS protocol parameters, or the ACS 500 Modbus Manual (ACS500MODBUS-US-04) for information on the Modbus protocol parameters.

  • Page 63: Group 20.2 Start/Stop

    Chapter 6 – Parameters 4 CURRENT LIMIT This setting is the output current limit the ACH 500 will supply to the motor. If the rated current of the motor is lower than the rated current of the ACH 500, set the current limit in accordance with the motor rating in standard applications.
  • Page 64 Chapter 6 – Parameters TORQ BOOST Automatic start current boost, which may be necessary in applications requiring high starting torque. Automatic torque boost is active only from 0 Hz to 20 Hz or until the reference speed is reached. Torque boost is not activated if the output frequency falls below 20 Hz while running.
  • Page 65 Chapter 6 – Parameters Figure 6-4 shows DC Hold. Figure 6-4 DC Hold motor DC Hold Ref. 1.5 Hz When both reference and output frequencies drop below 1.5 Hz, the drive will stop generating sinusoidal current and inject DC into the motor. The voltage value is the voltage set in the DC Hold Voltage.

  • Page 66: Group 20.3 Accel/Decel

    Chapter 6 – Parameters Group 20.3 These parameter values can be altered with the ACH 500 running, except Accel/Decel those marked with (O). The Range/Unit column in Table 6-12 shows parameter values. The text following the table explains parameter values in detail.
  • Page 67 Chapter 6 – Parameters Figure 6-5 Acceleration and Deceleration Ramp Shapes [Hz] Linear t [s] 1.25 3 ACCEL TIME 1 The time required for the output frequency to change from minimum to maximum frequency. Regardless of the settings, the maximum acceleration/ deceleration is 120 Hz/0.1s and the minimum is120 Hz/1800s.

  • Page 68: Group 20.4 Motor Control

    Chapter 6 – Parameters 6 DECEL TIME 2 Refer to Parameter 20.3.4. 7 ACCEL REF2 TIME Corresponds to the time required for the reference to change from 0 to 100 percent and vice versa, if the PI-Controller is not used. 8 DECEL REF2 TIME Refer to Parameter 20.3.7.
  • Page 69 Chapter 6 – Parameters 1 SWITCHING FREQ Motor noise can be minimized by adjusting the switching frequency to a value that does not create resonances in the motor and load. The optimum switching frequency is the lowest frequency where the noise is acceptable. As the switching frequency goes up, the inverter efficiency goes down, so it is best to use as low a switching frequency as possible relative to acceptable noise levels for the particular application.
  • Page 70 Chapter 6 – Parameters AUTOMATIC The motor voltage is automatically controlled to minimize the motor losses and noise. This setting is suitable for a motor which has a slowly changing load torque and which operates mainly below nominal load. This feature should not be used with undersized motors (motor hp below drive rated hp).
  • Page 71 Chapter 6 – Parameters 5 IR COMPENSATION This parameter allows extra torque at speeds between 0.1 Hz and the set field weakening point. This parameter differs from the Torq Boost option of the Start Function in that it is always valid in the above mentioned speed range. When using IR Compensation, always set Parameter 20.4.3 (V/Hz Ratio) to LINEAR.
  • Page 72 Chapter 6 – Parameters 6 IR-COMP VOLTAGE This parameter sets the compensation voltage level in Manual IR Compensation. Keep the boost voltage as low as possible for the application, as the motor will overheat rapidly or an overcurrent fault may occur if a high level of compensation is applied.
  • Page 73 Chapter 6 – Parameters 9 NOMINAL SLIP For the precise operation of the Slip Compensation function, the ACH 500 must know the nominal slip of the motor. Set the nominal slip as a percentage of the nominal motor speed with a range of 0.1 – 10.0%, 0.1% step. nameplate speed Slip = (1 - ) x 100...

  • Page 74: Group 20.5 Crit Frequencies

    Chapter 6 – Parameters Group 20.5 These parameter values can be altered with the ACH 500 running. The Range/ Crit Frequencies Unit column in Table 6-14 shows parameter values. The text following the table explains parameter values in detail. Table 6-14 Group 20.5 Parameter Range/Unit Description...
  • Page 75 Chapter 6 – Parameters In some mechanical systems, certain frequency ranges can cause resonance problems. With this Group, it is possible to set up to five different frequency ranges that the ACH 500 will skip over. For example, it is not necessary that Parameter 20.5.4 (Crit Freq 2 Low) be greater than Parameter 20.5.3 (Crit Freq 1 High), just as long as the Low parameter of any one set is lower than the High parameter of the same set.

