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ABB ACQ80-04 Quick Installation And Start-Up Manual

Standard control program
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ABB DRIVES FOR WATER
ACQ80-04 standard control program
Quick installation and start-up guide
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  • Page 1 — ABB DRIVES FOR WATER ACQ80-04 standard control program Quick installation and start-up guide to do...

  • Page 2: List Of Related Manuals

    Document library on the Internet on the inside of the back cover. For manuals not available in the Document library, contact your local ABB representative. The code below opens an online listing of the manuals applicable to the product:...

  • Page 3: En - Quick Installation And Start-Up Guide

    EN - Quick installation and start-up guide 3 EN - Quick installation and start-up guide This guide briefly instructs how to install and start-up the ACQ80-04 drive of all frame sizes (R0...R8). For complete information, see ACQ80-04 hardware and firmware manuals.
  • Page 4 Ensure the cooling The maximum ambient temperature without derating is 40 °C (+104 °F). No condensation or frost is allowed. For more information on the ambient temperature, see ACQ80-04 drives (0.75 to 160 kW) hardware manual (3AXD50000044998 [English]).  Protect the drive and input power cable If you use gG fuses, make sure that the operating time of the fuse is below 0.5 seconds.

  • Page 5: Install The Drive

    EN - Quick installation and start-up guide 5 Install the drive You can install the drive: • to a DIN installation rail with integrated lock. Applies to frames R0...R2 only. • with screws to a suitable surface (wall or assembly plate). Applies to all frames R0...R8.
  • Page 6 6 EN - Quick installation and start-up guide  Installing a drive with screws (frames R0...R8) All drives of frames R0...R8 can be installed on the wall with screws. See details of Standard frame sizes (R0...R8) on page 58. WARNING! The drive module (frames R6...R8) is heavy (45 to 70 kg). Use a suitable lifting device.
  • Page 7 EN - Quick installation and start-up guide 7 See the example below of the mounting screws in frame R0. Frames R5...R8 only: 6. Remove the front cover with fastening screws (6a), move the cover to the top side (6b) and then up (6c). 7.

  • Page 8: Check The Insulation Of The Input And Motor Cables And The Motor

    • Measure the insulation resistance between each phase conductor and the Protective Earth conductor using a measuring voltage of 1000 V DC. The insulation resistance of an ABB motor must exceed 100 Mohm (reference value at 25 °C or 77 °F). For the insulation resistance of other motors, see the manufacturer’s instructions.

  • Page 9: Connect The Power Cables

    3 ~ M (PE) (PE) For alternatives, see ACQ80-04 hardware manual. Use a separate grounding PE cable (2a) or a cable with a separate PE conductor (2b) if the conductivity of the shield does not meet the requirements for the PE conductor.
  • Page 10 10 EN - Quick installation and start-up guide  Connection procedure: frames R0...R2 WARNING! If the drive is connected to an IT (non-grounded) system or to a corner-grounded TN system, disconnect the EMC filter grounding screw and varistor (VAR) grounding screw. 1.
  • Page 11 EN - Quick installation and start-up guide 11  Connection procedure: frames R3...R4 WARNING! If the drive is connected to an IT (non-grounded) system or to a corner-grounded TN system, disconnect the EMC filter grounding screw and varistor (VAR) grounding screw. 1.
  • Page 12 12 EN - Quick installation and start-up guide 10. Install the grounding shelf for the control cables (included with the mounting screws in a plastic bag in the delivery) onto the grounding shelf for the power cables. 11. Ground the motor cable shield at the motor end.
  • Page 13 EN - Quick installation and start-up guide 13  Connection procedure: frames R5...R8 WARNING! If the drive is connected to an IT (non-grounded) system or to a corner-grounded TN system, disconnect the EMC filter grounding screw and varistor (VAR) grounding screw. 1.
  • Page 14 14 EN - Quick installation and start-up guide 9. Twist the motor cable shield into a bundle and put yellow-green insulation tape on it, fit a cable lug, and connect it to the grounding terminal. See figure below. 10. Connect the phase conductors of the motor cable to the terminals of T1/U, T2/V and T3/W.
  • Page 15 EN - Quick installation and start-up guide 15 15. Frame R8 only: If you installed parallel cables, install the second grounding shelf for the parallel power cables (15a). Repeat steps 11...14 (15b). M5×25 M5×12 16. Install the grounding shelf of the control cables. 17.

  • Page 16: Connect The Control Cables

    See section Default I/O connections (ABB standard macro) on page for the default I/O connections of the ABB standard macro. For other macros, see ACQ80-04 firmware manual (3AXD50000042620 [English]). Connect the cables as described under in ACQ80-04 firmware manual (3AXD50000042620 [English]).

  • Page 17: Default I/O Connections (Abb Standard Macro)

    EN - Quick installation and start-up guide 17 Default I/O connections (ABB standard macro) Reference voltage and analog inputs Signal cable shield (screen) Open for configuration 1…10 kohm AGND Analog input circuit, common +10V 10 V DC reference voltage Open for configuration...

  • Page 18: Install Optional Modules, If Any

    Input signal Output signal For information on cable connection and drive operation, see Control Connections in the hardware manual (3AXD50000170661). Install optional modules, if any See chapter Electrical installation in ACQ80-04 hardware manual.

  • Page 19: Check The Compatibility With It (Ungrounded) System

    EN - Quick installation and start-up guide 19 Check the compatibility with IT (ungrounded) system The internal EMC filter is not suitable for use on an IT (ungrounded) system. Disconnect the EMC filter and varistor before connecting the drive to the supply network.
  • Page 20 20 EN - Quick installation and start-up guide Reinstall covers (frames R3...R8) Frames Action R3, R4 1. Reinstall the cover: Put the tabs on the cover top in their counterparts on the housing and press the cover. 2. Tighten the retaining screw at the bottom with a screwdriver. 1.

  • Page 21: Start-Up And Use

    Start up and use 21 Start up and use This section describes how to install and start-up the drive using the basic control panel. Only limited information may be available in this manual. For detailed information of all Menus and Sub menus, see the ACS-BP-S basic control panel user manual (3AXD50000032527 [English]).
  • Page 22 22 Start up and use Display The control panel display shows the following elements: 1. Control location and related icons: Indicates how the drive is controlled. 35.6 Hz • Loc: The drive is in local control, that is, controlled from the control panel.
  • Page 23 Start up and use 23 Main menu The Main menu includes the following control panel elements: Motor data (23) Start stop control (24) Connection macro (24) Diagnostics (25) Backup data (25) Parameter settings (25)  Sub menus The sub-menu items allows you to change settings and set actions. Some sub menus also have menus and/or option lists.
  • Page 24 I/O example, ABB standard (2- connections. See menu wire). description below. → Selected macro is ABB standard (2-wire) 1) ABB standard (2-wire) - 2) PID - Suitable for closed- Default macro for general loop control systems such as purpose.

  • Page 25: Backup Data

    Start up and use 25 Diagnostics Displays the active faults and warnings and how to fix and reset. For information about fault and warning codes, see Diagnostics on page 57. 1) Active Fault - Displays active 2) Fault History - Lists the faults.
  • Page 26 26 Start up and use Options menu In the home screen, press Back button to navigate to the Options menu. The menu includes the following control panel elements: 1) Reference value: Speed 2) Rotation direction: 35.6 Hz (rpm) or frequency (Hz). Forward or reverse NOTE: Speed reference can be...

  • Page 27: Fault And Warning Messages

    Start up and use 27 Fault and warning messages Fault messages The display shows the active fault message when a problem is 46.0Hz detected. When a fault message code is displayed: 1001 1. Identify and eliminate the cause. See list of Fault messages page 63.
  • Page 28 28 Start up and use...