  • Page 76: Main 30 Protection Parameters

    Chapter 6 – Parameters Main 30 Protection Parameters Group 30.1 These parameter values can be altered with the ACH 500 running. The Range/ Fault Function Unit column in Table 6-15 shows parameter values. The text following the table explains parameter values in detail. Table 6-15 Group 30.1 Parameter Range/Unit...
  • Page 77 Chapter 6 – Parameters PRE SPEED7 The ACH 500 drives the motor at a preset speed selected with Parameter 10.3.8 (Preset Speed 7) when in external mode. Note: If the selected control location is Keypad, the ACH 500 stops in case of serial communication fault.
  • Page 78 Chapter 6 – Parameters Motor heating is calculated assuming a load curve. The load curve is defined by the Motor Load Curve, Zero Speed Load, and Break Point parameters. If Motor Load Curve is set to 100%, the Motor Thermal Protection allows the motor to be loaded to 100% of the current set by Start-up Data Parameter F (Motor Current -FLA).
  • Page 79 Table 6-16 shows some motor thermal times measured by ABB. The default value is set to 700s, which is the value for a Class 20 trip curve. This has been tested and is UL Listed as motor overload protection.
  • Page 80 Chapter 6 – Parameters Figure 6-13 shows motor thermal time. Figure 6-13 Motor Thermal Time Motor Load Temp. Rise 100% Motor Therm Time 5 MOTOR LOAD CURVE The Motor Load Curve sets the maximum allowable operating load of the motor. The load is adjustable from 50% to 150%. Refer to Figure 6-12 for an example of motor load curve.
  • Page 81 Chapter 6 – Parameters • This condition has lasted longer than the period set in Parameter 30.1.10 (Stall Time/Freq). Figure 6-14 shows stall protection. Figure 6-14 Stall Protection Stall Region Stall Current Stall Frequency ƒ 9 STALL CURRENT This parameter sets the current level that must be exceeded for the stall protection to activate.
  • Page 82 Chapter 6 – Parameters Figure 6-15 shows underload protection. Figure 6-15 Underload Protection Underload Curve Underload Region ƒ 13 UNDERLOAD CURVE This parameter provides you with five selectable curves. Torque limit for underload logic. Figure 6-16 shows five available Underload Curve types. If the load drops below the set curve for a longer time than the time set by Parameter 30.1.12, the underload protection will activate.

  • Page 83: Group 30.2 Automatic Reset

    Chapter 6 – Parameters Group 30.2 These parameter values can be altered with the ACH 500 running. The Range/ Automatic Reset Unit column in Table 6-17 shows parameter values. The text following the table explains parameter values in detail. Table 6-17 Group 30.2 Parameter Range/Unit Description...

  • Page 84: Group 30.3 Supervision

    Chapter 6 – Parameters 5 UNDERVOLTAGE If you select YES, the ACH 500 resumes operation when the DC bus voltage returns to normal level. If the number of reset attempts is set to 0 and this parameter is set to YES, the drive will always reset in an undervoltage condition.
  • Page 85 Chapter 6 – Parameters Figure 6-17 shows an example of a supervision indication. Figure 6-17 Supervision Indication 1 OUTPUT FREQ 1 This parameter allows you to activate an output frequency supervision FUNC function. Relay outputs such as Parameters 10.6.1 (Relay RO1 Output), 10.6.2 (Relay RO2 Output), and 10.6.3 (Relay RO3 Output) and displays are used to indicate that the output frequency drops below (LOW LIMIT) or exceeds (HIGH LIMIT) the supervision limit.

  • Page 86: Group 30.4 Information

    Chapter 6 – Parameters Group 30.4 You cannot alter these parameter values. The Range/Unit column in Table 6- Information 19 shows parameter values. The text following the table explains parameter values in detail. Table 6-19 Group 30.4 Parameter Range/Unit Description 1 CRI PROG VERSION CRHxxy Control Interface Card program...