  • Page 29: Parameters List

    Parameters List 29 Parameters List Index Name Range/List Unit Default 01 Actual values 01.01 Motor speed used -30000.00…30000.00 01.02 Motor speed estimated -30000.00…30000.00 01.03 Motor speed% -1000.00…1000.00 01.06 Output frequency -500.00…500.00 01.07 Motor current 0…30000.00 01.08 Motor current% of motor nom 0…1000.0 01.09 Motor current% of drive nom...
  • Page 30 30 Parameters List Index Name Range/List Unit Default 04 Warnings and faults 04.01 Tripping fault 0x0000...0xffff 0x0000 04.02 Active fault 2 0x0000...0xffff 0x0000 04.03 Active fault 3 0x0000...0xffff 0x0000 04.06 Active warning 1 0x0000...0xffff 0x0000 04.07 Active warning 2 0x0000...0xffff 0x0000 04.08 Active warning 3 0x0000...0xffff...
  • Page 31 Parameters List 31 Index Name Range/List Unit Default Name Name Name Off1 control Ramp in zero User bit 0 Off2 control Reset User bit 1 Off3 control Inching 1 User bit 2 Inching 2 User bit 3 Ramp out zero Remote cmd Ramp hold Ext ctrl loc...

  • Page 32: Loading Package Name

    32 Parameters List Index Name Range/List Unit Default 06.29 MSW bit 10 selection False[0], True[1], Above limit[2] Above limit[2] 06.30 MSW bit 11 selection False[0], True[1], Ext ctrl loc[2] Ext ctrl loc[2] 06.31 MSW bit 12 selection False[0], True[1], Ext run enable Ext run enable [2] 06.32 MSW bit 13 selection False[0], True[1]...
  • Page 33 Parameters List 33 Index Name Range/List Unit Default 10.25 RO1 ON delay 0.0...3000.0 10.26 RO1 OFF delay 0.0...3000.0 10.27 RO2 source See parameter 10.24 RO1 Running [7] source 10.28 RO2 ON delay 0.0...3000.0 10.29 RO2 OFF delay 0.0...3000.0 10.30 RO3 source See parameter 10.24 RO1 Fault (-1) [15]...
  • Page 34 34 Parameters List Index Name Range/List Unit Default 12.20 AI1 scaled at AI1 Max -32768.000...32767.000 50.000 12.21 AI2 actual value 0.000…20.000 0.000 12.22 AI2 scaled value -32768.000…32767.000 0.000 12.23 AI2 forced value 0.000…20.000 12.25 AI2 unit selection V[2], mA[10] 12.26 AI2 filter time 0.000…30.000 0.100 12.27 AI2 Min...

  • Page 35: Speed Reference Conditioning

    Parameters List 35 Index Name Range/List Unit Default 21.19 Scalar start mode 0...4 Normal Normal[0] Automatic[2] Automatic+boost[4] Flying start+boost[6] Const time[1] Torque boost[3] Flying start [5] 21.22 Start delay 0.00…60.00 10.00 21.23 Smooth start Disabled[0], Enabled Disabled[0] always[1], Start only[2] 21.24 Smooth start current 10.0...100.0...

  • Page 36: Fault Functions

    36 Parameters List Index Name Range/List Unit Default 30.09 Cur Lim Monitor Time 0.00...120.00 10.00 30.10 Current Limit Actions No Action[0], Warning[1], Warning[1] Fault[2] 30.11 Minimum speed -30000.00...30000.00 -3000.00 30.12 Maximum speed -30000.00...30000.00 3000.00 30.13 Minimum frequency -500.00...500.00 -50.00 30.14 Maximum frequency -500.00...500.00 50.00 30.17 Maximum current...
  • Page 37 Parameters List 37 Index Name Range/List Unit Default 31.12 Auto-reset selection 0x0000…0xffff 0x0000 Value Value Value Overcurrent 4…9 Reserved External fault 3 Overvoltage Selectable fault External fault 4 Undervoltage External fault 1 External fault 5 AI supervision fault External fault 2 31.13 Selectable fault 0x0000…0xffff...
  • Page 38 38 Parameters List Index Name Range/List Unit Default 32.07 Supervision 1 signal 0, 1, 3, 4, 6...10, 23...27 Frequency[3] Process PID Output Zero[0] Current[4] Freq ref used[22] feedback[25] power[8] Process PID Speed[1] Inverter temperature[23] Torque[6] AI1[9] setpoint[26] Process PID Process PID output[24] Frequency[3] DC voltage[7] AI2[10]...