  • Page 87: Main 40 Application Parameters

    Chapter 6 – Parameters Main 40 Application Parameters Group 40.1 These parameters can only be seen when you select the HVAC-PI macro. PI-Controller These parameter values can be altered with the ACH 500 running, except those marked with (O). The Range/Unit column in Table 6-21 shows parameter values.
  • Page 88 Chapter 6 – Parameters If the parameter value is set to 3.0%, the PI-Controller operates as an I-Controller. Table 6-22 lists a few examples of gain settings, and the resulting output frequency change to a 10% change in error and a 50% change in error. Table 6-22 Gain Settings Output Frequency Output Frequency Change...
  • Page 89 Chapter 6 – Parameters Figure 6-18 shows PI-Controller Gain, I-Time, and Error Value. Figure 6-18 PI-Controller Gain, I-Time, and Error Value Error Value PI-Controller Gain Gain PI-CONT I-TIME 9 ACT 1 MIN SCALE Minimum scaling factor of the Actual Value 1. Setting range is -1600 to + 1600%.
  • Page 90 Chapter 6 – Parameters Figure 6-19 shows three examples of actual value scaling. Figure 6-19 Actual Value Scaling 10 V(100%) 10 V(100%) 100% 100% 100% 100% 8 V(75%) 8 V(80%) 4 V(25%) 4 V(40%) 2 V(0%) 0 V(0%) Actual Scaled Actual Actual Scaled Actual Actual...

  • Page 91: Group 40.2 Pump & Fan Control

    Chapter 6 – Parameters Group 40.2 Pump & Fan These parameters can only be seen when you select the P&F Autom. macro. Control These parameter values can be altered with the ACH 500 running, except those marked with (O). The Range/Unit column in Table 6-23 shows parameter values.
  • Page 92 Chapter 6 – Parameters Parameter Range/Unit Description 21 ERROR VALUE NO/YES PI-Controller error value INVERT inversion. 22 ACTUAL 1 INPUT (O) NO/AI1/AI2 Actual 1 signal input selection. 23 ACTUAL 2 INPUT (O) NO/AI1/AI2 Actual 2 signal input selection. 24 ACTUAL VALUE ACT1/ACT1 - ACT2/ PI-Controller output signal SEL (O)
  • Page 93 Chapter 6 – Parameters 1 PI-CONT GAIN This parameter defines the gain of the PI-Controller included in the Application macros of the ACH 500. Setting range is 3 – 800%. If you select 100%, a 10% change in error value causes controller output to change by 1.5 If the parameter value is set to 3.0%, the PI-Controller operates as an I-Controller.
  • Page 94 Chapter 6 – Parameters 4 REFERENCE STEP 2 0 – 100% Value that the setpoint (reference) is increased when the second lag motor is started. 5 REFERENCE STEP 3 0 – 100% Value that the setpoint (reference) is increased when the third lag motor is started.
  • Page 95 Chapter 6 – Parameters 7 SLEEP LEVEL 0 – 500 Hz (ACH 501) 0 – 120 Hz (ACH 502) Level to start sleep delay counter. 8 WAKE UP LEVEL 0 – 100% Level in % of the set reference range. This parameter determines the level of the actual value at which the ACH 500 will restart.
  • Page 96 Chapter 6 – Parameters 13 LOW FREQ 2 0 – 500 Hz (ACH 501) 0 – 120 Hz (ACH 502) Output frequency that the ACH 500 will go to after the second lag motor is started. If the output frequency goes below this limit by 1 Hz, the lag motor will stop.
  • Page 97 Chapter 6 – Parameters 1+1 motors 50.0% 1+2 motors 33.3% 1+3 motors 25.0% For example: if the values of the parameters are: Nbr of lag motors (40.2.17) = 2 Alternation level (40.2.19) = 25% Max frequency (20.1.2) = 51 Hz the alternation takes place at 38.3 Hz (25%/33.3% x 51 Hz) if the following conditions are true: •...
  • Page 98 Chapter 6 – Parameters 23 ACTUAL 2 INPUT AI1 OR AI2 24 ACTUAL VALUE SEL The Actual Value for the PI Controller can be a single signal, or two signals combined by subtraction, addition or multiplication. The choices are as follows.
  • Page 99 Chapter 6 – Parameters Figure 6-23 show three examples of actual value scaling. Figure 6-23 Actual Value Scaling 10 V(100%) 10 V(100%) 100% 100% 100% 100% 8 V(75%) 8 V(80%) 4 V(25%) 4 V(40%) 2 V(0%) 0 V(0%) Actual Scaled Actual Actual Scaled Actual Actual...
  • Page 100 Chapter 6 – Parameters 30 DISPLAY UNIT NO UNIT; bar; %; m/s; °C; °F; diff temp; kPa; 1/min; m /min; gpm; psi; dpsi; cFm; ft; in.; inHg Unit of ACT1 and ACT2 indicated on the display. 31 DISPL UNIT SCALE 0 –...

  • Page 101: Appendix A - Complete Parameter Settings

    Appendix A – Complete Parameter Settings The tables in this appendix list all the parameters and alternative settings for the ACH 500. Use these tables as reference guides when you are customizing macros for your ACH 500 application. A signal flow diagram is included at the end of this appendix.
  • Page 102 Appendix A – Complete Parameter Settings Custom Parameter Alternative Settings Setting OPERATING DATA 1 OUTPUT FREQUENCY 2 SPEED RPM; %; USER SCALING 3 MOTOR CURRENT 4 % RATED TORQUE 5 % RATED POWER 6 DC BUS VOLTAGE V; % OF RATED NOMINAL 7 OUTPUT VOLTAGE 8 DRIVE TEMPERATURE degrees C and F...
  • Page 103 Appendix A – Complete Parameter Settings Custom Parameter Alternative Settings Setting 10 CONTROL CONNECTIONS 10.1 START/STOP/DIRECTION 10.1.1 EXT 1 STRT/STP/DIR NOT SEL; DI1; DI1,2; DI1P,2P; DI 1P, 2P, 3; DI1P,2P,3P; DI6; DI6,5; KEYPAD 10.1.2 EXT 2 STRT/STP/DIR NOT SEL; DI6; DI6,5; DI1; DI1,2; DI1P,2P; DI 1P, 2P, 3; DI1P,2P,3P; KEYPAD 10.1.3 LOC/EXT DIRECTION REVERSE;...
  • Page 104 Appendix A – Complete Parameter Settings Custom Parameter Alternative Settings Setting 10.4.1 RUN ENABLE YES; DI1; DI2; DI3; DI4; DI5; DI6 10.4.2 FAULT RESET SELECT NOT SEL; DI1; DI2; DI3; DI4; DI5; DI6; ON STOP 10.4.3 PARAM. LOCK SEL OP DATA 20; DI1; DI2; DI3; DI4; DI5; DI6 10.4.4 EXTERNAL FAULT NOT SEL;...
  • Page 105 Appendix A – Complete Parameter Settings Custom Parameter Alternative Settings Setting 10.8 EXT COMMUNICATION 10.8.1 DRIVE ID-NUMBER 1 - 247 10.8.2 PROTOCOL MODBUS; GS-BUS 10.8.3 BIT RATE SELECT 0:1200; 1:2400; 3:4800; 4:9600 10.8.4 PARITY 0:NONE; 1:FAULT; 2:FAULT+STOP 10.8.5 COMMS FAULT FUNCT 0:NONE;...
  • Page 106 Appendix A – Complete Parameter Settings Custom Parameter Alternative Settings Setting 20.3.4 DECEL TIME 1 0.1s – 1800s 20.3.5 ACCEL TIME 2 0.1s – 1800s 20.3.6 DECEL TIME 2 0.1s – 1800s 20.3.7 ACCEL REF2 TIME 0.1s – 1800s 20.3.8 DECEL REF2 TIME 0.1s –...
  • Page 107 Appendix A – Complete Parameter Settings Custom Parameter Alternative Settings Setting 30 PROTECTION/INFORMAT 30.1 FAULT FUNCTION 30.1.1 SERIAL FAULT FUNC STOP; PRE SPEED7 30.1.2 AI <MIN FUNCTION NO; WARNING; FAULT; PRE SPEED7; LAST SPEED 30.1.3 MOT TEMP FLT FUNC NO; WARNING; FAULT 30.1.4 MOTOR THERM TIME 300s –...
  • Page 108 Appendix A – Complete Parameter Settings Custom Parameter Alternative Settings Setting 30.3 SUPERVISION 30.3.1 OUTPUT FREQ 1 FUNC NO; LOW LIMIT; HIGH LIMIT 30.3.2 OUTPUT FREQ 1 LIM 0 Hz – 500 Hz (ACS 501); 0 Hz – 120 Hz (ACS 502) 30.3.3 OUTPUT FREQ 2 FUNC NO;...
  • Page 109 Appendix A – Complete Parameter Settings Custom Parameter Alternative Settings Setting 40.2 PUMP & FAN CONTROL (CAN BE SEEN ONLY WITH P&F AUTOM MACRO) 40.2.1 PI-CONT GAIN 3% – 800% 40.2.2 PI-CONT I-TIME 0.1s – 320s 40.2.3 REFERENCE STEP 1 0% –...
  • Page 110 Appendix A – Complete Parameter Settings Figure A-1 Signal Diagram How to Set References CONTROL LOCATION KEYPAD R1 KEYPAD PI EXTERNAL KEYPAD REF 1 CRIT FREQUENCIES 20.5.2/20.5.3 KEYPAD PI (REF 2) 20.5.4/20.5.5 20.5.6/20.5.7 20.5.8/20.5.9 PRESET SPEED 1-7 EXTERNAL REF 1 SEL REF 1&2 20.5.10/20.5.11 10.2.2...