  • Page 39: Motor Thermal Protection

    Parameters List 39 Index Name Range/List Unit Default 32.49 Supervision 5 low -21474836.00… 21474836.00 - 0.00 32.50 Supervision 5 high -21474836.00… 21474836.00 - 0.00 32.51 Supervision 5 hysteresis 0.00...100000.00 0.00 32.55 Supervision 6 function See parameter 32.05 Disabled[0] Supervision 1 function 32.56 Supervision 6 action No action[0], Warning[1],...
  • Page 40 40 Parameters List Index Name Range/List Unit Default 36 Load analyzer 36.01 PVL signal source Output power[8] Not selected[0] Motor torque[6] Speed ref used[12] Reserved[15] Motor speed used[1] DC voltage[7] Torque ref used[13] Process PID out[16] Output frequency[3] Output power[8] Freq ref used[14] Other...
  • Page 41 Parameters List 41 Index Name Range/List Unit Default Name Bit Name Bit Name Bit Name Name Internal PID sleep Tracking PID active Reserved setpoint mode mode active Setpoint Output limit Sleep boost 7 10 PID set 13...15 Reserved frozen high Output limit Output frozen 5 Reserved...

  • Page 42: Monitoring/Scaling Settings

    42 Parameters List Index Name Range/List Unit Default 40.44 Set 1 sleep delay 0.0...3600.0 60.0 40.45 Set 1 sleep boost time 0.0...3600.0 40.46 Set 1 sleep boost step 0.0...200000.0 PID unit 1 40.47 Set 1 wake-up deviation -200000.00...200000.00 PID unit 1 0.00 40.48 Set 1 wake-up delay 0.00...60.00...

  • Page 43: Panel Port Communication

    Parameters List 43 Index Name Range/List Unit Default 46.05 Current scaling 0…30000 10000 46.06 Speed ref zero scaling 0.00...30000.00 0.00 46.07 Frequency ref zero scaling 0.00...1000.00 0.00 46.11 Filter time motor speed 2…20000 46.12 Filter time output frequency 2…20000 46.13 Filter time motor torque 2…20000 46.14...
  • Page 44 44 Parameters List Index Name Range/List Unit Default 50.14 FBA A reference 1 -2147483648…2147483647 Note: Applicable only when 79.40 MPPT reference is disabled. If parameter MPPT reference is enabled, then the parameter should be set to it’s default value. 50.15 FBA A reference 2 Not applicable.
  • Page 45 58.18 EFB control word 0000h…FFFFh 0.0.0.0 58.19 EFB status word 0000h…FFFFh 0.0.0.0 58.25 Control profile ABB Drives[0], DCU Profile[5] - ABB Drives[0] 58.26 EFB ref1 type Speed or 0...5 Frequency[0] Speed or frequency[0] Transparent[1] General[2] Speed[4] Frequency[5] Note: Applicable only when 79.40 MPPT reference...
  • Page 46 46 Parameters List Index Name Range/List Unit Default 58.101 0...6, 11...16, 21, 24, 31, 32, Data I/O 1 CW 16bit[1] 33, 40, 41, Other... None[0] SW 16bit[4] Ref1 32bit[12] Act2 32bit[16] AO1 data storage[32] CW 16bit[1] Act1 16bit[5] Ref2 32bit[13] CW2 16bit[21] AO2 data storage[34] Feedback data Ref1 16bit[2] Act2 16bit[6]...

  • Page 47: Flow Calculation

    Parameters List 47 Index Name Range/List Unit Default 79.15 Enable tank level operation Disable[0] Disable[0] DI1[2] DI3[4] DI5[6] Other... Enable[1] DI2[3] DI4[5] DI6[7] 79.17 Tank low sensor DI5[6] Not selected[0] DI1[2] DI3[4] DI5[6] Other... Selected[1] DI2[3] DI4[5] DI6[7] 79.18 Tank high sensor See parameter 79.17 Tank DI6[7]...
  • Page 48 95.04 Control board supply Internal 24V[0], External Internal 24V[0] 24V[1] 95.15 Special HW settings 0b0000…0b1111 0b0000 Name Name Name Reserved ABB Sine filter 2...15 Reserved 95.20 HW options word 1 0b0000…0b1111 0b0000 Name Name Supply frequency 60 Hz du/dt filter activation 14…1 1…12...
  • Page 49 OEM access level 3 Long menu Parameter lock 5...9 Reserved Reserved 96.04 Macro select 0, 1, 14 Done[0] Done[0] ABB standard[1] PID[14] 96.05 Macro active See parameter 96.04 Macro select standard[1] 96.06 Parameter restore 0, 2, 8, 32, 62, 512, 1024,...

  • Page 50: Motor Control

    50 Parameters List Index Name Range/List Unit Default 96.101 Confirm user pass code 10000000…99999999 96.102 User lock functionality 0000h…FFFFh 0000h 97 Motor control 97.01 Switching frequency reference 2 kHz[2], 4 kHz[4], 8 kHz[8], 4 kHz[4] 16 kHz[16] 97.02 Minimum switching frequency 1, 2, 4, 8, 12 1.5 kHz[1] 1.5 kHz[1]...
  • Page 51 Parameters List 51 Index Name Range/List Unit Default 99.15 Motor polepairs calculated 0…1000 99.16 Motor phase order U V W[0], U W V[1] U V W[0]...
  • Page 52 52 Parameters List...

  • Page 53: Technical Data

    44.3 18kW5-4 31.86 56.9 18.5 022kW-4 37.58 67.9 030kW-4 50.65 037kW-4 59.64 045kW-4 71.9 055kW-4 86.60 075kW-4 118.47 090kW-4 138.07 110kW-4 168.30 132kW-1 200.98 160kW-4 239.38 External charging circuit required. For details on charging unit, contact your local ABB representative.
  • Page 54 54 Technical data Fuses  uR and aR fuse Drive type Minimum Input uR and aR ACQ80-04 short current Rated Rated Bussmann IEC 60269 circuit current voltage designation size current type 3 phases U = 400 V (380...480 V) 0kW75-4...
  • Page 55 Technical data 55  gG fuses Drive type Minimum Input gG (IEC 60269) ACQ80-04 short current Rated Rated IEC 60269 circuit current voltage designation size current type 3 phases U = 400 V (380...480 V) 0kW75-4 OFAF000H6 01kW1-4 OFAF000H6 01kW5-4...
  • Page 56 56 Technical data  gR fuses Drive type Minimum Input gG (IEC 60269) ACQ80-04 short current Rated Rated IEC 60269 circuit current voltage designation size current type 3-phase U = 380…480 V 0kW75-4 170M2694 01kW1-4 170M2694 01kW5-4 170M2695 02kW2-4 170M2695 03kW0-4 11.5...

  • Page 57: Typical Ac Input Power Cable Specifications

    Technical data 57  DC fuses Drive type Fuse (A) Drive type Fuse (A) ACQ80-04- ACQ80-04- 3-phase U = 380…480 V 0kW75-4 022kW-4 01kW1-4 030kW-4 01kW5-4 037kW-4 02kW2-4 045kW-4 03kW0-4 055kW-4 04kW0-4 075kW-4 05kW5-4 090kW-4 07kW5-4 110kW-4 011kW-4 132kW-4 015kW-4...

  • Page 58: Dimensions, Weights, Free Space, And Screw Sizes

    58 Technical data Dimensions, weights, free space, and screw sizes Frame ACQ80-04 Dimensions and weight Free space Screw size sizes IP20 Weight Above Below 14.9 19.0 28.0 45.0 55.0 70.0  Standard frame sizes (R0...R8) Symbols IP20 Height of front side...