  • Page 111: Appendix B - Programming Digital Inputs

    Appendix B – Programming Digital Inputs Table B-1 shows the available digital inputs and how these digital inputs can be applied to different tasks. Table B-1 Digital Inputs Parameter Name/Task of Parameter Digital I/O Configuration Value 10.1.1 EXT 1 STRT/STOP/DIR RUN/STOP DI1;...
  • Page 112 Appendix B – Programming Digital Inputs Parameter Name/Task of Parameter Digital I/O Configuration Value 10.3 PRESET SPEED SEL Single speed: DIx* Three speeds: DI1,2 0 0 No Preset Speed DI3,4 1 0 Preset Speed 1 DI5,6 0 1 Preset Speed 2 1 1 Preset Speed 3 Seven speeds: DI1,2,3...
  • Page 113 Index 6-20 Boost 6-18 ACC/DEC 1OR2 SEL 6-20 6-18 ACC/DEC RAMP SHAPE BRAKE CHOPPER 6-22 6-34 ACCEL REF2 TIME BREAK POINT 6-21 6-53 ACCEL TIME 1 BYPASS CONTROL 6-21 ACCEL TIME 2 Accel/decel 6-20 Acceleration time 6-20 Carrier frequency 6-23 6-43, 6-52 ACT 1 MAX SCALE Cautions, definition...
  • Page 114 Index Group 30.3 supervision 6-38 Group 30.4 information 6-40 Eprom version 6-40 Group 40.1 PI-controller 6-41 6-51 ERROR VALUE INV. Group 40.2 pump and fan control 6-45 6-42 ERROR VALUE INVERT Group level ESD warning access EXT 1/EXT 2 SELECT defined Ext communication 6-16...
  • Page 115 Index Macros, defined Main 10 control connection parameters Operating data Main 20 drive parameters 6-16 access Main 30 protection parameters 6-30 functions Main 40 application parameters 6-41 overview Main level parameter selection access parameters defined defined parameters listed illustrated 6-39 OUTPUT FREQ 1 FUNC Manual 6-39...
  • Page 116 Index Pump and fan macro 5-12 Start-up external connections 5-13 parameters parameter settings 5-14 Start-up data sample application 6-54 described using the menu Start-up data parameters 6-18 STOP FUNCTION Ramp shape, accel/decel 6-20 6-39 SUPERVIS MESSAGES 6-11 RC FILTER ON AI1 Supervision 6-38 6-11...

  • Page 117: Index

    Index ACH 500 Programming Manual...

This manual is also suitable for:

Ach 501Ach 502B seriesAch 500

Table of Contents