  • Page 59: Warning Messages

    Diagnostics 57 Diagnostics Warning messages Code Warning/Aux code Cause What to do (aux code (hex) visible only on assistant control panel and drive composer) 64FF Fault reset A fault has been reset. Event. Informative only. A2B1 Overcurrent Output current exceeded Check motor load, acceleration internal fault limit.
  • Page 60 A5EA Measurement circuit Fault in drive internal Contact your local ABB temperature temperature measurement. representative. A5EB PU board powerfail Power unit power supply failure. Contact your local ABB representative. A5ED Measurement circuit ADC Measurement circuit fault. Contact your local ABB representative.
  • Page 61 (aux code (hex) visible only on assistant control panel and drive composer) A5EE Measurement circuit DFF Measurement circuit fault. Contact your local ABB representative. A5EF PU state feedback State feedback from output Contact your local ABB phases not matching with representative.
  • Page 62 60 Diagnostics Code Warning/Aux code Cause What to do (aux code (hex) visible only on assistant control panel and drive composer) A6E5 AI parametrization Current/voltage hardware Adjust the hardware setting on the setting of an analog input does drive control unit or the parameter not correspond to parameter 12.15/12.25.
  • Page 63 Diagnostics 61 Code Warning/Aux code Cause What to do (aux code (hex) visible only on assistant control panel and drive composer) A8A0 AI supervision Analog signal is beyond limits. Check the signal level, input wiring, and the defined limits. 1 – AI1 less minimum 3 –...
  • Page 64 62 Diagnostics Code Warning/Aux code Cause What to do (aux code (hex) visible only on assistant control panel and drive composer) AFAA Autoreset A fault is about to be autoreset. Informative warning. AFE1 Emergency stop (off2) Emergency stop (mode Check that it is safe to continue selection off2) command.

  • Page 65: Fault Messages

    Drive software is not able to read the Reset the fault or cycle the power to drive rating ID. the drive. If the fault persists, contact your local ABB representative. 2281 Calibration Measured offset of output phase Try performing the current calibration current measurement or difference again.
  • Page 66 1 – Auxiliary fan 1 broken 2 – Auxiliary fan 2 broken 5091 Safe torque off Safe torque off function is active. Check safety circuit connections parameter 95.04 Control board supply. 5092 PU logic error Power unit memory is cleared. Contact ABB.
  • Page 67 Redundant Duplicated measurements are Contact ABB. measurement beyond limits. 5096 Overtemperature hw Excessive hardware temperature. Contact your local ABB representative. 5098 I/O communication Communication failure to standard Try resetting the fault or cycle the loss I/O. power to the drive.
  • Page 68 Reboot the control unit using Note: This fault cannot be reset. parameter 96.08 Control board boot or by cycling power. If the problem persists, contact ABB. 6581 Parameter system Parameter load or save failed. Try forcing a save using parameter 96.07 Parameter save...
  • Page 69 Check used supply voltage and incorrect supply voltage selection in voltage selection parameter 95.01 parameter 95.01 Supply voltage. Supply voltage. Other - Contact your local ABB representative, quoting the auxiliary code.
  • Page 70 68 Diagnostics Code Fault / Aux. code Cause What to do (hex) code visible only on assistant control panel and drive composer) 7310 Overspeed Motor is turning faster than highest Check the minimum/maximum speed allowed speed. settings, parameters 30.11 Minimum speed 30.12 Maximum speed,...
  • Page 71 Diagnostics 69 Code Fault / Aux. code Cause What to do (hex) code visible only on assistant control panel and drive composer) D4B0 Running dry Dry run protection is activated. Check the pump inlet for sufficient water level. Check dry run protection settings in parameter group 82 Pump protections.
  • Page 72 70 Diagnostics...

  • Page 73: Further Information

    Address any inquiries about the product to your local ABB representative, quoting the type designation and serial number of the unit in question. A listing of ABB sales, support and service contacts can be found by navigating to abb.com/searchchannels. Product training For information on ABB product training, navigate to new.abb.com/service/training.
  • Page 74 © Copyright 2019 ABB. All rights reserved. Specifications subject to change without notice.

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